Volkswagen Cars 2000-05

Removal & Installation 1

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Click image to see an enlarged view

Fig. Remove the power steering pump once all fasteners and lines have been removed

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the power steering V-belt.
  4.  
  5. Detach the hoses from the power steering pump and cover the ends of the hoses with a plastic bag to prevent dirt from entering.
  6.  
  7. Remove the fasteners from the adjusting bracket. Then remove the bracket from the assembly.
  8.  
  9. Disconnect the pivot bracket and the pump by removing the bolts.
  10.  
  11. Pull the bracket and pump away from the engine as an assembly.
  12.  

To install:

  1. Install the pump and the brackets as an assembly to the engine block.
  2.  
  3. Install the adjusting bracket to the engine block and power steering pump.
  4.  


NOTE
There is no need to tighten the pivot bracket bolts at this time. They must be loose to allow an adjustment later in this procedure.

  1. Attach the pump adjusting bracket.
  2.  
  3. Install the lower power steering hose.
  4.  
  5. Fill the reservoir with power steering fluid.
  6.  
  7. To bleed the power steering pump, rotate the pump pulley by hand.
  8.  


WARNING
Severe damage will occur if the pump is not bled before the engine is started.

  1. Install the pressure hose.
  2.  
  3. Install the V-belt.
  4.  
  5. Fill the pump reservoir to the proper mark.
  6.  
  7. Connect the negative battery cable.
  8.  

  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. If installed, remove the lower engine shield. If necessary, carefully raise and support the vehicle to remove.
  4.  
  5. On A4 and 1998-00 Passat models, place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body and Trim, Service Position, Front Bumper, Hood Lock Carrier.
  6.  
  7. On 1.8L engines
  8.  
    1. Relieve the tension on the ribbed fan belt and install a suitable dowel to keep the tensioner retracted. For additional information, please refer to the following topic(s): General Information and Maintenance.
    2.  
    3. Remove the engine cooling fan. For additional information, please refer to the following topic(s): Engine and Engine Overhaul, Engine Cooling Fan.
    4.  
    5. Remove the pulley from the water pump.
    6.  
    7. Remove the ribbed belt and counter hold the power steering pump pulley using Tool No. VAG 1590 or its equivalent placed over the triangulated drive flange and remove the pulley.
    8.  

  9. On all other models, remove the power steering drive belt. For additional information, please refer to the following topic(s): General Information and Maintenance.
  10.  
  11. Clamp off the pump to reservoir suction line with a suitable clamping tool.
  12.  
  13. Place a suitable drain pan under the pump, and remove the suction hose.
  14.  
  15. Remove the pressure hose, typically requiring a 22mm ( 7 / 8 inch) wrench, and remove the hose.
  16.  
  17. Remove the pump mounting bolts and remove the pump.
  18.  

To install:

  1. Fill the pump with the recommended hydraulic fluid through the suction port, turning the pump by hand until fluid flows out of the pressure side port.
  2.  
  3. The balance of the installation is in reverse order of removal. Note the following:
  4.  
    1. Tighten the following as indicated:
    2.  


      Power steering pump-to-mounting bracket: 15 ft. lbs. (20 Nm)
       
      Water pump pulley-to-pump: 18 ft. lbs. (25 Nm)
       
      Power steering pump pulley-to-pump: 18 ft. lbs. (25 Nm)
       
      Banjo bolt-to-power steering pump: 37 ft. lbs. (50 Nm)
       

    3. Use new seals where applicable.
    4.  
    5. Top off the hydraulic fluid, with the recommended type of fluid. For additional information, please refer to the following topic(s): General Information and Maintenance.
    6.  
    7. Check the system for leakage and repair as necessary.
    8.  
    9. Properly bleed the steering system.
    10.  


4-Cyl.



  1. Remove the engine sound insulator.
  2.  
  3. Set the lock carrier in the service position, as outlined in the Engine Mechanical Section.
  4.  
  5. For gasoline engines, remove the drive belt using a wrench to turn the belt tensioner in direction shown in the illustration to relieve belt tension. Secure with a suitable drift.

    Click image to see an enlarged view

    Fig. For gasoline engines, remove the drive belt using a wrench to turn the belt tensioner in direction shown by the arrow to relieve belt tension. Secure with a suitable drift

  6.  
  7. For diesel engines, remove the drive belt by using a wrench to turn the belt tensioner in the direction shown in the illustration to relieve belt tension.

    Click image to see an enlarged view

    Fig. For diesel engines, remove the drive belt by using a wrench to turn the belt tensioner in the direction shown by the arrow to relieve belt tension

  8.  
  9. If necessary, perform the following:
    1. Remove the water pump pulley.
    2.  
    3. Remove drive belt.
    4.  
    5. Remove power steering pump pulley.
      NOTE
      It may be necessary to file out corners of water pump wrench V.A.G 1590 to make it fit properly.



