Power Steering Pump: Service and Repair

Special tools, workshop equipment, test and measuring appliances and aux. items required





^ 3094 Hose clamps
^ 3204 Locking pin
^ VAG1331 Torque wrench
^ VAG 1590 Water pump wrench

Removing
- Remove engine noise insulation.
- Set lock carrier to service position

Removing ribbed V-belt on vehicles with 4 cyl. gasoline engine





- Turn tensioning device in direction of arrow to relieve tension on ribbed belt.
- Secure with special tool -3204-.

Removing ribbed V-belt on vehicles with 4 cyl. diesel engine





- Turn tensioning device in direction of arrow to relieve tension on ribbed belt.





This work sequence only affects vehicles with 4-cyl. gasoline engine
- Unscrew coolant pump ribbed belt pulley.
- Remove ribbed belt.
- Unscrew power steering pump ribbed belt pulley.
It may be necessary to file out corners of tool VAG 1590

This work sequence only affects vehicles with 5-cylinder engine.
- Loosen power steering pump belt pulley hex socket head bolt.
- Mark direction of rotation of ribbed belt.
- Remove radiator fan from viscous coupling.





- Turn tensioning roller to left (arrow) until ribbed V-belt tension is relieved.
- Remove ribbed belt.
For ease of illustration the routing is shown without the lock carrier being in position
The continued work sequence is valid for all engines





- Clamp off intake and return lines using hose clamps -3094-.
- Position drip tray underneath.





- Remove hose clamp -1- from suction hose.
- Pull off suction hose, remove from retainer and place to side.
- Unbolt pressure hose -2-, 22 mm AF





- Unscrew hex bolts -1- and hex socket head bolt-2-.
- Take out pump.

Installing
- Fill power steering pump with hydraulic oil.
Fill pump with oil via suction union.
- Turn hub by hand until oil emits from pressure side.





- Tighten bolts -1- and -2- to 20 Nm.
Installation is continued in reverse sequence
- Install new sealing rings onto banjo bolt.





- Tighten pressure hose banjo bolt -2-.
- Install suction hose.





- Tighten coolant power steering pump pulley hex socket head bolts to 25 Nm.
- Install radiator fan to viscous coupling.





- Install ribbed belt.

Note: When installing the belt make sure it is correctly seated in the pulley.

For ease of illustration the routing is shown without the lock carrier being in position
- Top up hydraulic oil G 00200.
- Install bumper
- Start engine and check belt running.
- Check hydraulic oil level.
- Check steering system for leaks.
- Bleed steering system.