Power Steering Pump: Service and Repair

Power steering pump, removing and installing (Vehicles with 4-cyl. engine)





Special tools required

Removing





- Remove undertray.
- Remove front bumper.
- Move lock carrier to assembly position.

Lock carrier, moving to assembly position





1. Lock carrier
2. Bolt
^ Qty. 6
^ 50 Nm (37 ft. lbs.)
3. Bolt
^ 50 Nm (37 ft. lbs.)
4. Bolt
^ Qty. 2
^ 8 Nm (70 inch lbs.)
5. Seal
6. Bowden cable
7. Hole in side panel
8. Bolt
^ Qty. 2
9. Hole for special tool
^ Special tool 3369
- Remove front bumper.
- Remove air guide between lock carrier and air cleaner on lock carrier.
- Remove bolt -3- and screw special tool 3369 onto right and left-hand longitudinal members.
- Remove bolts -2- and -4- and pull lock carrier forward in area of special tool 3369.


Removing ribbed V-belt on vehicles with 4-cyl. gasoline engine





- Turn tensioning device in direction of arrow to relieve tension on ribbed belt.
- Secure with special tool -3204-.

Removing ribbed V-belt on vehicles with 4-cyl. Diesel engine





- Turn tensioning device in direction of arrow to relieve tension on ribbed belt.

Vehicles with 4-cyl. gasoline engine





- Remove pulley from coolant pump.
- Remove ribbed belt.
- Remove power steering pump ribbed belt pulley.

Note: It may be necessary to file out corners of tool VAG 1590

Continuation for all vehicles





- Clamp off suction and return lines with clamps 3094 or equivalent.
- Place oil tray under engine compartment.





- Remove clamp -1- from suction hose.
- Pull off suction hose, remove from retainer and place to side.
- Remove pressure hose banjo bolt -2- (22 mm AF).





- Remove bolts -1- and socket head bolt -2-.
- Remove power steering pump.

Installing
- Fill pump with hydraulic fluid through suction port.
- Turn pump hub by hand until fluid flows out of pressure side port.





- Tighten bolts -1- and -2- to 20 Nm (15 ft. lbs.).
The remaining installation is done in the reverse order of removal noting the following points:
- Install new sealing rings onto banjo bolt.





- Tighten pressure hose banjo bolt -2- to 50 Nm (37 ft. lbs.).
- Install suction hose.





- Tighten coolant/power steering pump pulley bolts to 25 Nm (18 ft. lbs.).
- Install radiator fan to viscous coupling.
Tightening torque: 10 Nm (7 ft. lbs.)





- Install ribbed belt

Note: Make sure the belt is correctly seated in the pulley when installing. For ease of illustration the routing is shown without the lock carrier in position

- Top up hydraulic fluid with G 00200.
- Install bumper.
- Start engine and check belt operation.
- Check hydraulic fluid level. Refer to Power Steering Fluid; Testing and Inspection.
- Check steering system for leaks. Refer to Power Steering Fluid; Testing and Inspection.
- Bleed steering system. Refer to Power Steering Fluid; Service and Repair.