V6 TDI Engine
Power Steering Pump
Assembly Overview I - Power Steering Pump for Engine, Generation I, without SCR.
• Always replace seals.
• Do not reuse fluid you have drained.
• Only use hydraulic oil.
1 Power Steering Pump
• For the correct allocation, refer to the Parts Catalog
• Fill with hydraulic oil before installation
• Checking delivery pressure, refer to => [ Power Steering Pump Delivery Pressure, V6 TDI, Generation I without SCR, Checking ] Power Steering Pump Delivery Pressure, V6 TDI, Generation I Without SCR, Checking
• Removing and installing => [ Vane Pump, Removing and Installing: ] Overhaul
2 Belt Pulley
3 Bolt
• 23 Nm
4 Bracket
5 Bolt
• 23 Nm
6 Bolt
• 23 Nm
7 Banjo Bolt
• 35 Nm
8 Seal
• Quantity: 2
• Always replace.
9 Pressurized Line
• Note installed position.
10 Intake Hose
• Note installation position on reservoir, refer to => [ Location of Hoses on Reservoir and Reservoir Bracket to Body ] Service and Repair
• Note power steering pump location.
11 Marking
• On intake hose
• Must align with marking on vane pump
12 Spring Clamp
• Remove and install with spring type clip pliers (VAS 5024 A)
13 Marking
• On vane pump
• Must align with marking on intake hose
Installation Position of Intake Hose and Pressure Line at Vane Pump
- Install intake hose - arrow A - so that markings - 1 and 2 - align.
- Install pressure line - arrow B - so that the stop bar - 3 - rests against pump housing - 4 -.
Assembly Overview II - Power Steering Pump for Engine Generation I with SCR and Generation II
• Always replace seals.
• Do not reuse fluid you have drained.
• Only use hydraulic oil.
1 Power Steering Pump
• Allocation, refer to the Parts Catalog
• Fill with hydraulic oil before installation
• Checking delivery pressure, refer to => [ Power Steering Pump Delivery Pressure, V6 TDI, Generation I without SCR, Checking ] Power Steering Pump Delivery Pressure, V6 TDI, Generation I Without SCR, Checking
• Removing and installing => [ Vane Pump, Removing and Installing: ] Overhaul.
2 Bolt
• 23 Nm
3 Belt Pulley
4 Bracket
5 Bolt
• 23 Nm
6 Bushing
• Drive the bushing back slightly to install the power steering pump.
7 Bolt
• 23 Nm
8 Bolt
• 9 Nm
9 Pressurized Line
• Insert the pressure line completely when installing.
10 Seal
• Always replace.
11 Intake Hose
• Note installation position on reservoir, refer to => [ Location of Hoses on Reservoir and Reservoir Bracket to Body ] Service and Repair
12 Marking
• On the intake hose
• Note power steering pump location: The P marking on the intake hose must line up with the X marking - arrow - on the power steering pump.
13 Spring Clamp
• Tension with spring type clip pliers (VAS 5024 A)
Special tools, testers and auxiliary items required
• Hose Clamps Up to 25 mm Dia. (3094)
• Torque Wrench 5-50 Nm (V.A.G 1331)
• Spanner Wrench (3212)
• Torx(R) Socket T60 (T40087)
• Used Oil Collection and Extraction Device (V.A.G 1782)
• Spring Type Clip Pliers (VAS 5024 A)
• Bit reversible ratchet with a bit insert (commercially available)
• Hydraulic fluid
General Information
Vane pump is not designed to be serviced. If there are customer complaints, the cause must be determined using a pressure and leak test. If there is a malfunction, replace the vane pump.
• If fluid is low in reservoir, always check steering system for leaks.
• If there are leaks in the area of the line connections, the lines/connections must first be inspected for leaks, tightened as necessary and wiped dry.
• Pump is delivered without oil. Therefore, hydraulic oil must be filled before installation and turned by hand. Otherwise, noises when driving or damage to pump may occur.
Removing
- With vehicles with air suspension, place vehicle on hoist. Refer to => [ Positioning Vehicle on Hoist and Wheels ] Positioning Vehicle on Hoist and Wheels.
- Extract hydraulic oil from reservoir using (V.A.G 1782).
- Carefully pull engine cover off from 4 retaining pins - arrows -.
- Remove air guide hose - arrows -.
Applies to Engine, Generation I with SCR and Generation II
- Loosen the air guide pipe - 4 - (if equipped) in the center and move it upward. Remove the bolt - 1 and 2 - and loosen the bolt - 3 -.
• Be sure not to damage any parts when moving the air guide pipe - 4 -.
Applies to All
- Mark ribbed belt running direction
- Release the tension on the ribbed belt and remove it from the power steering pump belt pulley.
- Remove bolts - arrows -. Counter hold belt pulley with (3212) when doing so.
Applies to Engine, Generation I without SCR
- Lay several cloths under the power steering pump and hydraulic pipes.
- Clamp the intake hose using (3094) and remove from power steering pump.
- Remove banjo bolt - 1 -.
- Remove bolts - 1 -.
- Remove the bolt - 2 - and remove the power steering pump - 3 -.
Applies to Engine, Generation I with SCR and Generation II
- Lay several cloths under the power steering pump and hydraulic pipes.
- Clamp the intake hose using (3094) and remove from power steering pump.
- Remove the bolts - 1 - and remove the pressure line from the power steering pump.
- Remove bolts - 1 -.
- Remove the bolt - 2 - and remove the power steering pump - 3 -.
Installing
Install in reverse order of removal. Note the following:
• Clean oiled places in engine compartment.
• Always replace seals.
• Before installing new pump on intake side, fill hydraulic oil and turn by hand until oil escapes on pressure side.
• Charge air system hose supports and hoses must be free of oil and grease before installation.
• Secure all hose connections with hose clamps appropriate to the model. Refer to the Parts Catalog.
- Turn the hub by hand until oil runs out of the pressure side.
- To assist attachment of vane pump, drive threaded sleeve for rear bolt back slightly in bracket.
- Install the power steering pump.
- Tighten the front bolts.
- Tighten the rear bolts.
- Bolt belt pulley onto vane pump.
- Secure the intake hose. Note location of suction hose on power steering pump.
- Use a new seal - item 8 - => [ (Item 8) Seal ] or O-ring - item 10 - => [ (Item 10) Seal ].
- Tighten the pressure line threaded connector.
Tightening specifications: Assembly overview - power steering pump for engine, generation I, without SCR.
Tightening specifications: Assembly overview - power steering pump for engine generation I with SCR and generation II.
- Clean oiled places in engine compartment.
- Install ribbed belt and check alignment of ribbed belt
- Top off hydraulic oil.
- Check power steering fluid level. Refer to => [ Power Steering, Checking Hydraulic Oil Level ] Power Steering, Checking Hydraulic Oil Level.
- Bleed steering system. Refer to => [ Steering System, Bleeding after Reinstalling ] Service and Repair.
- Check the steering system for leaks. Refer to => [ Steering System, Checking for Leaks ] Steering System, Checking For Leaks.
- On vehicles with air suspension, position vehicle on wheels. Refer to => [ Positioning Vehicle on Hoist and Wheels ] Positioning Vehicle on Hoist and Wheels.
• When installing ribbed belt, ensure it is correctly seated in ribbed belt pulley.
1 Belt pulley - generator
2 Idler pulley
3 Idler pulley
4 Belt pulley - coolant pump
5 Belt pulley - power steering pump
6 Ribbed belt pulley - A/C compressor
7 Tensioner pulley
8 Belt pulley - crankshaft