Power Steering Fluid Reservoir: Service and Repair

48 - Power steering pump, refill tank, hydraulic lines for vehicles with 1.8L, 2.0L and TDI engines

Assembly overview
I - Vehicles with high-mounted power steering pump
II - Vehicles with low-mounted power steering pump





1. Refill tank

2. Pressurized line mount
Vehicles with TDI engine and A/C system

3. Pressurized line mount
Vehicles with 2.0L and TDI engines without A/C system
Vehicles with 1.8L turbo engine with A/C system
Vehicles with 2.0L engine with A/C system
Vehicles with 1.8L turbo engine without A/C system

4. Intake hose mount
5. Pressurized line mount
On 5-speed manual transmission 02J
On 6-speed manual transmission 02M


6. Power steering pump
^ Before installing, fill with oil at low-mounted power steering pump.
^ Before installing, fill with oil at high-mounted power steering pump.

7. Pressurized line mount
On automatic transmission 01M

Refill tank assembly





1. Cover with dipstick
^ Oil level- Between Min. and Max. marking; engine temperature approximately 50°C - arrow A -
^ Check oil level
^ Open screw cap e.g. using toggle

2. Spring clip
3. Return hose
4. Intake hose
5. Bolt
^ M6 x 45

6. Refill tank
7. Battery console

Pressurized line and intake hose mount for vehicles with TDI engine and A/C system





1. Power steering pump
^ Check delivery pressure
^ Before installing, fill with power steering fluid

2. Intake hose
3. Spring clip
4. Pressurized line
5. Banjo fitting
^ M16 x 1.5

6. Seals
^ Replace

7. Socket head bolt
^ M10 X 30

8. Hex nut
^ M8

9. Clamp
10. Cylinder block

Pressurized line and intake hose mount for vehicles with 2.0L and TDI engines without A/C system and vehicles with 1.8L turbo engine and A/C system





1. Power steering pump
^ Checking delivery pressure
^ Before installing, fill with power steering fluid

2. Intake hose
3. Spring clip
4. Pressurized line
5. Banjo fitting
^ M16 x 1.5

6. Seals
^ Replace

7. Clamp
8. Hex bolt
^ M8 x 20

9. Hex bolt
^ M10 x 25

10. Clip
11. Bracket
12. Cylinder block

Pressurized line and intake hose mount for vehicles with 2.0L engine and A/C system and vehicles with 1.8L turbo engine without A/C system





1. Power steering pump
^ Checking delivery pressure
^ Before installing, fill with power steering fluid: High-mounted power steering pump

2. Intake hose
3. Spring clip
4. Pressurized line
5. Banjo fitting
^ M16 x 1.5

6. Seals
^ Replace

7. Hex nut
8. Clamp
9. Hex bolt
^ M8 x 20

10. Hex bolt
^ M1 0 X 25

11. Bracket
12. Cylinder block

Pressurized line and intake hose mount for vehicles with TDI pump injector engine





1. Power steering pump
^ Checking delivery pressure
^ Before installing, fill with power steering fluid

2. Banjo fitting
^ M16 x 1.5

3. Seals
^ Replace

4. Pressurized line
5. Spring clip
6. Socket
^ Only for power steering pumps manufactured by Kayaba

7. Hex bolt
^ M8 x28

8. Clamp
9. Intake hose
10. Cylinder block
11. Bracket
12. Hex bolt
^ M10 x 25

13. Hex bolt
^ M8 x20

14. Oil filter housing
15. Transmission
16. Hex bolt
^ M10 x 55
^ M10 x 50 (direct shift transmission 02E only)