Volkswagen Golf Variant / Jetta. Manual - part 421

 

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Volkswagen Golf Variant / Jetta. Manual - part 421

 

 

♦ Hose Clip Pliers - VAS6362-

♦ Not Illustrated:
♦ Pickup Clamp - VAG1526B/2-
♦ Diesel Pressure Tester Kit - VAS6551-
♦ Diesel Pressure Tester Kit - Adapter Set - Connection Hose 2

- VAS6551/5-2-

♦ Suction Pump - VAS5226-

8. Special Tools    

267

1

Safety Precautions when Working on

Charge Air System And Turbocharg‐

er

WARNING

When doing any assembly work, especially in the engine com‐

partment,  pay  attention  to  the  following  due  to  the  limited

space.

♦ Route all lines and wires in their original locations.
♦ For example, for fuel lines, hydraulic lines, EVAP system

lines, coolant and refrigerant lines, brake fluid lines and

vacuum lines.

♦ Make sure that there is sufficient clearance to all moving

or hot components.

If testing equipment is required during a road test, note the fol‐

lowing:
♦ The testing equipment must always be secured to the rear seat

and operated by a second technician from this location.

If the vehicle is involved in a collision while testing equipment is

operated from the front passenger seat, the person sitting in that

seat could be seriously injured when the airbag deploys.

268

Guidelines for Clean Working Condi‐

tions

When Working on the Charge Air System and Turbocharger,

Carefully Follow the “7 rules” for Clean Working Conditions:
♦ Thoroughly clean the connection points and the surrounding

area before loosening.

♦ Place the removed parts on a clean surface and cover them.

Only use lint-free cloths.

♦ Carefully cover or seal opened components if the repair is not

performed immediately.

♦ Only install clean parts: remove the replacement parts from

their packaging just before installing them. Do not use parts

that have been loosely stored or unpackaged (for example, in

tool boxes etc.).

♦ Transport and protective packaging and sealing caps are to

be removed only immediately prior to installation.

♦ During repairs, clean oil from connections and hose ends.
♦ When the fuel system is open: avoid working with compressed

air if possible. Do not move the vehicle if possible.

When working on the turbocharger, carefully observe the follow‐

ing rules for clean working conditions:

2. Guidelines for Clean Working Conditions    

269

Turbocharger

Note

Various hose connections are secured.

The charge air system must be properly sealed.

Always replace the self-locking nuts, seals, gaskets and

clamps.

Fill with engine oil before installing the turbocharger oil supply

line on the connections

After installing the turbocharger, let engine idle for approxi‐

mately one minute to ensure adequate oil supply to the turbo‐

charger.

Caution

♦ Follow the safety precautions when working on the charge

air system and turbocharger. Refer to

⇒ “1 Safety Precautions when Working on Charge Air

System And Turbocharger”, page 268

 .

♦ Pay attention to the guidelines for clean working condi‐

tions. Refer to

⇒ “2 Guidelines for Clean Working Conditions”,

page 269

 .

Always pay attention to these instructions before and during

work.

⇒ “3.1 Overview - Turbocharger with Exhaust Manifold and At‐

tachments”, page 270
⇒ “3.2 Turbocharger with Exhaust Manifold, Removing and In‐

stalling, Engine Codes CBEA, CJAA”, page 276
⇒ “3.3 Turbocharger with Exhaust Manifold, Removing and In‐

stalling, Engine Codes CBDA, CBDB, CEGA”, page 279
⇒ “3.4 Vacuum Diaphragm with Charge Air Pressure Actuator

Position Sensor G581 , Replacing”, page 282

3.1

Overview - Turbocharger with Exhaust

Manifold and Attachments

Caution

♦ Follow the safety precautions when working on the charge

air system and turbocharger. Refer to

⇒ “1 Safety Precautions when Working on Charge Air

System And Turbocharger”, page 268

 .

♦ Pay attention to the guidelines for clean working condi‐

tions. Refer to

⇒ “2 Guidelines for Clean Working Conditions”,

page 269

 .

Always pay attention to these instructions before and during

work.

270

 

 

 

 

 

 

 

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