Power Steering Pump W/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
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 with oil 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. Sockethead bolt
^ 10 Nm (89 inch lbs.)
6. Reservoir

Pressure line and suction hose (TDI engine with A/C)

1. Power steering pump
^ Checking delivery pressure
^ Fill with oil before installing
2. Suction hose
3. Mounting bracket
4. Pressure hose
5. Hex bolt
^ 10 Nm (89 inch lbs.)
6. Clamp
7. Banjo bolt
^ 30 Nm (22 ft. lbs.)
8. Seal
^ Always replace
9. Suction hose
10. Reservoir

Pressure line and suction hose (TDI and 2.0 liter engines without A/C)

1. Power steering pump
^ Checking delivery pressure
^ Fill with oil before installing
2. Suction hose
3. Pressure hose
4. Banjo bolt
^ 30 Nm (22 ft. lbs.)
5. Seal
^ Always replace
6. Suction hose
^ White or yellow ring must seat within retainer
7. Retainer
8. Hex nut
9. Mounting bracket

Pressure line and suction hose (vehicles with A/C and 2.0 liter or VR6 engines)

1. Power steering pump
^ Checking delivery pressure
^ Fill with oil before installing
2. Suction hose
3. Pressure hose
4. Pressure switch
^ Switches at 40 bar (580 psi)
^ Tighten to 15 Nm (11 ft. lbs.)
5. Seal
^ Always replace
6. Banjo bolt
^ 30 Nm (22 ft. lbs.)
7. Seal
^ Always replace
8. Suction hose
^ White or yellow ring must seat within retainer
9. Retainer
10. Hex bolt
11. Mounting bracket

Pressure line and suction hose (1.8 liter engines with O9A transmission)

1. Power steering pump
^ Checking delivery pressure
^ Fill with oil before installing
2. Suction hose assembly with bracket
3. Pressure hose
4. Pressure switch
^ Switches at 40 bar (580 psi)
^ Tighten to 15 Nm (11 ft. lbs.)
5. Seal
^ Always replace
6. Banjo bolt
^ 30 Nm (22 ft. lbs.)
7. Seal
^ Always replace
8. Fixing screw
9. Guiding bolt
10. Hex nut
11. Rivet nut
12. Mounting bracket

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

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

Pressure line (automatic transmission), securing

1. Securing bolt on starter
2. Hex bolt
^ 22 Nm (16 ft. lbs.)
3. Clamp
4. Hex nut
^ 25 Nm (18 ft. lbs.)
5. Mounting bracket
6. Pressure hose
7. Securing - bolt on transmission