Repair instructions

3.1 Rules for cleanliness

When working on the fuel supply and injection system, pay careful attention to the following rules for cleanliness:

• Thoroughly clean all joints and surrounding areas before dismantling.
• Place removed parts on a clean surface and cover them over. Use lint-free cloths only.
• Carefully cover opened components or seal them 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 been kept unpackaged (for example in toolboxes).
• If system is open, do not work with compressed air. Do not move the vehicle.
• Make sure that no fuel gets onto the fuel hoses. Should this occur, the fuel hoses must be cleaned immediately.
• Protect disconnected electrical connectors from dirt and water, and reconnect them only when dry.

3.2 Foreign objects in engine

Prevent the ingress of foreign bodies. When carrying out installation work on the engine, open channels must be sealed with suitable plugs such as those from the engine bung set - VAS 6122-.

3.3 Contact corrosion

Contact corrosion can occur if non-approved fasteners are used on the vehicle (bolts, nuts, washers etc.).

For this reason, only connecting elements with a special surface coating have been fitted.

In addition, rubber, plastic and adhesives are made of non-conductive materials.

If there is any doubt about the suitability of parts, a general rule is to use new parts ⇒ Electronic Parts Catalogue.

3.4 Routing and attachment of lines

• Avoid interchanging and ensure that the original installation position is restored. Mark the lines for the fuel, hydraulic and vacuum systems and for the activated charcoal filter system as well as electrical lines before they are removed. Where necessary, make sketches or take photographs.
• To avoid damaging pipes and wires, ensure adequate clearance from all moving or hot components in the engine compartment on account of the confined space.

3.5 Fitting radiator and condensers

Even if installed correctly, the radiator, the condenser and the charge air cooler may have small dents in their fins. This does not mean that these components have been damaged. It is not permissible to renew radiators, condensers or charge air coolers only because of such minor dents.