Vehicles With Pump In Lower Section

Power steering pump: vehicles with power steering pump in lower section, removing and installing





Special tools and equipment
^ 3094 Hose clamps
^ VAG 1331 Torque wrench
^ VAS 5024 Assembly pliers
The power steering pump is not serviceable. If problems in the pump are suspected, determine the cause using pressure tests, leakage test. If malfunctioning, replace complete unit.

CAUTION: Pumps supplied as replacement parts are not filled with oil. Pumps must be filled with hydraulic oil Part No. G 002 000 and rotated by hand before use. Otherwise the pump may be damaged or noisy during operation.

Notes:
^ Part numbers are listed here for reference only. Always check with your Parts department for the latest information.
^ 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 panel -arrows-.





- Remove left noise insulation -arrows-.

Vehicles with TDI engine
- Remove intake air duct between charge air cooler and turbocharger.





Continued for all vehicles
- Loosen belt pulley socket-head bolt.
Counter-hold using hex wrench if necessary.





- Turn tensioning device in direction of arrow to relieve tension on ribbed belt.
- Mark direction of travel of ribbed belt mark direction before removing the ribbed belt. Reinstalling a used belt in the opposite direction could damage the belt.
- When installing the belt, make sure that it is correctly seated in the pulleys.
- Remove ribbed belt.
- Remove belt pulley socket-head bolt.





- Clamp off suction hose with hose clamps -3094-.
- Open -hose clip -3- and pull off suction hose.
Use special tool VAS 5024.
- Disconnect suction hose.
- Remove banjo bolt -4-.
- Seal pressure line using a plastic bag or similar.
- Remove hex. bolts -1- and -2-.
- Remove pump.

Installing
- Fill power steering pump with hydraulic oil via suction union.
- Turn hub by hand until oil emits from pressure side.
- Install power steering pump into bracket and tighten bolts to 25 Nm (18 ft. lbs.).





- Install suction hose and install hose clamp.
Marking -arrow A- must align with casting seam -arrow-.
Hose clamp must close off marking -arrow B-.
- Install new seals onto banjo bolt.
- Tighten banjo bolt to 38 Nm (28 ft. lbs.).
The remainder of the installation is the reverse of removal.