Vehicles With Upper Area Mounted Power Steering Pump

Power steering pump; vehicles with upper area mounted power steering pump, removing and installing

Power steering pump is not serviceable. If malfunction in pump is suspected, determine cause with the help of pressure tests, leak test and troubleshooting program. If malfunctioning replace power steering pump.

Notes:

^ Pumps supplied as replacement parts are not filled with oil. Therefore it is essential to fill the pump with hydraulic oil Part No. G 002 000 and to rotate it by hand, otherwise the pump may be damaged or noisy during operation.
^ Type of oil: hydraulic oil Part No. G 002 000
^ Oil system capacity: 0. 7... 0. 9 ltr. (11.8. - 15.2 oz.).

Removing





- Remove noise insulation.





- Loosen belt pulley hex. socket head bolt.
Counter-hold with a hex. key if necessary.





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

For ease of illustration, the relieving of belt pulley tension is shown without charge air line.

- Mark direction of rotation of ribbed belt.
- Remove ribbed belt.
- Remove belt pulley hex. socket head bolt.

Removing suction line and suction hose

Suction line lower spring clip can only be opened with headlight removed.

Remove bumper for this.

Removing suction hose

- Pull connector off intake line.
- Open spring-type clamps -1-, -2- and -3-.





- Remove suction hose -A-.

Removing suction line

We recommend that the flexible pliers from tool set VAS 5024 be used to remove the suction line lower spring spring-type clip.

- Unclip all electrical cables and hoses.
- Open spring-type clamps -1- with flexible pliers.





- Remove suction line -B-.





- Clamp off suction hose with hose clamps -3094-.
- Open spring-type clip -3- and pull off suction hose.
Use special tool VAS 5024 for this.





- Clamp off return supply hose with hose clamps -3094-.
- Remove banjo bolt -2-.
- Seal pressure line/hose with a plastic bag or similar.





- Remove hex. bolts -1- and -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 comes from pressure side.
- Install power steering pump on bracket and tighten bolts to 25 Nm (18 ft. lbs.).





- Install suction hose and spring-type clip.

The mark -arrow A- must align with casting seam -arrow-.
The spring-type clip must close off mark -arrow B-.

- Install new O-rings on banjo bolt.
- Tighten banjo bolt to 30 Nm (22 ft. lbs.).

Installation is continued in reverse sequence