      Click image to see an enlarged view

      Fig. Using the proper wrench to remove the water pump pulley

    6.  

  10.  
  11. Clamp off intake and return line using hose clamps 3094, or equivalent.

    Click image to see an enlarged view

    Fig. Use the proper type of hose clamps to clamp off the intake and return lines.

  12.  
  13. Place a fluid catch pan underneath the lines.
  14.  
  15. Remove the hose clamp from intake line.
  16.  
  17. Pull off suction hose, the remove from retainer and place to side.
  18.  
  19. Unbolt and remove the pressure hose.

    Click image to see an enlarged view

    Fig. Remove the intake line hose clamp (1), pull the suction hose off, then unbolt the pressure hose (2)

  20.  
  21. Remove the hex bolts and hex socket head bolt, then remove the power steering pump.

    Click image to see an enlarged view

    Fig. Remove the hex bolts (1) and hex socket head bolt (2), then remove the power steering pump

  22.  

To install:

  1. Fill the power steering pump with hydraulic fluid through the intake line. Turn the hub by hand until oil runs out of the pressure side.
  2.  
  3. Tighten the pump mounting bolts to 15 ft. lbs. (20 Nm).
  4.  
  5. The remainder of installation is the reverse of the removal procedure, noting the following:
    1. Install new sealing rings onto banjo bolt, then install and tighten the banjo bolt.
    2.  
    3. Tighten pressure hose banjo bolt.
    4.  
    5. Install the intake hose.
    6.  
    7. Tighten coolant/power steering pump pulley hex socket head bolts to 18 ft. lbs. (25 Nm), if removed..
    8.  
    9. Install the radiator fan to viscous coupling.
    10.  
    11. Install the drive belt, making sure it is properly seated in the pulley.
    12.  

  6.  
  7. Top off hydraulic oil G 002 000 .
  8.  
  9. Install lock carrier and bumper.
  10.  
  11. Start the engine and check belt running.
  12.  
  13. Check the power steering fluid level and add fluid if necessary.
  14.  
  15. Check the steering system for leaks.
  16.  
  17. Bleed the power steering system, as outlined in this section.
  18.  

6-Cyl.



  1. Make sure you have the radio code.
  2.  
  3. Remove engine cover.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Tag and disconnect the spark plug cables from the ignition coils.
  8.  
  9. Remove hex bolts and double bolt, then position the ignition coils aside.

    Click image to see an enlarged view

    Fig. Unfasten the hex bolts (arrows A) and double bolt - (arrow B), then position the ignition coils aside

  10.  
  11. Mark the direction of rotation of the drive belt.
  12.  
  13. Remove the drive belt, as follows:
    1. Relieve the belt tension by rotating the 10mm bolt in the direction of shown in the illustration.
    2.  
    3. Align the holes, as shown in the illustration.
    4.  
    5. Insert locking pin 3204 to secure.
    6.  
    7. Remove the belt from the belt pulley.

      Click image to see an enlarged view

      Fig. Relieve the belt tension by rotating the 0mm bolt in the direction of the arrow. Align hole (A) and hole (B)

    8.  

  14.  
  15. Remove belt pulley from power steering pump, using water pump wrench V.A.G 1590 to counter-hold if necessary.
  16.  
  17. Remove the hex bolt from the pressure line.
  18.  
  19. Place a fluid catch pan under vehicle.
  20.  
  21. Clamp off suction hose with hose clamp 3094 .
  22.  
  23. Remove the banjo bolt.
  24.  
  25. Set the pressure line aside.
  26.  
  27. Cover or cap the pressure line to avoid debris from entering the system.
  28.  
  29. Open the hose clip, then pull the intake hose from the pump.
  30.  
  31. Remove the pump mounting bolts, then remove the power steering pump with bracket.

    Click image to see an enlarged view

    Fig. View of the banjo bolt (1), pressure line (2), hose clip (arrow A) and power steering pump mounting bolts (arrows)

  32.  

To install:

  1. Fill the power steering pump with hydraulic fluid. Fill pump with fluid through the intake line. Turn the hub by hand until oil runs out of the pressure side.
  2.  
  3. Install the power steering pump with bracket and fasten the bolts.
  4.  
  5. Push on the intake hose and secure with new hose clamps.
  6.  
  7. Install the pressure line on the power steering pump and fasten the union bolt.
  8.  
  9. Remove the hose clamp from the intake line.
  10.  
  11. Install the drive belt pulley to pump .
  12.  
  13. Install the drive belt. Rotate the belt tensioner to relieve tension, then remove the locking pin and tension the belt.
    NOTE
    When installing the drive belt, make sure that the direction of rotation and seating in the pulley are correct.

