Power Steering Pump, Vehicles With Dynamic Steering
Power Steering Pump, Vehicles with Dynamic Steering
Power Steering Pump Overview
• Always replace seals.
• Do not reuse fluid you have drained.
• Only use hydraulic oil.
1 Bracket
2 Sleeve
• Drive the sleeve back slightly to install the power steering pump.
3 Bolt
• 20 Nm
4 Clamp
• Tension using hose clamp pliers (V.A.G 1275)
• Always replace if removed.
5 Intake Hose
• The marking "P" on the suction hose - arrow - must align with the formed seam - arrow - on the power steering pump.
6 Power Steering Pump Control Valve (V119)
• The power steering pump and the control valve are one component and can only be replaced together.
7 Steering Hydraulic Pump (V119)
• With power steering pump control valve
• The power steering pump and the control valve - item 6 - => [ (Item 6) ] are one component and can only be replaced together.
• Allocation, refer to the Parts Catalog
• Fill with hydraulic oil before installation
• Checking delivery pressure, refer to => [ Power Steering Pump Delivery Pressure, Checking ] Testing and Inspection
• Bleed the steering, refer to => [ Steering, Bleeding after Replacing ] Service and Repair.
• Check hydraulic fluid level, refer to => [ Power Steering Fluid Level, Checking ] Power Steering Fluid Level, Checking.
• Steering system, checking for leaks, refer to => [ Steering, Checking for Leaks ] Steering, Checking For Leaks
8 Seal
• Always replace if removed.
9 Union Nut
• 38 Nm
10 Pressure Line
• Insert the pressure line completely when installing.
• Note the installation position: The angle between the line connection and power steering pump axle is approximately 59°
• Depending on the version, also mounted to the A/C compressor
11 Bolt
• 22 Nm
12 Belt Pulley
13 Bolt
• 20 Nm
• For securing the bracket to the engine.
• Note the different bolt lengths.
14 Bolt
• 20 Nm
• For securing the bracket to the engine.
• Note the different bolt lengths.
15 Bolt
• 20 Nm
• For securing the power steering pump to the bracket
16 Bolt
• 20 Nm
• For securing the bracket to the engine.
Removing
Special tools, testers and auxiliary items required
• Hose Clamps Up to 25 mm Dia. (3094)
• Hose Clamp Pliers (V.A.G 1275)
• Torque Wrench 5-50 Nm (V.A.G 1331)
• Tool Insert, AF 17 (V.A.G 1331/6)
• Used Oil Collection and Extraction Device (V.A.G 1782)
• Drip Tray for VAS 6100 (VAS 6208)
• Spanner Wrench (3212)
• Engine Bung Set (VAS 6122)
General Information
Vane pump is not designed to be serviced. If there are customer complaints, the cause must be determined using a pressure and leak test. If there is a malfunction, replace the vane pump.
• If power steering fluid is low in reservoir, check 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.
• Power steering pump is delivered without oil. Therefore, hydraulic oil must be filled before installation and turned by hand. Otherwise, noises when driving or damage to power steering pump may occur.
- Place the vehicle on a hoist.
- Remove the engine cover upward - arrows -.
- Extract hydraulic oil from reservoir using (V.A.G 1782).
- Clamp off the suction hose - 1 - and return hose - 2 - using the (3094).
• The (3094) must not be secured on the return hose - 2 - in the check valve area. Otherwise, check valve will be damaged.
• The check valve is located in the return hose - 2 - between the hose clamps - arrows -.
- Remove noise insulation.
- Open the clamp - 1 - on the left longitudinal member and remove the coolant hose - 2 -.
- Remove the nuts - 1 - and the coolant reservoir - 2 - with the lines attached.
- Release and disconnect the connector on the coolant reservoir - 2 -.
• Identify direction of travel before removing ribbed belt. Reversed direction of travel with a used belt can lead to malfunctions. When installing ribbed belt, make sure it is seated correctly on pulleys.
- Move the tensioner in the direction of the - arrow - to release the tension on the ribbed belt.
