Vehicles With Pump In Upper Section

Power steering pump: vehicles with power steering pump in upper 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:
^ Type of oil: hydraulic oil Part No. G 002 000.
^ Oil system capacity: 0.7 - 0.9 ltr (11.8 - 15.2 oz.).
^ Part numbers are listed here for reference only. Always check with your Parts department for the latest information.

Removing





- Remove noise insulation tray -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 using a crayon or marker 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 bolts.

Removing suction line and suction hose
- Remove connector off suction line.
- Open hose clamps using VAS 5024.
- Remove suction hose and suction line.





- Clamp off return hose with hose clamps 3094.





- Clamp off suction hose with hose clamps 3094.
- Open hose clamp -1- and disconnect suction hose.
- Remove banjo bolt -2-.
- Seal pressure line with 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 hose clamp.
The mark -arrow A- must align with casting seam -arrow-.
Hose clamp must close off mark -arrow B-.
- Install new sealing rings onto banjo bolt.
- Tighten banjo bolt to 38 Nm (28 ft. lbs.).
The remainder of the installation is the reverse of removal.