Power Steering Pump: Service and Repair

COMPONENT LOCATION AND INFORMATION

NOTE: The power steering uses hydraulic oil Part No. G 002 000 or equivalent.

1. Pressure hose with pressure line
- Disconnect from hose line to check pump pressure
- First remove brake booster to replace
2. Bolt with washer
- Tighten to: 10 Nm (84 inch lb)
3. Mounting point on intake manifold
- To mount pressure line
4. Power steering pump
- Checking pressure, refer to Testing and inspection. Testing and Inspection
- Not repairable
- Before disconnecting supply hose block off with clamp 3094
- Before installing, fill intake side of pump with hydraulic oil and turn by hand until fluid runs out of pressure side
5. Pulley
- Remove to remove power steering pump
- Removing:
- Loosen bolts item 6
- Relieve tension on ribbed belt, refer to Fig. 1 and Fig. 2, below.
- Remove bolts and pulley
6. Bolt
- Loosen while belt is tight
- Tighten to: 25 Nm (18 ft lb)
7. Socket-head bolts with washers
- Tighten to: 25 Nm (18 ft lb)
8. Socket-head bolts with washers
- Tighten to: 25 Nm (18 ft lb)
9. Mounting bracket
- Removing, refer to Sequence of Operations below.
- Bushing and socket-head bolt, item 18, discontinued on left side
10. Ignition coils with bracket
- Disconnect ignition wires and remove from power steering pump mounting bracket
11. Hex bolt
- Tighten to: 25 Nm (18 ft lb)
- For ignition coil bracket
12. Banjo bolt
- Tighten to: 40 Nm (30 ft lb)
13. Seal
- Always replace
14. Seal
- Always replace
- Install on fitting item 15
15. Hose fitting
- Tighten to: 50 Nm (37 ft lb)
- Install in pump with seal item 14
16. Hose clamp
- Tighten with VAG1275
- Can be replaced by screw-type clamps
17. Bolt with washer
- Tighten to: 25 Nm (18 ft lb)
18. Bolt
- Tighten to: 25 Nm (18 ft lb)
- Discontinued on left side (along with bushing)
19. Bracket
- Mounted to cylinder head
20. Supply hose
- From reservoir
- Fastened on bracket item 19
21. Bolt with washer
- Tighten to: 10 Nm (84 inch lb)





Fig. 1 Relieving tension on ribbed belt (early version)
- Disconnect ignition coils with bracket, and remove upper belt guard.
- Using box wrench, turn tensioner in direction shown (arrow) and install mandrel 3204.

NOTE:
- Mark the running direction of the belt.
- Re-installing the belt with running direction reversed can damage the belt.

- Remove belt from pulley.





Fig. 2 Relieving tension on ribbed belt (late version)
- Disconnect ignition coils with bracket, and remove upper belt guard.
- Turn tensioner in direction shown (arrow) and install mandrel 3204 through holes -A- and -B-.

NOTE:
- Mark the running direction of the belt.
- Re-installing the belt with running direction reversed can damage the belt.

- Remove belt from pulley.

MOUNTING POWER STEERING PUMP TO BRACKET
- Loosely install bolts (8 and 18 in illustration).
- Tighten bolt (8 in illustration), then bolt (18 in illustration), to specified torque.

MOUNTING POWER STEERING PUMP WITH BRACKET TO ENGINE CYLINDER BLOCK
- Loosely install bolts (7 and 17 in illustration).
- Tighten bolt (7 in illustration), then bolt (17 in illustration), to specified torque.