- Remove the ribbed belt from the power steering pump belt pulley.
- Release the tensioner and remove the tool.
- Mark the position of the belt pulley to the hub. Make a marking - arrow -.
• If the power steering pump will be replaced, transfer the marking from the hub on the old pump to the new one.
• Because of space restrictions, it is not possible to see the position of the belt pulley holes to the holes in the hub when installing.
- Remove bolts - arrows -. Use (3212) as counter hold.
- Remove belt pulley for vane pump.
- Place the (VAS 6208) under the power steering pump.
- Carefully cut through the cable ties - 1 - for the wiring harness - 2 -.
- Remove the clamp - 4 - from the intake hose - 3 -. Remove the suction hose - 3 -.
- If the pressure line is also attached to the Air Conditioning (A/C) compressor, then remove the bolt - C - for the bracket - D -.
- Remove the union nut - 1 - and pull the pressure line out of the power steering pump.
- Release and disconnect the connector - 2 -.
- Seal the power steering pump and line connections using clean sealing plugs.
- Remove the power steering pump from the bracket. Remove the front bolts - 1 - and rear bolt - 2 -.
• The bolt - 2 - cannot be seen in the bracket. The illustration shows it unscrewed.
- Remove the bolts - 1 - from the bracket - 3 -.
- Release and disconnect the connector - 3 -.
- Remove the bolt - 1 - and the bracket - 2 -.
- Remove the bolt - 3 -.
- Drive the sleeve - 2 - in the bracket back slightly to install the power steering pump.
- Remove the power steering pump.
Installing
Install in reverse order of removal. Note the following:
Tightening specifications, refer to => [ Power Steering Pump, Vehicles with Dynamic Steering ]
• Replace seals and gaskets.
• Before installing the new power steering pump on the intake side, fill the hydraulic oil and install it by hand until oil drains out on the high pressure side.
• Secure all hose connections with new hose clamps, refer to the Parts Catalog.
- Insert the power steering pump with the bracket.
- Position the bracket - 2 - using the bolt - 1 -.
- Connect the connector - 3 -.
- Note the installation dimension of the clamp. Dimension - a - must be 4 mm.
- Before installing the power steering pump, connect the intake hose - 1 - and align the marking - 5 - on the power steering pump with the "P" marking - 3 -.
- Secure the suction hose - 1 - with the new clamp - 2 -.
- Secure the wiring harness on the supports using a new cable tie - 4 -.
• The clamp - 2 - cannot be tightened using the (V.A.G 1275) when the power steering pump is installed due to restricted space.
- Attach the bracket - 3 - and tighten the bolts - 1 -.
• The sleeve - 2 - is driven back slightly.
- Turn the hub by hand until oil runs out of the pressure side.
- Insert the power steering pump in the bracket.
- First install the bolts - 1 - loosely.
- Then install the rear bolt - 2 - loosely.
- Install and tighten the bolts - 1 and 2 -.
- Press the pressure line into the power steering pump as far as the stop. Then tighten the union nut - 1 -.
- Connect the connector - 2 -.
- If the pressure line is also attached to the A/C compressor, then tighten the bolt - C - for the bracket - D -.
- Clean oiled places in engine compartment.
- Align the marking - arrow - made on the belt pulley to the marking made on the hub.
- Tighten the belt pulley bolts - arrows -.
Install power steering pump ribbed belt.
- Check power steering fluid level. Refer to => [ Power Steering Fluid Level, Checking ] Power Steering Fluid Level, Checking.
- Bleed the steering. Refer to => [ Steering, Bleeding after Replacing ] Service and Repair.
- Check the steering for leaks. Refer to => [ Steering, Checking for Leaks ] Steering, Checking For Leaks.
- Install noise insulation.
- Install ribbed belt and check alignment of ribbed belt.
• When installing ribbed belt, ensure it is correctly seated in ribbed belt pulley.
1. Generator
2. Idler pulley
3. Coolant pump
4. Power Steering Pump
5. A/C Compressor
6. Tensioner pulley
7. Crankshaft