Steering: Service and Repair
Power steering pump with hydraulic lines/hoses, assembly overview
I - Vehicles with high mounted power steering pump
II Vehicles with low mounted power steering pump
1. Reservoir
2. Pressure hose/line mounting
Vehicles with TDI engine and A/C
3. Pressure hose/line mounting
Vehicles with TDI engine and no A/C
4. Pressure hose/line mounting
Vehicles with TDI engine and A/C
5. Pressure hose/line mounting
On 5-speed manual transmission 02J
6. Pressure hose/line mounting
On automatic transmission
7. Power steering pump
Disassembling and assembling reservoir
1. Cap with dip stick
^ Oil level: between min. and max. marks;
Engine temperature approx. 50° C (122°F)
^ Arrow A: oil level with engine cold
^ With engine cold, oil level must not rise above Min. marking
^ Check oil level with cap screw on
^ Open cap with e.g. a bar
2. Hose clamp
3. Return hose
4. Suction hose
5. Hex. socket head bolt, 10 Nm (89 inch lbs.)
6. Reservoir
Securing pressure line and suction hose on vehicles with TDI engine and A/C
1. Power steering pump
2. Suction hose
3. Mounting bracket
4. Pressure hose
5. Hex. bolt, 10 Nm (89 inch lbs.)
6. Clamp
7. Banjo bolt, 38 Nm (28 ft. lbs.)
8. Sealing ring
^ Always replace
9. Suction hose
10. Reservoir
Securing pressure line and suction hose on vehicles with 1.9 TDI and 2.0 ltr. engines without A/C
1. Power steering pump
2. Suction hose
3. Pressure hose
4. Banjo bolt, 38 Nm (28.03 ft. lbs.)
5. Sealing ring
^ Always replace
6. Suction hose
White or yellow ring must seat within retainer item - 7 -
7. Retainer
8. Hex. nut
9. Mounting bracket
Securing pressure line and suction hose on vehicles with A/C and 2.0 ltr. or VR6 engines
1. Power steering pump
2. Suction hose
3. Pressure hose
4. Banjo bolt, 38 Nm (28.03 ft. lbs.)
5. Sealing ring
^ Always replace
6. Suction hose
White or yellow ring must seat within retainer item - 7 -
7. Retainer
8. Hex. nut
9. Mounting bracket
Securing pressure line and suction hose on vehicles with 1.8 ltr. engines with A/C
1. Power steering pump
2. Suction hose
3. Pressure hose
4. Pressure switch
^ Switches at 40 bar (580 psi)
- Tighten to 15 Nm (11 ft. lbs.)
5. Sealing ring
^ Always replace
6. Banjo bolt, 38 Nm (28.03 ft. lbs.)
7. Sealing ring
^ Always replace
8. Suction hose
White or yellow ring must seat within retainer item - 9 -
9. Retainer
10. Hex nut
11. Mounting bracket
Pressure line and suction hose vehicles with 1.8 ltr. engines with AG350 (09A) transmission
1. Securing bolt on starter
2. Mounting bracket
3. Hex nut, 25 Nm (18 ft. lbs.)
4. Clamp
5. Hex bolt, 22 Nm (16 ft. lbs.)
6. Pressure hose
7. Securing bolt on transmission
Securing pressure line on 5 & 6 -speed manual transmission 02J &02M
1. Pressure line
2. Speed nut
3. Clamp
4. Hex. bolt, 22 Nm (16 ft. lbs.)
5. Hex. nut, 25 Nm (18 ft. lbs.)
6. Mounting bracket
7. Pressure hose
8. Hex. bolt, 22 Nm (16 ft. lbs.)
Securing pressure line on automatic transmission 01M
1. Securing bolt on starter
2. Hex. bolt, 22 Nm (16 ft. lbs.)
3. Clamp
4. Hex. nut, 25 Nm (18 ft. lbs.)
5. Mounting bracket
6. Pressure hose
7. Securing bolt on transmission