Power steering pump, removing and installing Page 1 of 20
48-44
Power steering pump,
removing and installing
Notes:
Power steering pumps cannot be repaired. If
problems in the pump are suspected carry out
pressure and leakage tests. Replace the pump
if it is malfunctioning.
Check steering system for leaks if the fluid level
in the reservoir is low.
If there are leaks at the line connections first
tighten connections, wipe dry and then re-check
for leaks.
Checking the hydraulic fluid level page 48-
22 .
Bleeding the steering system page 48-24 .
Checking the steering system for leaks page
48-25 .
Type of hydraulic fluid: G 002 000
Hydraulic system fluid capacity: 0.7-0.9 Liters
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Power steering pump, removing and installing Page 2 of 20
(12-15 oz.)
CAUTION!
Pumps supplied as replacement parts are not
filled with fluid. Therefore it is essential to fill
the pump with hydraulic fluid G 002 000 and
to rotate pump several times by hand.
Otherwise the pump may be damaged or be
noisy during operation.
Part numbers are listed here for reference
only. Always check with your Parts
department for the latest information.
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Power steering pump, removing and installing Page 3 of 20
48-45
Power steering pump (4-cyl. engine),
removing and installing
Special tools, test equipment and auxiliary
items
3204 3369 3094
VAG1590
Repair Manual, Body Exterior
Repair Manual, Body Interior
Repair Manual, Engine Mechanical
Removing
- Remove noise insulation panel.
- Remove front bumper:
Repair Manual, Body Exterior, Repair Group 63
- Move lock carrier to service position page 48-46 .
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Power steering pump, removing and installing Page 4 of 20
48-46
Lock carrier, moving to service position
1 -
Bolt (6x)
50 Nm (37 ft lb)
2 -
Bolt
50 Nm (37 ft lb)
3 -
Bolts (4x)
8 Nm (71 in. lb)
4 -
Bolts (2x)
8 Nm (71 in. lb)
5 -
Access hole for 3369 support tool
6 -
Hole in front end
For securing lock carrier in service position
7 -
Lock carrier
8 -
Weather stripping for hood
9 -
Bowden cable for hood
10 -
Holes in side panel
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Power steering pump, removing and installing Page 5 of 20
48-47
Moving to service position
- Remove front bumper:
Repair Manual, Body Exterior, Repair Group 63
- Remove intake air duct located between lock
carrier and air cleaner.
- Remove bolt - 2 - and install 3369 support tool
on left and right-hand sides.
- Remove bolts - 1 -, - 3 - and - 4 - then pull lock
carrier forward on 3369 support tool.
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Power steering pump, removing and installing Page 6 of 20
48-48
Removing ribbed belt on vehicles with 4-cyl.
gasoline engine
- Move tensioner in direction of arrow to loosen ribbed belt.
- Secure using 3204 drift.
CAUTION!
Mark the running direction before removing. Reinstalling a used belt
in reversed running direction could damage the belt.
Removing ribbed belt on vehicles with 4-cyl. Diesel engine
- Move tensioner in direction of arrow to loosen ribbed belt.
CAUTION!
Mark the running direction before removing. Reinstalling a used belt
in reversed running direction could damage the belt.
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Power steering pump, removing and installing Page 7 of 20
48-49
Removing power steering pump pulley
(vehicles with 4-cyl. gasoline engine)
- Remove coolant pump pulley.
- Remove ribbed belt.
CAUTION!
Mark the running direction before removing. Reinstalling a used belt
in reversed running direction could damage the belt.
- Remove power steering pump pulley.
- If necessary, file down corners of VAG1590 water pump wrench.
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Power steering pump, removing and installing Page 8 of 20
48-50
Removing power steering pump (all engines)
- Using 3094 hose clamps, pinch off suction and return hoses.
- Place oil catch pan in position.
- Remove hose clamp -1- from suction hose.
- Remove suction hose, press out of retainer and lay to side.
- Remove pressure line -2-.
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Power steering pump, removing and installing Page 9 of 20
48-51
Removing power steering pump (power
steering pump FP-4) m.y. 1997
- Remove hose clamp from suction hose -1-.
- Remove suction hose and lay to side.
- Remove expansion hose -2-.
- Remove bolts -1- and socket-head bolt -2-.
- Remove pump.
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Power steering pump, removing and installing Page 10 of 20
48-52
Installing
Installation note:
Before installing a new power steering pump,
add hydraulic fluid to the suction end and turn the
pump by hand until fluid emerges from the
discharge end.
- Turn pump by hand until fluid emerges from discharge end.
- Tighten bolts -1- and -2-.
Tightening torque: 20 Nm (15 ft lb)
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Power steering pump, removing and installing Page 11 of 20
48-53
Installing power steering pump (power
steering pump FP-4) m.y. 1997
- Install pressure line and tighten banjo bolt -2-.
Always replace seals
Tightening torque: 50 Nm (37 ft lb)
- Install suction hose -1-.
