6-Cylinder FSI

Power Steering Pump, without Dynamic Steering

Assembly 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 Bolt

• 20 Nm

• For securing the bracket to the engine.

• Note the different bolt lengths.

5 Bolt

• 20 Nm

• For securing the bracket to the engine.

• Note the different bolt lengths.

6 Clamp

• Tension using hose clamp pliers (V.A.G 1275).

• Always replace if removed.

7 Intake Hose

• The marking "P" on the suction hose - arrow - must align with the formed seam - arrow - on the power steering pump.

8 Seal

• Always replace if removed.

9 Pressurized Line


• Insert the pressure line completely when installing.

• Depending on the version, also mounted to the A/C compressor.

10 Bolt

• 9 Nm

11 Power Steering Pump

• Allocation, refer to the Electronic Parts Catalog (ETKA).

• 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 => [ Power Steering, Bleeding after Replacing ] Power Steering, Bleeding after Replacing.

• Checking hydraulic fluid level, refer to => [ Power Steering, Checking Fluid Level ] Power Steering, Checking Fluid Level.

• Steering system, checking for leaks => [ Steering System, Checking for Leaks ] Steering System, Checking For Leaks.

12 Belt Pulley

13 Bolt

• 22 Nm

14 Bolt

• 20 Nm

• For securing the power steering pump to the bracket.

15 Bolt

• 20 Nm

• For securing the bracket to the engine.

Removing

Special tools, testers and auxiliary items required

• Hose clamps up to 25 mm diameter (3094)

• Spanner wrench (3212)

• Hose clamp pliers (V.A.G 1275)

• Torque wrench (V.A.G 1331)

• Used Oil Collection and Extraction Device (V.A.G 1782)

• Shop Crane Drip Tray (VAS 6208)

• Sealing plug set (VAS 6122)

General Information

• The power steering 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 pump.

• If there is no fluid in the reservoir, then the steering system must always be checked 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).

- Remove the intake hose - 1 - and the return hose - 2 - with 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 the noise insulation. Refer to => Body Exterior 66 Description and Operation.

- Open the clamp - 1 - on the left longitudinal member and remove the coolant hose - 2 -, where applicable.






- 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 counterhold.






- Remove belt pulley for pump.

- Place the (VAS 6208) under the power steering pump.

- Carefully cut through the cable ties - 1 - for the wiring harness - 2 - if applicable.






- Remove the clamp - 4 - from the intake hose - 3 -. Remove the suction hose - 3 -.

- If the pressure line is also attached to the A/C compressor, then remove the bolt - C - for the bracket - D -.






- Remove the bolts - 1 - and pull the pressure line - 2 - out of the power steering pump.






- 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 power steering pump.

Installing






Install in reverse order of removal. Pay attention to the following:

- Drive the sleeve - 2 - in the bracket back slightly to install the power steering pump.

Ignore - 1 - and - 2 -.

Tightening specifications, refer to => [ Power Steering Pump, without 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. Allocation, refer to the Electronic Parts Catalog (ETKA).

• The clamp - 2 - cannot be tightened using the (V.A.G 1275) when the power steering pump is installed due to restricted space.

- 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 -, where applicable.

- Note the installation dimension of the clamp. Dimension - a - must be 4 mm.






- 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 -.

• Make sure the intake hose is installed correctly and is not twisted or bent.

- Turn the hub by hand until oil runs out of the pressure side.

- Press the pressure line - 2 - into the power steering pump as far as the stop. Then tighten bolts - 1 -.






- 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, Checking Fluid Level ] Power Steering, Checking Fluid Level.

- Bleed the steering. Refer to => [ Power Steering, Bleeding after Replacing ] Power Steering, Bleeding after Replacing.

- Check the steering for leaks. Refer to => [ Steering System, Checking for Leaks ] Steering System, 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