Replacing High Pressure Steering Hose

High pressure steering hose (to accumulator), replacing






CAUTION: Before removing hose release residual pressure in pressure accumulator by pumping brake pedal firmly at least 20 times

Before removing a defective high pressure hose, check the routing of the hose to determine if it has been kinked, twisted or installed incorrectly.

Check if pressure accumulator is twisted out of position
Check engine mounts and engine rubber stop for damage and replace if necessary
Check if high pressure hose has been twisted at coupling with damper pipe due to incorrect installation
Check that metal line at end of high pressure hose contacts stop pin on pressure accumulator
Check if damper pipe is bent (can be recognized by bent retainer bracket)

Removing

On vehicles with cooling fan for injectors, release two retainer straps, separate connector and remove fan motor
Remove banjo bolt from hydraulic pump at connection to accumulator. Seal connection on damper pipe with a plug
Remove bolts in damper pipe retaining bracket and seal threaded connection in central hydraulic pump with a plug






Hold pressure accumulator with an oil filter wrench (arrow) while removing banjo bolt from accumulator

CAUTION: Hydraulic fluid will escape.

Note: The oil filter wrench will keep the accumulator from being turned out of position when loosening the banjo bolt.

Seal threaded connection on accumulator with a plug
Remove high pressure hose and damper pipe from top of engine compartment
Loosen union of high pressure hose and damper pipe
Remove damper hose from damper pipe

Installing

Remove plugs from high pressure hose and pressure accumulator
Clean seal contact surface on pressure accumulator thoroughly
Feed high pressure hose into engine compartment from underneath

CAUTION: DO NOT install 0-ring seals in place of metal seals or vice versa. DO NOT kink high pressure hose when installing.






CAUTION: DO NOT interchange banjo bolts 2 and 12.
2 = damper pipe to central hydraulic pump.
12 = high pressure hose to accumulator.






Connect high pressure hose to pressure accumulator with new banjo bolt 12 and new seals. Hold accumulator with oil filter wrench when tightening bolt

Note: The metal connection on the damper hose must make contact with the stop pin on the accumulator.

When tightening the connection, the banjo bolt must be in a vertical position.

Carefully insert new damper hose into new damper pipe
Thread union together by hand but DO NOT tighten
Remove plug from central hydraulic pump and clean seal contact surface thoroughly
Remove plug from damper pipe

CAUTION: DO NOT install 0-ring seals in place of metal seals or vice versa. DO NOT twist high pressure hose when tightening connection.

Connect damper pipe to central hydraulic pump with new banjo bolt and new seals. Hand tighten only
Fasten damper pipe to pump with mounting bolts at retaining bracket
Tighten banjo bolt
Tighten union while holding 10 mm hexagonal with a wrench
Clean hydraulic fluid off all parts

Checking

Check hydraulic fluid level in reservoir; top up with hydraulic fluid G 002 000 if necessary
Swivel central hydraulic pump towards upper stop on tensioner. Replace V-belt it pump contacts upper stop with belt installed
Run engine at idle and check for leaks at all connections
Install injector fan motor