Power Steering Pump

Assembly overview
It is not intended that repair work be carried out on the power steering pump. If complaints are received determine cause with the help of pressure tests.

Notes:
^ If reservoir fluid level is low then check steering system for leaks.
^ In the case of leaks at the line connections first tighten connections and wipe dry then recheck for leaks.
^ Pumps supplied as spare parts are not filled with oil. Therefore it is essential to fill the pump with hydraulic oil G 002 000 and to rotate pump by hand, otherwise the pump may be damaged or be noisy during operation.
^ Type of oil: hydraulic oil G 002 000
^ Oil system capacity: 0. 7 to 0. 9 liter.





1. Power assisted steering gear
2. Pressure hose
3. Return hose
4. Cap with dip stick
^ Checking oil level
5. Strainer
6. Hex bolt, 9 Nm
7. Reservoir
8. Rubber mounting
9. Hose clip
^ Tension with VAG 1275
^ Always replace
10. Return hose
^ Between reservoir and cooling line
11. Hose clip
^ Tension with VAG 1275
^ Always replace
12. Hex bolt, 10 Nm
13. Cooling line
14. Cable tie
15. Hose clip
^ Tension with VAG 1275
^ Always replace
16. Suction hose
17. Hex bolt, 8 Nm
18. Retainer
^ Bolted to cylinder head
19. Hose clip
^ Tension with VAG 1275
^ Always replace
20. Threaded - union, 50 Nm
21. Oil seal, 18 x 24
^ Always replace
22. Oil seal, 16 x 22
^ Always replace
23. Power steering pump
^ Checking delivery pressure
^ Fill with oil before installing
24. Banjo bolt, 50 Nm
25. Pressure hose
^ Tighten to 40 Nm
- Screw onto pressure hose, when doing this counter hold on pressure hose hex.
^ Bolted to intake line with hex bolt -item 26
26. Hex bolt, 8 Nm
27. Bracket
28. Hex nut, 20 Nm
29. Washer
30. Coolant line

Power steering pump, assembly overview for vehicles with 6 cylinder engine
Special tools, workshop equipment, test and measuring appliances and aux. items required





^ 3094 Hose clamps
^ VAG 1402 Power steering test module
^ VAG 1402/3 Adapter





- Unclip engine cover and take off.





- Unscrew ribbed belt cover -arrows-.
- Clamp off suction hose with hose clamp -3094-.





- Press connector spring clip and pull connector off injector.
- Unscrew line from pressure hose (arrow), when doing this counter-hold on pressure hose hex.





- Screw adapter VAG 1402/3 into line in place of pressure hose.





- Screw pressure gauge -VAG 1402 hose onto adapter -VAG 1402/3-.
- Close gauge shut-off valve (lever to left).
- Install injector connector onto injector.
- Remove hose clamp from suction hose.
- Start engine and if necessary, add fluid to reservoir.
- Read off gauge pressure with engine at idling speed (do not measure longer than 10 seconds). Specification: 110 - 120 bar.
If the specifications are not reached, replace power steering pump.
- Check hydraulic oil level.
- Check steering system for leaks.
- Bleed steering system.

Power steering pump, assembly overview for vehicles with 6 cylinder engine

Notes:
^ Replace sealing rings.
^ Do not reuse drawn off hydraulic oil.
^ Hydraulic oil: Part No. G 002 000
^ Quantity of oil in system approx. 1 liter.





1. Pressure line with hose
2. Hex bolt, 8 Nm
3. Hole on intake line
4. Power steering pump
^ Checking delivery pressure
^ Fill with oil before installing = Note
5. Belt pulley
6. Hex socket head bolt, 25 Nm
^ When loosening and tightening counterhold with VAG 1590 if necessary
7. Hex bolt, 25 Nm
8. Hex socket head bolt, 25 Nm
9. Bracket
10. Ignition coil with bracket
11. Hex socket head bolt, 25 Nm
12. Banjo bolt, 50 Nm
= Page 48-93, item 24
13. Oil seal, 16 x 22
^ Always replace
14. Oil seal, 1 8 x 24
^ Always replace
15. Threaded - union, 50 Nm
16. Hose clip
^ Tension with VAG 1275
^ Always replace
17. Hex bolt, 25 Nm
18. Sleeve, slotted
19. Hex socket head bolt, 25 Nm
20. Mounting - bracket
21. Suction line with hose
22. Hex bolt, 8 Nm