Power Steering Pump, Removing and Installing

Power steering pump, removing and installing

Special tools, testers and auxiliary items required:

^ Hose Clamps Up To 25 mm Dia. 3094
^ Torque wrench V.A.G. 1331
^ Pliers for spring-type clamps VAS 5024A

Power steering pump is not designed to be serviced. If a customer has reported a problem, determine cause via the pressure test and leak test. If there is a malfunction, replace the power steering pump.

Note:
^ Replacement pumps from the distribution center do not contain any fluid. Before installing, fill pump with hydraulic oil G 002 000 and turn pump by hand. Otherwise, the pump may be noisy when operating or may even be damaged.
^ Oil type: Hydraulic fluid G 002 000
^ Oil capacity in system: 0.7 to 0.9 l

Removing





- Remove sound insulation pan - arrows -.





- Remove left sound insulation - arrows -

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

Continued for all vehicles





- Loosen hex socket head bolts for belt pulley. If necessary, counterhold using a hex socket wrench.
- Mark rotational direction of ribbed belt.





- Move tensioner in direction of - arrow - to release tension on ribbed belt.
- Remove ribbed belt.
- Remove hex socket head bolts for belt pulley.

Removing intake manifold and intake hose
- Disconnect connector from intake manifold.
- Loosen spring clips using spring clip pliers VAS 5024A.
- Remove intake hose and intake manifold.





- Pinch off return line using Hose Clamps Up To 25 mm Dia. 3094.





- Clamp off intake hose using Hose Clamps Up To 25 mm Dia. 3094.
- Open spring clip - 1 - and disconnect intake hose.
- Remove banjo bolt - 2 -.
- Seal pressurized line using a plastic bag or something similar.





- Remove hex bolts - 1 - and - 2 -
- Remove pump.

Installing
- Fill hydraulic oil into power steering pump.
Fill oil at pump intake connection.
- Turn hub by hand until oil exits from pressure side.
- Insert power steering pump in bracket and tighten bolts.
- Install spring clip and intake hose.





Marking - arrow A - must align with cast seam - arrow -.
Spring clip must seal with marking - arrow B -.
- Install new seals on banjo fitting.
- Tighten banjo bolt.
- Bleed steering system.
Rest of installation is performed in reverse order of removal.