Vehicles With Low-Mounted Pump

Vehicles with low-mounted pump

Special tools, testers and auxiliary items required





^ Connecting rod support 3090





^ Hose clamps up to 25 mm dia. 3094





^ Pliers V.A.S 5024

Removing





- Remove cover - 1 - on lock carrier (right-side) and - 2 - above expansion tank.





- Remove cover panel above cylinder head cover and, if necessary, in front of intake manifold.





- Remove bolts - 1 - and disconnect connector - 2 -.
- Remove retaining plate upward.





- Remove nuts - 2 - and - 3 -.
- Open pipe clamps - 1 - and - 4 -.
- Move air intake pipe - 5 - to the side.
- Remove pipe clamp - 4 -.

Note: Before removing ribbed belt, mark direction of rotation with chalk or felt pen. A used belt can break if it runs in the opposite direction. Make sure that the belt is properly seated in the pulleys when installing.





- Move tensioner in direction of - arrow - to loosen ribbed belt.
- Remove ribbed belt.





The tensioner can be locked with a 4.5 mm diameter drift (approx. 55 mm long). Connecting rod support 3090 can also be used.





- Remove center, left and right noise insulation - arrows -.





- Remove connecting pipe between charge air coolers at left...
Tightening torque: 20 Nm





- .. and right longitudinal members, and detach both hoses from charge air coolers.
- Remove oil cooler from connecting pipe and from noise insulation panel (left-side).
- Remove connecting pipe.





- For vehicles with 132 kW engine, code AJQ
- Remove air intake pipe going to charge air cooler at longitudinal member (bottom right).





- Detach pulley, counterholding with Allen key.

Secondary air pump motor





- Working from top of engine compartment, loosen bolt - 1 - approx. two turns (visible through gap for oil dipstick at intake manifold bracket).

Note: For ease of illustration, bracket and secondary air pump are shown with engine removed from vehicle.





- Disconnect connector and hoses at secondary air pump.





- Remove bolts - 2 - and - 3 - securing secondary air pump bracket.
- Swing bracket clear to the side and pull out secondary air pump downward.





- Clamp off intake hose (fluid reservoir/power steering pump) using special tool - 3094 -.
- Open spring-type clip - 3 - and remove intake hose.
- Unbolt expansion hose - 4 -.

On vehicles equipped with pressure switch, first disconnect connector and remove switch.

- Unbolt power steering pump from bracket, - 1 - and - 2 -.

When installing, note the following:
Tightening torques see Low-mounted power steering pump assembly overview

- Routing of ribbed belt on vehicles with no A/C system
- Routing of ribbed belt on vehicles with A/C system

Note:
^ Replacement pumps are not filled with fluid. Therefore it is essential to fill the pump with hydraulic fluid G002000 and to rotate the pump by hand before installing, otherwise the pump may be damaged or be noisy during operation.
^ Contact surfaces and threads on both sides of power steering pump must be free from paint.
^ Do not reuse hydraulic fluid which has been drained off.
^ Always replace seals.





- Attach spring-type hose clip and intake hose as illustrated.
- Lengthways mark - A - on intake hose must be aligned with seam on pump housing.
- Do not install spring-type hose clip beyond transverse mark - B -.