Power Steering Pump: Service and Repair

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

Note:
- Replace sealing rings.
- Do not reuse drawn off hydraulic oil.
- Hydraulic oil: Part No. G 002 000
- Quantity of oil in system approximately 1 liter.
1. Pressure line with hose
2. Hex bolt, 8 Nm
3. Hole on intake line
4. Power steering pump
^ Checking delivery pressure, Refer to Power Steering Pump, Testing and Inspection, Power Steering pump delivery pressure for vehicles with 6-cylinder engine
^ Fill with oil before installing
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
13. Oil seal, 16 x 22
^ Always replace
14. Oil seal, 18 x 24
^ Always replace
15. Threaded union, 50 Nm
16. Hose clip
^ Tighten 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

Removing:
- Remove upper engine cover.
- Remove ribbed belt guard
- Relieve tension on ribbed belt
- Remove belt pulley, counter-hold with VAG 1590 if necessary.
- Pull ignition cable out of ignition coils -10 -.
- Clamp off suction hose with 3094.
- Remove suction and pressure lines.
- Remove bracket item - 9 - and remove complete with power steering pump.
- Remove bolts for power steering pump from bracket and take off power steering pump.

Installing:
Install in reverse order.

Note: Ignition cable application must equate to numbers marked.





Fig. 1 Unclipping top engine cover and removing





Fig. 2 Removing ribbed belt guard





Fig. 3 Relieving tension and removing ribbed belt

- To relieve tension on ribbed belt, push hex socket head wrench (10 mm AF) downward.
- Align hole -A- with hole -B-.
- Insert pin -3204- to secure.
- Take ribbed belt off belt pulley.





Fig. 4 Allocating ignition cables to ignition coils
A - Ignition coil for cylinders 5 and 3
B - Ignition coil for cylinders 4 and 2
C - Ignition coil for cylinder 6 and 1
Ignition cables are marked with number 1... 6.
- Allocate ignition cables 6 and 1 to ignition coil -C-.
- Allocate ignition cables 2, 3, 4 and 5 in the same manner.





1. Power assisted steering gear
^ Assembly overview, Refer to Power Steering Gear, Service and Repair, Power Steering Gear Disassembling and Assembling
2. Pressure hose
3. Return hose
4. Backplate
5. Cap with dip stick
^ Checking oil level
6. Hex bolt, 9 Nm
7. Reservoir
8. Rubber mounting
9. Hose clip
^ Tighten with VAG 1275
^ Always replace