Removal and Installation
Hydraulic PumpWhenever the hydraulic pump is replaced, the following requirements must be met to ensure proper system operation.
- hydraulic pump must be properly tilled and primed prior to operation
- the fluid reservoir and strainer must be cleaned
- correct banjo bolts must be used at the pump fittings (depends on pump tag color and code number on pump tag)
CAUTION: Always replace banjo bolts at the hydraulic pump.
Follow the procedure below to correctly replace the hydraulic pump.
Central hydraulic pump, replacing
Work sequence
- prior to removing old pump, bleed the hydraulic accumulator by pumping the brake pedal 20 to 25 times with the engine oft
- loosen pump pulley bolts and pump bracket bolts
- remove hydraulic lines from pump
- remove pump from vehicle with brackets and pulley attached
- unbolt return line from hydraulic brake servo to reservoir at the servo (arrow A)
- remove clamp from steering gear return hose at reservoir and carefully pull hose off (arrow B)
- remove nuts and washers holding reservoir bracket to engine compartment panel and pull reservoir assembly out toward front of vehicle
- unfasten accumulator hose at bottom of reservoir and pull hose oft (arrow C)
- remove reservoir with bracket and two hoses attached
- wash out reservoir, strainer and attached hoses, with clean solvent
CAUTION: Do not use solvent which could damage rubber hoses or seals when cleaning hydraulic system components.
Use only clean solvent.
NOTE: If the strainer cannot be thoroughly cleaned or is damaged, replace it with a new part. Use the newer version strainer, Pant No.443 422 385A.
- install reservoir assembly in vehicle and attach hoses and lines disconnected during removal
Hydraulic pump, priming
NOTE: On new or replacement pumps, read procedure described on pink tag supplied in the box.
CAUTION: Part Numbers may be different for different models, model years and options. Always consult with the Parts Dept. for correct application.
- assemble pump brackets and pulley to new pump
CAUTION: Use only hydraulic fluid, Part No. G 002 000.
- pour some hydraulic fluid into outlet port (arrow A) and rear chamber (arrow C) of new pump
- fill suction chamber (arrow B) with hydraulic fluid
- rotate pump slowly by hand through tour to five complete revolutions (fluid will be discharged at arrow C). Keep suction chamber (arrow B) full of fluid
- install new hydraulic pump in vehicle
- separate pump to accumulator line at fitting and check if damper hose is missing or restricted
- reassemble accumulator line and connect to pump
- connect pressure line to pump using correct banjo bolt:
Rear chamber port
- pump with red tag:
use banjo bolt with small hole Part No. N 903 246.01
- pump with silver tag:
use banjo bolt with three large holes and no screen Part No. N 021 071 2
- connect suction line to pump using correct banjo bolt:
A - silver tag pumps
B - red tag pumps (with any code number)
- use Part No. N 902 669.01 (identified with 2 grooves on bolt head)
- tighten suction line banjo bolt to 40 Nm (29 ft lb)
- fill reservoir with hydraulic fluid, Part No. G 002 000
Pump operation, checking
CAUTION: Do not turn the front wheels unless the hydraulic system is filled with fluid. Damage to the steering rack could result if wheels are turned after the hydraulic system has been emptied.
- start engine while holding brake pedal down firmly
NOTE: The brake pedal will be drawn down by hydraulic pressure when the brake portion of the pump begins to operate.
- if brake pedal does not go down in 30 seconds, stop engine and let vehicle sit for 30-45 seconds
- repeat pump operation checking procedure
- inspect all hoses and fittings for leaks
- bleed steering system by turning steering wheel lock to lock several times quickly
- add more hydraulic fluid if level drops below "MAX" marking
NOTE: Reservoir must be free of air bubbles when steering wheel is turned.