Removal and Installation
Power Steering Components
=> [ Power Steering Pump ]
=> [ Power Steering Pump Seal and O-Ring ]
=> [ Suction and Return Hoses, Installed Position ]
Power Steering Pump
Special tools, testers and auxiliary items required
• 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)
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.
• Replace the power steering pump seal and O-ring before installing.
Vane pump is not designed to be serviced. If a customer has reported a problem, determine cause via pressure test and leak test. If there is a malfunction, replace the vane pump.
Removing
- 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).
- Remove the engine.
- Lower the engine with the transmission attached onto the (VAS 6131).
- Remove the left catalytic converter.
- Remove the left drive axle heat shield bolts - arrows - and shield.
- Remove the left drive axle from the transmission flange.
- Remove the left front wheel.
- Place the (VAS 6208) underneath to collect the hydraulic fluid.
- Remove the clamp from the suction hose - 1 -.
- Remove the suction hose from the pump.
- Remove the pressure line banjo bolt - 2 - and line from the pump.
- Remove the bolts - 4 -.
- Remove the bolt - 3 -.
- Remove the power steering pump.
- If the power steering pump - 1 - is replaced, the seal - 2 - and input shaft - 3 - must also be replaced.
- Replace the power steering pump seal and O-ring - arrow -. Refer to => [ Power Steering Pump Seal and O-Ring ].
Installing
Installation is performed in the reverse order of removal. Observe the following when doing so:
• Replace the seals and gaskets.
• Clean any hydraulic fluid that leaked into the engine compartment.
• Always replace the O-ring on the input shaft of the pump.
• 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.
• Hose connections and hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps appropriate to the model.
- Complete the power steering pump as shown in the illustration and install on the engine.
1. Power steering pump
2. Seal
3. Input shaft
- Install the pressure line and banjo bolt - 2 - to the pump. Refer to - item 6 - in => [ Power Steering Pump Assembly Overview ] Power Steering Components.
- Tighten the bolts - 4 -. Refer to - item 3 - in => [ Power Steering Pump Assembly Overview ] Power Steering Components.
- Tighten the bolt - 3 -. Refer to - item 6 - in => [ Power Steering Pump Assembly Overview ] Power Steering Components.
- Install the suction hose - 1 - to the pump and secure with the clamp.
- Top off the hydraulic fluid.
Suction hose, location on power steering pump. Refer to => [ Suction and Return Hoses, Installed Position ].
- Clean any hydraulic fluid from areas on the subframe.
- Install the drive axle. Refer to => [ Drive Axle ] Drive Axle.
- Install the left catalytic converter.
- Install the engine.
- Only tighten the subframe bolts to the specification, do not tighten them further (only tighten the bolts after an alignment).
CAUTION!
If the vehicle will be driving on the streets, all bolts and nuts must be tightened properly!
- 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.
- Perform a vehicle alignment. Refer to => [ Wheel Alignment ] Wheel Alignment.
Power Steering Pump Seal and O-Ring
Special tools, testers and auxiliary items required
• Pulling hook (T20143/1)
• Thrust piece (T40052)
Removing
- Remove the power steering pump. Refer to => [ Power Steering Pump ].
- Pry the seal out with the (T20143/1).
- Replace the O-ring - 2 - for the power steering pump input shaft.
Installing
Installation is performed in the reverse order of removal. Observe the following when doing so:
- Coat the O-ring - arrow - lightly with engine oil and insert it in the power steering pump input shaft.
- Drive the seal in with the (T40052).
- Install the power steering pump.
Suction and Return Hoses, Installed Position
- The marking - P - on the suction hose - 2 - must align with the formed seam on the pump - 1 - - 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.
