8-Cylinder FSI

Power Steering Pump, Vehicles with Dynamic Steering

Overview

• Always replace seals.

• Do not reuse fluid you have drained.

• Only use hydraulic oil.

• When replacing the power steering pump, replace its seal and o-ring.

• Only use grease to lubricate.






1 Power Steering Pump (V119)

• With power steering pump control valve ((V119))

• The power steering pump and the control valve => [ (Item 6) ] are one component and can only be replaced together.

• Fill with hydraulic oil before installation.

• Checking delivery pressure, refer to => [ Power Steering Pump, Checking Delivery Pressure ] Testing and Inspection.

• Grease the power steering pump splines when installing.

• Bleed the steering. Refer to => [ Steering, Bleeding After Replacing ] Service and Repair.

• Check hydraulic fluid level. Refer to => [ Power Steering Fluid Level, Checking ] Power Steering Fluid Level, Checking.

• Steering system, checking for leaks, refer to => [ Steering, Checking for Leaks ] Steering, Checking For Leaks.

2 Input Shaft

• Grease the splines on the input shaft and power steering pump all the way around Allocation, refer to the Electronic Parts Catalog (ETKA).

• Grease the hole on the pump side and on the engine side or on the end of the shaft. Allocation, refer to the Electronic Parts Catalog (ETKA).

3 Seal

• Grease when installing.

4 Bolt

• Transmission/engine/power steering pump bolt.

5 Bolt

• 25 Nm

6 Power Steering Pump Control Valve ((V119))

• The power steering pump and the control valve are one component and can only be replaced together.

7 Intake Hose

• The marking "P" on the suction hose - arrow - must align with the formed seam - arrow - on the power steering pump.

8 Clamp

• Tighten using the hose clamp pliers (V.A.G 1275).

• Always replace if removed.

9 Pressure Line

• Insert the pressure line completely when installing.

• Observe installation position: The angle between the line connection and power steering pump axle is approximately 53°.

10 Union Nut

• 38 Nm

11 Seal

• Always replace if removed.

Removing

Special tools, testers and auxiliary items required

• Hose clamps up to 25 mm diameter (3094)

• Hose clamp pliers (V.A.G 1275)

• Torque wrench (V.A.G 1331)

• Torque wrench (V.A.G 1332)

• Used Oil Collection and Extraction Device (V.A.G 1782)

• Shop Crane Drip Tray (VAS 6208)

General Information

• The power steering 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 pump.

• If power steering fluid is low in reservoir, 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.

• Power steering pump is delivered without oil. Therefore, hydraulic oil must be filled before installation and turned by hand. Otherwise, noises when driving or damage to power steering pump may occur.

• Replace the power steering pump seal and o-ring before installing.

- Place the vehicle on a hoist.

- Extract hydraulic oil from reservoir using (V.A.G 1782).

- Clamp off the suction hose - 1 - and return hose - 2 - using the (3094).






• The (3094) must not be secured on the return hose - 2 - in the check valve area. Otherwise, check valve will be damaged.

• The check valve is located in the return hose - 2 - between the hose clamps - arrows -.

- Remove noise insulation.

- Lower the subframe.

- Remove heat shield for left drive axle - arrows -.






- Place the drip tray underneath.

- Remove the clamp - 2 - from the intake hose - 1 - and remove the intake hose - 1 - from the power steering pump.






- Disconnect the connector (not illustrated) on the regulator valve.

- Remove the union nut - 3 - and remove the pressure line - 4 - from the power steering pump.

- Remove the bolts - 5 - and the bolt - 6 -.

- Remove the power steering pump with input shaft.

- If necessary, remove the power steering pump input shaft - arrow - from the engine by hand.






- If the power steering pump - 1 - is replaced, the seal - 2 - and input shaft - 3 - must also be replaced.






- Replace the power steering pump seal and o-ring - arrow -.






Installing

Install in reverse order of removal. Note the following:

• Replace seals and gaskets.

• Clean oiled places in engine compartment.

• Always replace the o-ring on the input shaft and power steering pump.

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

• grease the splines on the input shaft and power steering pump all the way around Grease the hole on the pump side and on the engine side or on the end of the shaft, allocation, refer to the Electronic Parts Catalog (ETKA).

• Hose supports and hoses must be free of oil and grease before installation.

• Secure all hose connections with new hose clamps Electronic Parts Catalog (ETKA).

Tightening specifications, refer to => [ Power Steering Pump, Vehicles without Dynamic Steering ] Power Steering Pump, Vehicles Without Dynamic Steering.

- Grease the splines on the power steering pump - 1 - and input shaft - 3 - all the way around.






- Replace the sealing ring - 2 -.

- Complete pump as shown in illustration and install on engine.

1. Power steering pump

2. Seal

3. Grease the input shaft, the splines on the input shaft and power steering pump all the way around Grease the hole on the pump side and on the engine side or on the end of the shaft. Allocation, refer to the Electronic Parts Catalog (ETKA).


Note the installation position of the intake hose on the power steering pump => [ (Item 9) Pressure Line ].

- Turn the hub by hand until oil runs out of the pressure side.

- Install and tighten the bolts - 5 - and - 6 -.






- Place the suction hose - 1 - on the power steering pump and secure it with a new clamp - 2 -.

- Remove pressure line - 4 - at the power steering pump => [ (Item 9) Pressure Line ].

- Install subframe.

- Only tighten the subframe bolts to the specification, do not tighten them further (only tighten the bolts after an alignment).

If vehicle will be driving on the streets, all screws and nuts must be tightened properly!

- Top off hydraulic oil.

- Bleed the steering. Refer to => [ Steering, Bleeding After Replacing ] Service and Repair.

- Check power steering fluid level. Refer to => [ Power Steering Fluid Level, Checking ] Power Steering Fluid Level, Checking.

- Check all open line connections for leaks. Refer to => [ Steering, Checking for Leaks ] Steering, Checking For Leaks.

- Install noise insulation.

- Wheel alignment is required, see Table. Refer to => [ Wheel Alignment ] Wheel Alignment.

Tighten the subframe bolts to the end position after the alignment.