  14.  
  15. Install ignition coils to power steering pump bracket. Tighten hex bolts and double bolt.
    NOTE
    The spark plug cables are marked with numbers 1 to 6 that correspond with the ignition coils.

  16.  
  17. Connect the spark plug cables to the ignition coil. Refer to the accompanying illustration.

    Click image to see an enlarged view

    Fig. View of the ignition coil identification for connecting the spark plug cables-A - cylinders 5 and 3, B - cylinders 4 and 2, C - cylinders 6 and 1

  18.  
  19. The remainder of installation is the reverse of the removal procedure.
  20.  
  21. Check the power steering fluid level and add fluid if necessary.
  22.  
  23. Check the steering system for leaks.
  24.  
  25. Bleed the power steering system, as outlined in this section.
  26.  

V8 Engines



  1. Make sure you have the radio code.
  2.  
  3. Remove engine cover.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Set the lock carrier in the service position, as outlined in the Engine Mechanical Section.
  8.  
  9. Separate the connector from the horn.

    Click image to see an enlarged view

    Fig. View of the horn (1) connector (arrow) and lock carrier (2)

  10.  
  11. Place a piece of wood about 2 inches (50mm) thick between longitudinal member and lock carrier, as shown in the illustration.

    Click image to see an enlarged view

    Fig. Place a piece of wood about 2 inches (50mm) thick between the longitudinal member (1) and lock carrier (2)

  12.  
  13. Clamp off intake and return lines using hose clamp 3094 or equivalent hose clamp.
  14.  
  15. Unfasten the A/C line bracket mounting bolts. Do NOT disconnect the A/C lines at any time during this procedure.
  16.  
  17. Mark the direction of rotation of the drive belt.
  18.  
  19. Rotate the tensioner as far as the stop, as shown in the illustration, then remove the belt.

    Click image to see an enlarged view

    Fig. Rotate the belt tension in the direction of the arrow to the stop, then remove the drive belt

  20.  
  21. Remove the crankcase vent from the retainer.
  22.  
  23. Place a fluid catch pan under the vehicle.
  24.  
  25. Remove banjo bolt and hex bolt, then position the pressure line aside. Cover or cap the pressure line to avoid debris from entering the system.

    Click image to see an enlarged view

    Fig. Remove banjo bolt (1) and hex bolt (2), then position the pressure line (3) aside

  26.  
  27. Remove the hex bolt.
  28.  
  29. Remove power steering pump pulley.
    NOTE
    When removing the drive pulley, take note of the adjusting shim located under it. It is important for measuring and adjusting the power steering pump.


    WARNING
    Do not remove the shim from the pump gear yet.

  30.  
  31. Open the hose clip, then pull the intake hose from the power steering pump.

    Click image to see an enlarged view

    Fig. View of the hex bolt (arrow A), power steering pump pulley (arrows B), and hose clip (arrow C)

  32.  
  33. Measure the distance from the front side of the hub with the shim to the power steering pump bracket, using a depth gauge and note the measurement.

    Click image to see an enlarged view

    Fig. Measure the distance from the front side of the hub with the shim (1) to the power steering pump bracket (3) using a depth gauge (2) and note the measurement

  34.  
  35. Unfasten the upper power steering pump securing bolt, using an Allen key shortened to a length of about 3 inches (75mm).

    Click image to see an enlarged view

    Fig. Unfasten the upper power steering pump securing bolt (arrow), using an Allen key shortened to a length (a) of about 3 inches (75mm)

  36.  
  37. Push the belt drive pulley as shown in the illustration, and remove the 2 mounting bolts.

    Click image to see an enlarged view

    Fig. Push the belt drive pulley (1) in the direction of the arrow, then remove the and remove 2 bolts (arrows)

  38.  
  39. Unclip the connectors from the retainer, then remove the bolts from the back side of the power steering pump and remove the pump.
  40.  

To install:

  1. Fill the power steering pump with hydraulic fluid. Fill the pump with fluid through the intake pipe. Turn the hub by hand until oil runs out of pressure side.
  2.  
  3. Install the power steering pump in bracket and tighten the 2 mounting bolts to 17 ft. lbs. (23 Nm). Tighten the front mounting bolts to 17 ft. lbs. (23 Nm).
  4.  
  5. Use the Allen key to tighten the upper power steering pump securing bolt to 17 ft. lbs. (23 Nm).
  6.  
  7. Measure the distance from the front side of the hub without the shim to the power steering pump bracket, using a depth gauge and note the measurement.

    Click image to see an enlarged view

    Fig. Measure the distance from the front side of the hub without the shim (1) to the power steering pump bracket (3) using a depth gauge (2) and note the measurement

  8.  
  9. Determine the necessary shim thickness using values measured before removing and after installing. Note the following example:
    1. Value before removing power steering pump, with the shim: 33.65mm
    2.  
    3. Value after installing the power steering pump, without the shim: 32.85mm
    4.  
    5. You need a shim that is 0.80mm thick (33.65-32.85 = 0.80)
      NOTE
      The shims are available in the following sizes: 0.6, 0.8, 1.0, 1.2 and 1.4mm.

