Power Steering Pump: Service and Repair

WM 489819 Removing and installing hydraulic pump - as of model year 2009

Tools





Technical values





Information





Overview of hydraulic pump





Preliminary work

DANGER

Vehicle raised incorrectly.

- Danger of fatal injury or material damage should the vehicle fall down.

-> Raise the vehicle at the prescribed jacking points.

1. Raise the vehicle.
-> 4X00IN01 Lifting the vehicle Service and Repair
2. Place protective covers on the vehicle to avoid damaging the body and passenger compartment.
3. Disconnect the battery. => 2706IN Work instructions after disconnecting the battery.
4. Remove rear wall cover.





Rear wall cover

-> 555919 Removing and installing rear wall cover Service and Repair
5. Remove engine compartment cover.





Engine compartment cover

-> 108319 Removing and installing engine cover
6. Remove resonance tube.
-> 247419 Removing and installing resonance tube - section on "Removing" Service and Repair
7. Remove right intake-air distributor.
-> 244619 Removing and installing intake-air distributor - section on "Removing" Service and Repair

Removing hydraulic pump

WARNING

Danger of injury and material damage when using Pentosin.

- Risk of skin irritation and damage to skin.
- Damage to hoses and wiring.

-> Wear protective gloves and goggles.
-> In the event of contact (eyes or skin), wash immediately with water.
-> Collect emerging Pentosin.
-> Use caps to protect the wiring against soiling and damage.
-> Clean hoses and wiring immediately.

Information

Cover engine openings (e.g. intake openings, crankcase, lines, open containers, etc.) with a cloth to prevent dirt and foreign bodies from getting into the openings.

The air-conditioning lines on the compressor do not need to be opened in order to remove the hydraulic pump. After removal, place the air-conditioning compressor on a suitable protective support (e.g. foam or neoprene).





Overview of hydraulic pump





1. Remove drive belt and pulley.
Loosen the M8 screws on the pulley before removing the drive belt.
-> 137819 Removing and installing drive belt Service and Repair.
1.1. Loosen screws -2- on the pulley -1-.





Pulley

1.2. Turn the tensioner -3- clockwise at the hexagon (a/f 30) using a ring wrench -2- and take off the drive belt -1-.





Relieving drive belt

1.3. Allow the tensioner to slide back to its initial position.
2. Remove the engine vent hose.
2.1. Release the engine vent hose -1- on the engine vent pipe -2- and pull it off.





Engine vent hose

2.2. Remove the engine vent hose -1- from the clip holder.
2.3. Unscrew screw -3- and pull the engine vent hose -1- out of the oil separator housing.
2.4. Release the engine vent hose -1- at the oil filler neck -4- and on cylinder bank 4-6 -5- and pull it off.





Engine vent hose

3. Disconnect and remove air conditioning compressor.
3.1. Partially detach hydraulic pump.





Hydraulic pump

Unscrew M8 x 30 screws -1- and detach the holder and fuel hose -2- at the hydraulic pump -3-.
3.2. Remove B+ box on the air conditioning compressor.





B+ box

3.2.1. Open lid -1- of B+ box. Loosen and unscrew M8 nut -2- and remove B+ cable.
3.2.2. Loosen and unscrew nuts -3- on the B+ box. Remove B+ box and set it aside.
3.3. Disconnect electric cable plug on the air conditioning compressor.





Cable plug on air conditioning compressor

Pull off electric cable plug -1- and pull connector housing out of the holder -arrow-.
3.4. Disconnect air conditioning compressor.





Air conditioning compressor





Unscrew screws -2, 3- and remove the holder -4-.
3.5. Remove air conditioning compressor.





Air conditioning compressor

Guide the air-conditioning lines -2- towards the cut-out on the right -arrow- in such a way that the air-conditioning lines -2- are not strained. Swivel air conditioning compressor -1- out backwards and set it down.
4. Drain hydraulic fluid at underbody connection point.
4.1. Remove rear underbody panelling.





Cover for rear underbody

Replace fastening nuts -2- following removal.
4.2. Remove underbody panel at the left side.





Side cover

Replace fastening nuts -3- following removal.
4.3. Open the plug-in couplings for the steering hydraulic system on the underbody. Collect emerging Pentosin in a suitable container.





Pressure and return lines

4.3.1. Follow the instructions for disconnecting lines: -> 4X00IN Plug-in couplings for hydraulic lines - as of model year 2009 Procedures.





Special tool 9780

4.3.2. Open hydraulic lines using release tool 9780.





Releasing plug-in coupling (as of model year 2009)

Re-connect the hydraulic lines -1, 2- immediately after draining them. Make sure that the supply and return hydraulic lines are not confused and that the connecting couplings lock with an audible click when you connect them.
4.3.3. Drain remaining fluid from the reservoir.





Collecting Pentosin

Extract Pentosin fluid from the supply tank with a pump. Dispose of extracted Pentosin according to the relevant regulations. Lay a cloth under the tank to collect any emerging Pentosin.
5. Remove hydraulic pump.
5.1. Disconnect return line to the reservoir for the hydraulic pump (release and pull it out at the same time).





Return line and holder on pump

Disassembly tool, universal NR.21
If you do not have a special tool to hand, press the circlip -centre arrow- forward using two plastic spatulas or an open-ended wrench (a/f 12) and pull the return line -right arrow- out at the same time.
5.2. Close off the return bore on the reservoir -2- with a stopper -1-.





