Power Steering Fluid Reservoir: Service and Repair

Power steering pump with hydraulic lines/hoses, assembly overview
I - Vehicles with high mounted power steering pump
II - Vehicles with low mounted power steering pump





1 - Reservoir
2 - Pressure hose/line mounting
Vehicles with TDI engine and air conditioner. Not applicable.
3 - Pressure hose/line mounting
Vehicles with 1.4 ltr., 1.6 ltr. engine and air conditioner. Not applicable.
4 - Pressure hose/line mounting
Vehicles with 1.4 ltr., 1.6 ltr., 1.9 ltr. SDI/TDI engine and no air conditioner. Not applicable.
Vehicles with VR5 and VR6 engine with/without air conditioner
5 - Pressure hose/line mounting
Vehicles with TDI engine and air conditioner
6 - Pressure hose/line mounting
Vehicles with TDI engine without air conditioner
7 - Pressure hose/line mounting
On 5-speed manual transmission 02J
On 6-speed manual transmission 02M
Removing and installing instructions
8 - Pressure hose/line mounting
On automatic transmission 01M
On automatic transmission 09A
9 - Pressure hose/line mounting
On 5-speed manual transmission 02K. Not applicable.
10 - Power steering pump
^ Check delivery pressure
^ Fill with fluid before installing

Reservoir, disassembling and assembling





1 - Cap with dip stick
^ Oil level: between minimum and maximum marks; Engine temperature approximately 50°C
^ Arrow A: oil level with engine cold
^ With engine cold, oil level must not rise above Min. marking
^ Check oil level with cap screw on
^ Open cap with e.g. a bar

2 - Hose clamp
3 - Return hose
4 - Intake hose
5 - Internal hex head bolt, 10 Nm

6 - Reservoir

Securing pressure line and intake hose on vehicles with 1.4 ltr., 1.6 ltr., 1.9 ltr. SDI/TDI engines without an air conditioner

VR5 and VR6 with/without air conditioner





1 - Power steering pump
^ Check delivery pressure
^ Fill with fluid before installing

2 - Intake hose
3 - Pressure line
4 - Pressure switch
^ Switches at 40 bar
^ Tighten to 15 Nm

5 - Seal ring
^ Replace

6 - Banjo bolt, 38 Nm
7 - Seal ring
^ Replace

8 - Colored marks on intake hose
White or yellow ring must seat within retainer.

9 - Bracket
10 - Hex nut
11 - Bracket

Securing pressure line and intake hose on vehicles with TDI engine and A/C





1 - Power steering pump
^ Check delivery pressure
^ Fill with fluid before installing

2 - Intake hose
3 - Bracket
4 - Pressure line
5 - Hex bolt, 22 Nm
6 - Clamp
7 - Banjo bolt, 38 Nm
8 - Seal ring
^ Always replace

9 - Intake hose
10 - Reservoir

Securing pressure line and intake hose on vehicles with TDI engine without A/C





1 - Power steering pump
^ Check delivery pressure
^ Fill with fluid before installing

2 - Pressure line
3 - Banjo bolt, 38 Nm
4 - Seal ring
^ Replace

5 - Intake hose with coolant hose
6 - Reservoir

Securing pressure line on 5-speed manual transmission 02J and 5-speed





1 - Pressure line
2 - Speed nut
3 - Clamp
4 - Hex bolt, 22 Nm
5 - Hex nut, 22 Nm
6 - Bracket
7 - Pressure hose
8 - Hex bolt, 22 Nm

Securing pressure line on 6-speed manual transmission 02M





1 - Pressure line
2 - Hex nut, 22 Nm
3 - Clamp
4 - Securing starter bolt
5 - Hex bolt, 22 Nm
6 - Bracket
7 - Hex nut, 22 Nm
8 - Clamp

Securing pressure line on automatic transmission 01M





1 - Securing starter bolt
2 - Bracket
3 - Hex nut, 22 Nm
4 - Clamp
5 - Hex bolt, 22 Nm
6 - Pressure line
7 - Securing bolt on transmission

Securing pressure line on automatic transmission 09A





1 - Pressure line
2 - Bracket
3 - Hex bolt, 22 Nm
4 - Hex nut, 9 Nm
5 - Hex bolt, 22 Nm