Safety Precautions When Working On Charge Air System With Turbocharger; Rules For Cleanliness - Volkswagen CJDA Workshop Manual

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Industriemotoren - Industrial Engines 2009 ▶
Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015
1.1 Safety precautions when working on
charge air system with turbocharger
WARNING
When doing any repair work, pay attention to the follow-
ing due to the cramped conditions:
◆ Route all the various lines (e.g. for fuel, hydraulics,
activated charcoal filter system, coolant, refrigerant,
brake fluid and vacuum) and electrical wiring in their
original positions.
◆ Ensure that there is sufficient clearance to all moving
or hot components.
Note the following if testers and measuring instruments have to
be used during a road test:
◆ The test and measuring equipment must always be secured
and operated by a 2nd person.
1.2

Rules for cleanliness

Caution
When a mechanical fault is found on the turbocharger, e.g.
a destroyed compressor impeller, it is not sufficient to only
renew the turbocharger. To avoid subsequent damage, the
following work must be carried out:
◆ Check air filter housing, air filter element and intake ho-
ses for dirt/soiling.
◆ Check the whole charge air path and charge air cooler
for foreign objects.
If foreign objects are found in the charge air system, the
charged air routing must be cleaned and the charge air
cooler must be renewed, if necessary.
When working on the turbocharger, pay careful attention to the
following "rules for cleanliness":
◆ Thoroughly clean all unions and surrounding areas before
disconnecting.
◆ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
◆ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
◆ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
◆ Existing transport and protective packaging and sealing caps
must only be removed immediately prior to installation.
◆ When making repairs, remove oil from connection and hose
ends.
320 Repair Group 21 - Turbocharging/supercharging