Removal and Installation
Power Steering Components
=> [ Power Steering Pump ]
=> [ Suction and Return Hoses, Installed Position ]
Power Steering Pump
Special tools, testers and auxiliary items required
• Alignment gauge (3201)
• Spanner wrench (3212)
• Torque wrench (5-50 Nm) (VAG 1331)
• Torque wrench (40-200 Nm) (VAG 1332)
• Used oil collection and extraction device (VAG 1782)
• Spring type clip pliers (VAS 5024A)
• Drip tray for VAS 6100 (VAS 6208)
• Hydraulic fluid
General Information
The power steering pump is not designed to be serviced. If a customer has reported a problem, determine the cause via a pressure test and leak test. If there is a malfunction, replace the pump.
• If the fluid is low in the reservoir, always check the steering system for leaks.
• If there are leaks in the area of the line connections, the lines/connections must first be inspected for leaks, tightened as necessary and wiped dry.
• The pump is delivered without fluid. Therefore, the pump must be filled with hydraulic fluid before installation and turned by hand. Otherwise, noises when driving or damage to the pump may occur.
Removing
• To prevent damage to the ribbed belt, check the alignment of the Air Conditioning (A/C) compressor and the power steering pump pulleys.
Check the ribbed belt alignment after replacing the following components.
• Power steering pump
• Bracket for the power steering pump
- Place the vehicle on the hoist. Refer to => [ Positioning Vehicle on the Hoist and on its Wheels ] Positioning Vehicle on the Hoist and on its Wheels.
- Extract the hydraulic fluid from the reservoir using the (VAG 1782).
- Loosen the quick release fasteners - 1 and 2 - and remove the noise insulation.
- Remove the front bumper.
- Bring the lock carrier into the service position. Radiator Support
- Release the tension on the ribbed belt.
- Remove the ribbed belt from the power steering pump pulley.
- Place the (VAS 6208) underneath to collect the hydraulic fluid.
- Loosen the hose clamp - 4 - for the suction hose - 3 -.
- Remove the suction hose and lay aside.
- Remove the banjo bolt - 2 - for the pressure line - 1 -.
- Plug the connection holes with plugs.
- Install a piece of wood with a width of 50 mm - a - between the longitudinal member - 1 - and the lock carrier - 2 -.
- Remove the power steering pump - 1 - rear bolt - arrow -.
- Remove the bolts - 1 - for the power steering pump pulley - 2 -.
- Remove the power steering pump bolts - 3 -.
- Remove the power steering pump.
Installing
Installation is performed in the reverse order of removal. Especially observe the following during installation:
• Replace the seals and gaskets.
• Before installing the new pump, fill the pump on the intake side with hydraulic fluid and turn the pump by hand until the fluid leaks out on the pressure side.
• Secure all hose connections with new hose clamps.
- Turn the pump by hand until fluid runs out of the pressure line side.
Installed position: The lettering "vorne" on the pulley faces in the direction of travel.
- Tighten the power steering pump bolts - 3 -. Refer to - item 10 - in => [ Power Steering Pump Assembly Overview ] Power Steering Components.
- Tighten the bolts - 1 - for the power steering pump pulley - 2 -. Refer to - item 9 - in => [ Power Steering Pump Assembly Overview ] Power Steering Components.
- Tighten the power steering pump - 1 - rear bolt - arrow -. Refer to - item 12 - in => [ Power Steering Pump Assembly Overview ] Power Steering Components.
Checking and Adjusting the Belt Pulley Alignment
- Install the (3201) on the A/C compressor pulley.
- The power steering pump pulley must align with the A/C compressor pulley.
If the two belt pulleys are not aligned:
- Remove the power steering pump pulley.
- Use shims to adjust the distance so that two pulleys align.
- Then check the ribbed belt pulley alignment again using the (3201).
Installation, Continued
Installed position of the suction hose and pressure line on the pump and reservoir. Refer to => [ Suction and Return Hoses, Installed Position ].
- Install the new seals - 5 - on the banjo bolt.
- Tighten the banjo bolt - 2 -. Refer to - item 1 - in => [ Power Steering Pump Assembly Overview ] Power Steering Components.
- Install the suction hose - 3 - with a new clamp - 4 - and tighten the clamp. Note the installed position. Refer to => [ Suction and Return Hoses, Installed Position ].
- Top off the hydraulic fluid.
- Clean any hydraulic fluid that leaked into the engine compartment.
- Install the ribbed belt.
When installing the ribbed belt, make sure it is seated correctly on the pulleys.
• When installing the ribbed belt, ensure it is correctly seated on the pulleys.
1. Upper idler pulley
2. Vibration damper
3. Lower idler pulley
4. Power steering pump
5. A/C compressor
6. Belt tensioner
7. Generator
- Install the lock carrier.
- Install the bumper.
- Start the engine and check the belt running.
- Check the power steering fluid level. Refer to => [ Power Steering Fluid Level Checking ] Power Steering Fluid Level Checking.
- Check the steering system for leaks. Refer to => [ Steering System, Checking for Leaks ] Steering System, Checking For Leaks.
- Bleed the steering system. Refer to => [ Steering System, Bleeding after Reconstructing ] Service and Repair.
- Install the noise insulation.
- Place the vehicle on its wheels. Refer to => [ Positioning Vehicle on the Hoist and on its Wheels ] Positioning Vehicle on the Hoist and on its Wheels.
- Calibrate the Adaptive Cruise Control (ACC). Refer to => [ Adaptive Cruise Control Adjustment with VAS 6190 ] Adaptive Cruise Control Adjustment With VAS 6190.
Suction and Return Hoses, Installed Position
- The marking - P - on the suction hose - 1 - must align with the formed seam on the pump - 2 - - arrows -.
- The marking - 3 - on the suction hose and the marking - 4 - on the return hose must align with the formed seam - 2 - on the reservoir.
1. Bolt, 9 Nm