Removal and Installation
Power Steering Components
=> [ Power Steering Pump ]
=> [ Suction Hose Installed Position ]
Power Steering Pump
Special tools, testers and auxiliary items required
• Alignment gauge (3201)
• Spanner wrench (3212)
• Torque wrench (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
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.
- Remove the left front wheel.
• Secure the brake disc using two wheel bolts.
- Open the quick release fasteners - arrows - at the bottom left and right of the wheel housing liners.
- Loosen the quick release fasteners - 1 - and remove the front noise insulation.
• Press the locking pins on the wheel housing liners only about 5 mm into the expanding clip and not all the way through.
• This releases the locking pin so it can be removed.
• When installing, slide the locking pin back and the expanding clip can be used again.
- Press the locking pins on the expanding clips - 1 - on the front wheel housing liner about 5 mm deep into the expanding clip using a screwdriver.
- Remove the expanding clip.
- Remove the bolt - 2 - from the wheel housing liner.
- Remove both bolts - arrows - from the front wheel housing liner.
Do not remove the rear wheel housing liner - 2 -.
- Remove the upper bolt - arrow - from the front wheel housing liner.
• Press the locking pins on the wheel housing liners only about 5 mm into the expanding clip and not all the way through.
• This releases the locking pin so it can be removed.
• When installing, slide the locking pin back and the expanding clip can be used again.
- Press the locking pins on the expanding clips - arrow - on the front wheel housing liner about 5 mm deep into the expanding clip using a screwdriver.
- Remove the expanding clip.
- Repeat the procedure to remove the expanding clip - arrow - in the upper area of the front wheel housing liner.
- Repeat the procedure to remove the expanding clip - arrow - in the rear area of the front wheel housing liner - 1 -.
- Place the (VAS 6208) underneath to collect the hydraulic fluid.
- Loosen the 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.
- Remove both air guide hoses - arrows - on the bottom of the lower left air filter housing section. Press the release buttons together to do that.
- Disconnect the electrical connector - 3 - for the Mass Air Flow (MAF) sensor 2 (G246).
- Remove the hose - 2 - from the air guide hose.
- Remove the air guide hose - 1 - from the intake manifold.
- Remove the screws - arrows -.
- Remove the air filter housing left upper section.
- Remove the air duct - 1 -.
- Remove the screws - arrows -.
- Remove the air filter housing lower left section.
- Remove the engine cover upward, first at the rear and then in the center - 1 arrows -.
- Remove the engine cover forward from the intake manifold - 2 arrows -.
- Rotate the tensioner in the - direction of the arrow - to release the ribbed belt tension.
- Remove the ribbed belt from the power steering pump pulley, release the tensioner.
• The ribbed belt remains routed on the other belt pulleys.
- Remove the power steering pump pulley - 1 - bolts - arrows -.
- Remove the bolts - arrows - and the power steering pump.
Installing
Installation is performed in the reverse order of removal. Observe the following when doing so:
• 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.
- Tighten the bolts - arrows -. Refer to - items 5 and 8 - in => [ Power Steering Pump Assembly Overview ] Power Steering Components.
Checking and Adjusting the Belt Pulley Alignment
Installed position: The raised section - 1 - on the pulley faces in the direction of travel.
- Tighten the power steering pump pulley bolts - arrows -.
- Place the (3201) on the A/C compressor pulley.
- Determine the centered position of the power steering pump shaft by moving the pump shaft back and forth.
The power steering pump pulley must align with the A/C compressor pulley when centered.
If the two pulleys are not aligned:
- Balance out the distance from the power steering pump pulley - 2 - to the A/C compress pulley using shims - 3 - in varying thicknesses.
- Then check the pulley alignment again using the (3201).
Installation, Continued
- Install the new seals - 5 - on the banjo bolt.
- Tighten the banjo bolt - 2 -. Refer to - item 12 - 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 - item 15 - in => [ Power Steering Pump Assembly Overview ] Power Steering Components.
- Top off the hydraulic fluid.
- Clean any hydraulic fluid that leaked into the engine compartment.
- Install the ribbed belt.
- Bleed the steering system. Refer to => [ Steering System, Bleeding after Reconstructing ] Service and Repair.
- Check the steering system for leaks. Refer to => [ Steering System, Checking for Leaks ] Steering System, Checking For Leaks.
- 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.
Suction Hose Installed Position
- The marking - P - on the suction hose - 1 - must align with the formed seam on the pump - 2 - - arrows -.
- The marking on the suction hose - 2 - must align with the seam - 1 - on the reservoir.
- The marking on the return hose - 2 - must align with the seam - 1 - on the reservoir.