Mark -P- (upper arrow) must align with seam on pump (lower arrow)
- Remove 3094 hose clamps.
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Power steering pump, removing and installing Page 12 of 20
48-54
- Install pressure line and tighten banjo bolt -2-.
Always replace seals
Tightening torque: 50 Nm (37 ft lb)
- Install suction hose -1-.
- Tighten socket-head bolts for coolant pump pulley.
Tightening torque: 25 Nm (18 ft lb)
- Install fan at viscous coupling.
Tightening torque: 10 Nm (7 ft lb)
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Power steering pump, removing and installing Page 13 of 20
48-55
- Install ribbed belt.
CAUTION!
Mark the running direction before removing. Reinstalling a used
belt in reversed running direction could damage the belt.
Make sure that the belt is correctly seated in the pulleys.
Note:
Illustration is shown without the lock carrier installed for greater clarity.
- Top off hydraulic fluid page 48-22 .
- Install bumper:
Repair Manual, Body Exterior, Repair Group 63
- Start engine and make sure ribbed belt runs properly.
- Check hydraulic fluid level page 48-22 .
- Bleed steering system page 48-24 .
- Check steering system for leaks page 48-25 .
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Power steering pump, removing and installing Page 14 of 20
48-56
Power steering pump (6-cyl. engine),
removing and installing
Notes:
Always replace seals.
Do not reuse hydraulic fluid.
The power steering system uses hydraulic fluid,
Part No. G 002 000.
System hydraulic fluid capacity: approx. 1 liter
(1 qt).
1 -
Pressure line with hose
2 -
Bolt
8 Nm (71 in. lb)
3 -
Plate with mounting hole
At intake manifold
For mounting line - 1 -
4 -
Power steering pump
Fill with hydraulic fluid before installing
Notes, page 48-27
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Power steering pump, removing and installing Page 15 of 20
48-57
5 -
Belt pulley
6 -
Socket-head bolts
25 Nm (18 ft lb)
Counterhold using VAG1590 (if applicable)
while loosening and tightening
7 -
Bolts
25 Nm (18 ft lb)
8 -
Socket-head bolts
25 Nm (18 ft lb)
9 -
Power steering pump bracket
10 -
Ignition coils with bracket
11 -
Socket-head bolt
25 Nm (18 ft lb)
12 -
Banjo bolt
40 Nm (30 ft lb)
13 -
Seals 16 x 22
Always replace
14 -
Seal 18 x 24
Always replace
6 cyl. 2V gasoline engine only
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Power steering pump, removing and installing Page 16 of 20
48-58
15 -
Line union
50 Nm (37 ft lb)
Vehicles with V6 2V gasoline engine
Vehicles with power steering pump: FP-3
16 -
Clamp
Always replace
Use VAG1275 to tighten
17 -
Bolts
25 Nm (18 ft lb)
18 -
Slotted bushing
19 -
Socket-head bolt
25 Nm (18 ft lb)
20 -
Bracket
21 -
Suction line with hose
22 -
Bolt
8 Nm (71 in. lb)
Removing
- Unclip and remove engine cover Fig.
1 .
-
Unbolt and remove cover for ribbed belt
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Power steering pump, removing and installing Page 17 of 20
Fig. 2 .
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Power steering pump, removing and installing Page 18 of 20
48-59
- Loosen and remove ribbed belt Fig. 3 .
- Counterhold belt pulley - 5 - using VAG1590 (if
applicable) and remove.
- Disconnect ignition wires from ignition coils - 10 -
.
- Pinch off suction hose using 3094 hose clamp.
- Remove pressure and suction lines.
- Unbolt bracket - 9 - and remove together with
pump - 4 -.
- Remove bolts mounting pump to bracket and
remove pump.
Installing
- Install in reverse order of removal.
Note:
The ignition wires must be correctly reinstalled in
the correct firing order Fig. 4 .
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Power steering pump, removing and installing Page 19 of 20
48-60
Fig. 1 Unclipping and removing top engine cover
Fig. 2 Unbolting ribbed belt cover
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Power steering pump, removing and installing Page 20 of 20
48-61
Fig. 3 Loosening and removing ribbed belt
- Using 17 mm hex wrench, turn clockwise (arrow) to loosen ribbed belt.
- Align holes -A- and -B-.
- Insert 3204 drift to lock tensioner in position.
- Remove ribbed belt from belt pulley.
CAUTION!
Mark the running direction before removing. Reinstalling a used belt
in reversed running direction could damage the belt.
Fig. 4 Assignment of ignition wires to ignition coils
A - Ignition coil for cylinders 5 and 3
B - Ignition coil for cylinders 4 and 2
C - Ignition coil for cylinders 6 and 1
The ignition wires are numbered from 1 to 6:
- Connect ignition wires 5 and 3 to ignition coil -A-.
- Connect ignition wires 4 and 2 to ignition coil -B-.
- Connect ignition wires 6 and 1 to ignition coil -C-.
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