P/S Pump With Hydraulic Lines/Hoses, Assembly Overview

I - Vehicles with power steering pump in upper area
II - Vehicles with power steering pump in lower area





1-Reservoir
^ Disassembling and assembling
2-Pressure hose/line
^ Vehicles with TDI engine and air conditioner
^ Disassembling and assembling
3-Pressure hose/line
^ Vehicles with /TDI engine and no air conditioning
^ Disassembling and assembling
4-Pressure hose/line
^ Vehicles with TDI engine and air conditioning
^ Disassembling and assembling
5-Pressure hose/line
^ On 5-speed manual transmission 02J
^ Disassembling and assembling
6-Pressure hose/line
^ On automatic transmission
^ Disassembling and assembling
7-Pressure hose/line
^ Check pressure
^ Fill before installing

Reservoir, removing and installing





1-Cap with dip stick
^ Oil level: between min. and max. marks; Engine temperature approx. 50°C (122°F)
^ Check oil level with cap screw on
^ With engine cold, oil level must not rise above Min. marking
^ Open cap with e.g. a bar
^ Arrow A: oil level with engine cold
2-Hose clamp
3-Suction hose
4-Return hose
5-Socket-head bolt
^ 10 Nm (89 inch lb)
6-Reservoir

Pressure line and suction hose (TDI without air conditioner), securing





1-Power steering pump
^ Delivery pressure
^ Before installing fill with oil
2-Suction hose
3-Pressure hose
4-Pressure switch
^ Switches at 40 bar (580 psi)
^ Tighten to 15 Nm (11 ft lb)
5-O-ring
6-Banjo bolt
^ 30 Nm (22 ft lb)
7-O-ring
8-Suction hose
White or yellow ring must seat within retainer item -9-
9-Retainer
10-Nut
11-Mounting bracket

Pressure line and suction hose (vehicles with TDI engine and air conditioner), securing





1-Power steering pump
^ Checking delivery pressure
^ Before installing fill with oil
2-Suction hose
3-Mounting bracket
4-Pressure hose
5-Bolt
^ 10 Nm (89 inch lb)
6-Clamp
7-Banjo bolt
^ 30 Nm (22 ft lb)
8-O-ring
^ Always replace
9-Suction hose
10-Reservoir

Pressure line and suction hose (vehicles with TDI engine and no air conditioner), securing





1-Power steering pump
^ Checking delivery pressure
^ Before installing fill with oil
2-Pressure hose
3-Banjo bolt
^ 30 Nm (22 ft lb)
4-Sealing ring
^ Always replace
5-Suction hose with coolant hose
6-Reservoir

Pressure line (5-speed manual transmission 02J), securing





1-Pressure line
2-Speed nut
3-Clamp
4-Bolt
^ 22 Nm (16 ft lb)
5-Nut
^ 25 Nm (18 ft lb)
6-Mounting bracket
7-Pressure hose
8-Bolt
^ 22 Nm (16 ft lb)


Pressure line (automatic transmission), securing





1-Securing bolt on starter
2-Mounting bracket
3-Nut
^ 25 Nm (18 ft lb)
4-Clamp
5-Bolt
- 22 Nm (16 ft lb)
6-Pressure hose
7-Securing bolt on transmission