Power Steering Pump: Service and Repair

Power steering pump, removing and installing
Vehicles with 8-cylinder gasoline engine





Special tools and equipment
^ 3094 hose clamp
^ 3201 alignment gauge
^ 3212 spanner wrench
^ VAG 1331 torque wrench
Measurement range: 5 to 50 Nm.
^ VAG 1332 torque wrench
Measurement range: 40 to 200 Nm.

Removing





^ Remove bolts -arrows and remove engine covers -A- and -B-.

^ Remove cover -C- from reservoir.





^ Disconnect the green connector for the A/C compressor magnetic clutch and remove the lower part of the connectors from the bracket.

^ Expose wire to compressor. Cut cable tie at bottom -arrow-.

^ Remove right toothed belt cover.





^ Cover sharp edges with tape.





^ Remove electric fan. Remove bolt -arrow- to do so.

^ Pull sealing lip away from front end in area of electric fan.

^ To remove electric fan, turn it slightly in -direction of arrow-.

^ Lay electric fan to side.





^ Clamp intake hose using -3094-.





^ Remove noise insulation.

Note: Before removing ribbed belt note direction of rotation with chalk or felt-tip marker. Reversing the direction of rotation of a run-in belt can destroy the belt. When installing the ribbed belt make sure it is seated correctly on the pulleys.





^ Remove the refridgerant line clamp.

^ Move tensioner -direction of arrow- to release tension on ribbed belt.

^ Remove the ribbed belt and release the tension on the tension roller.





^ Clamp return hoses using -3094-.

^ Place pan underneath vehicle to catch hydraulic oil.

^ Remove expansion hose -1- and intake hose -2 from pump.

^ Connect connection holes with plugs.

^ Remove bolt -3- for pump/bracket.





^ Remove belt drive pulley from the power steering pump. Counterhold using -3212-.





^ Remove the pump from bracket and remove from bottomw.

Installing

^ Before installing a new pump on intake side, fill hydraulic oil and screw in by hand until oil escapes on pressure side.

^ Clean oiled places in engine compartment.

^ Installation position, expansion hose, please refer to:

^ Installation position, intake hose, please refer to:

^ Place the pump into the bracket from underneath and install all three bolts by hand.

^ Install the intak hose with new seals but do not tighten it yet.





^ Tighten both front bolts.





Note: Front of belt pulley is marked "front".





^ Bolt on pulley for vane pump. Counterhold using -3212-.

Check the Belt Pulley Alignment and Adjust it





^ Attach -3201- on A/C compressor pulley.

^ Pump pulley must align with pulley for A/C compressor.

If the two belt pulleys ar not aligned:
^ Remove the pump belt pulley.





^ Use shims to adjust distance so that the two pulleys align.





Installation Position Expansion Hose
Angle -a-: approximately 57°
^ Align the hose and tighten.
^ Install electric fan.





^ Route and connect the A/C compressor magnetic clutch wire.





^ Remove the tape.

^ Install covers for toothed belt, reservoir, and engine.





^ Tighten rear bolt on pump.





Installation Position of Intake line
Angle -b- : approximately 90°
^ Align the intake line and tighten.
^ Remove -3094-.

Installation Position Ribbed Belt





^ Installation position, please refer to:

Note: Note previously marked direction of rotation of belt and be sure that it is seated correctly on pulley.





^ Swing tensioner in -direction of arrow-.

^ Mount the ribbed belt and release the tension on the tension roller.

^ Install the refridgerant line clamp.

^ Check power steering lfuid level, please refer to:

^ Bleed steering system, please refer to:

^ Check steering system for leaks, please refer to:





^ Install noise insulation.