    6.  

  10.  
  11. Push on intake hose and install new hose clamps.
  12.  
  13. Install the bolt on power steering pump pulley and tighten to 17 ft. lbs. (23 Nm)
  14.  
  15. Install the hex bolt.
  16.  
  17. Install pressure line to power steering pump and fasten banjo bolt .
  18.  
  19. Remove the hose clamp from the intake and pressure lines.
  20.  
  21. Rotate the tensioner, then install the belt and turn the tensioning roller in the opposite direction until the belt is tensioned.
    NOTE
    When installing the belt, make sure that the direction of rotation and seating in the pulley are correct.

  22.  
  23. The remainder of installation is the reverse of the removal procedure.
  24.  
  25. Check the power steering fluid level and add fluid if necessary.
  26.  
  27. Check the steering system for leaks.
  28.  
  29. Bleed the power steering system, as outlined in this section.
  30.  

With P.A.S. High Mounted Pump




NOTE
This procedure requires the following special tools, or their equivalents:



Hose Clamps Up to 25 mm diameter 3094
 
Torque Wrench 5-50 Nm V.A.G 1331
 
Assembly tool for spring-type clip pliers VAS 5024
 


NOTE
Pumps from service parts inventory do not contain fluid. They must be filled with hydraulic fluid G 002 000 before installation and turned by hand, otherwise pump noise or damage can result in operation.

  1. Unfasten the retainers, then remove the noise insulator.
  2.  
  3. Loosen the belt pulley hex socket head bolt. Secure the pulley with a hex wrench if necessary.

    Click image to see an enlarged view

    Fig. Loosen the belt pulley hex socket head bolt. Secure the pulley with a hex wrench if necessary

  4.  
  5. Swivel the tensioning device in the direction of the arrow to relieve tension from the belt. For clarity, relieving belt pulley tension is shown without charge air line.

    Click image to see an enlarged view

    Fig. Swivel the tensioning device in the direction of the arrow to relieve tension from the belt. For clarity, relieving belt pulley tension is shown without charge air line.

  6.  
  7. Identify and mark the direction of rotation of the poly-V belt
  8.  
  9. Remove drive belt.
  10.  
  11. Remove belt pulley hex socket head bolt.
  12.  
  13. To remove the intake hose, open spring-type clamps, then remove the intake hose.

    Click image to see an enlarged view

    Fig. To remove the intake hose, open spring-type clamps (1, 2 and 3), then remove the intake hose (A).

  14.  
  15. Remove the intake line, as follows:
    NOTE
    It is recommended by the manufacturer to use the flexible pliers from tool set VAS 5024 to remove the suction line lower spring spring-type clip.

    1. Unclip all electrical cables and hoses.
    2.  
    3. Open the spring-type clamps with flexible pliers.

      Click image to see an enlarged view

      Fig. Open spring-type clamps (1) using flexible pliers.

    4.  
    5. Remove the intake line.
    6.  

  16.  
  17. Clamp off suction hose with Hose Clamps Up to 25mm dia. 3094 .
  18.  
  19. Using Spring-type clip pliers VAS 5024 or equivalent, spring the clamp - 3 - and pull off intake hose
  20.  
  21. Clamp return hose with Hose Clamps Up to 25mm dia. 3094 .
  22.  
  23. Remove the banjo bolt .
  24.  
  25. Close off the pressure line with a plastic bag or similar.
  26.  
  27. Remove the hex bolts, then remove the power steering pump.

    Click image to see an enlarged view

    Fig. Remove the hex bolts (1, 2), then remove the power steering pump

  28.  

To install:

  1. Fill the power steering pump with hydraulic fluid. Fill the pump with fluid through the suction pipe. Turn the hub by hand until oil runs out of the pressure side.
  2.  
  3. Install the power steering pump on the bracket and tighten the bolts to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the intake hose and spring-type clip. The mark must align with the casting seam. The spring-type clip must close off the mark.

    Click image to see an enlarged view

    Fig. Install intake hose and spring-type clip. The mark (arrow A) must align with casting seam (arrow). The spring-type clip must close off mark (arrow B)

  6.  
  7. Install new sealing rings onto banjo bolt, then install the bolt and tighten to 28 ft. lbs. (38 Nm).
  8.  
  9. The remainder of installation is the reverse of the removal procedure.
  10.  
  11. Check the power steering fluid level and add fluid if necessary.
  12.  
  13. Check the steering system for leaks.
  14.  
  15. Bleed the power steering system, as outlined in this section.
  16.  

 
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