Closing off return bore

5.3. Unscrew screw -1- on holder for hydraulic pump.





Holder for compressor

5.4. Remove hydraulic pump.





Hydraulic pump

5.4.1. Loosen and unscrew pressure line -1- on the hydraulic pump -3-. Counter at the connection piece (a/f 27) when detaching the pressure line -1- (a/f 16).
5.4.2. Unscrew M8 x 30 screw -2- on the hydraulic pump -3- and remove hydraulic pump -3- and reservoir.

Installing hydraulic pump

1. Install hydraulic pump.
1.1. Install hydraulic pump.





Hydraulic pump

1.1.1. Fit the hydraulic pump -3- and reservoir assembly and screw in and tighten M8 x 30 screw -2- on the hydraulic pump -3-.
1.1.2. Screw in and tighten pressure line -1- on the hydraulic pump -3-. Counter at the connection piece (a/f 27) when tightening the pressure line -1- (a/f 16).
=> Tightening torque: 35 Nm (26 ftlb.)
1.2. Screw in and tighten screw -1- on holder for hydraulic pump.





Holder for hydraulic pump

=> Tightening torque: 10 Nm (7.5 ftlb.)
1.3. Remove stopper -1-.





Removing stopper

1.4. Connect return line to the reservoir for the hydraulic pump.





Hydraulic pump return line

Fit and press in return line on the hydraulic pump reservoir -arrow-.
2. Guide in and fit air conditioning compressor.
2.1. Fit air conditioning compressor.





Air conditioning compressor

Guide the air-conditioning lines -2- towards the cut-out on the right -arrow- in such a way that the air-conditioning lines -2- are not strained. Swivel air conditioning compressor -1- forward and position it correctly.
2.2. Fit air conditioning compressor.





Air conditioning compressor





Fit holder -4- and screw in and tighten screws -2, 3-.
=> Tightening torque: 23 Nm (17 ftlb.)
2.3. Fit B+ box on the air conditioning compressor.





B+ box

2.3.1. Remove B+ box and fit it on the air-conditioning compressor holder. Screw on and tighten nuts -3- on the B+ box.
2.3.2. Connect B+ cable and screw on and tighten M8 nut -2-. Close lid -1- of B+ box.
2.4. Connect electric cable plug to the air conditioning compressor.





Electric cable plug for compressor

Press connector housing into the holder -arrow- and connect electric cable plug -1-.
2.5. Secure hydraulic pump.





Hydraulic pump

Fit holder with fuel hoses -2- to the hydraulic pump -3- and screw in two M8 x 30 screws -1-. Tighten the screws -1- and the three lower fastening screws (M8 x 30).
=> Tightening torque: 23 Nm (17 ftlb.)
3. Connect plug-in couplings for the steering hydraulic system.
3.1. Connect the plug-in couplings for the steering hydraulic system (pressure and return lines) on the underbody if necessary (if you have not already done so after draining the fluid.





Pressure and return lines

Make sure that the hydraulic line connections are not confused and are engaged correctly.
3.2. Install underbody panelling at the left side.





Side cover

Replace nuts and screws -2, 3-.
Tighten nuts and screws -2, 3-.
Nuts
=> Tightening torque: 5 Nm (3.5 ftlb.)+/-1 Nm (+/-0.5 ftlb.)
Screws
=> Tightening torque: 2 Nm (1.5 ftlb.)+/-1 Nm (+/-0.5 ftlb.)
3.3. Install rear underbody panelling.





Cover for underbody

Replace screws -1-.
Replace nuts -2-.
Tighten screws.
=> Tightening torque: 2 Nm (1.5 ftlb.)+/-1 Nm (+/-0.5 ftlb.)
Tighten nuts.
=> Tightening torque: 5 Nm (3.5 ftlb.)+/-1 Nm (+/-0.5 ftlb.)
4. Install pulley and tighten the drive belt.
-> 137819 Removing and installing drive belt Service and Repair.
4.1. Insert pulley and fit M8 screws on the pulley.





Pulley

4.2. Turn the tensioner -3- clockwise at the hexagon (a/f 30) using a ring wrench -2- and fit the belt -1-.
4.3. Allow the tensioner to slide back to its initial position.
4.4. Tighten screws -4- on the pulley.
=> Tightening torque: 23 Nm (17 ftlb.)
5. Install engine vent hose.
5.1. Connect the engine vent hose -1- at the oil filler neck -4- and on cylinder bank 4-6 -5-.





Engine vent hose

5.2. Fit and engage the engine vent hose -1- on the engine vent pipe -2-.





Engine vent hose

5.3. Insert engine vent hose -1- into the clip holder.
5.4. Insert engine vent hose -1- into the oil separator housing and screw in and tighten the screw -3-.
=> Tightening torque: 10 Nm (7.5 ftlb.)

Subsequent work

1. Install right intake-air distributor.
-> 244619 Removing and installing intake-air distributor - section on "Installing" Service and Repair
2. Install resonance tube.
Tighten screw-type clamps at the correct position.
-> 247419 Removing and installing resonance tube - section on "Installing" Service and Repair
3. Connect the battery.
-> 2706IN00 Work instructions after disconnecting the battery.
4. Fill in hydraulic fluid, bleed the power steering and check for leaks. Then check the power-steering fluid level again. -> 48020150 Checking power-steering fluid level Testing and Inspection.
5. Install engine compartment cover.





Cayman engine compartment cover

-> 108319 Removing and installing engine cover
6. Install rear wall cover.





Rear wall cover

-> 555919 Removing and installing rear wall cover Service and Repair