Volkswagen Cars 2000-05

Removal & Installation 2

Print

With P.A.S. Low 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. Remove the retainers and the noise insulator.
  2.  
  3. Loosen the belt pulley hex socket head bolt. If necessary, hold the pulley in place with a hex wrench.

    Click image to see an enlarged view

    Fig. Loosen the belt pulley hex socket head bolt. If necessary, hold the pulley in place with a hex wrench

  4.  
  5. Swivel the tensioner in direction of arrow in the illustration to relieve tension from the ribbed V-belt.

    Click image to see an enlarged view

    Fig. Swivel the tensioner in direction of arrow in the illustration to relieve tension from the ribbed V-belt

  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. Clamp off suction hose with Hose Clamps Up to 25 mm dia. 3094 .
  14.  
  15. Unclamp the Spring clamp - 3 -, using VAS 5024 spring-type clip pliers, or equivalent too, and pull off the intake hose.
  16.  
  17. Remove banjo bolt - 4 - .
  18.  
  19. Close off the pressure line with a plastic bag or similar.
  20.  
  21. Remove hex bolts - 1 - and - 2 - .

    Click image to see an enlarged view

    Fig. View of the hex bolts (1, 2), spring clamp (3) and banjo bolt (4)

  22.  
  23. Remove the power steering pump.
  24.  

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 mounting bolts to 18 ft. lbs. (25 Nm).
  4.  
  5. Install intake hose and install spring-type clip. Refer to the accompanying illustration. The mark must align with casting seam. The spring-type clip must close off the mark.

    Click image to see an enlarged view

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

  6.  
  7. Install new sealing rings onto banjo bolt, then install the banjo 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.  

 
label.common.footer.alt.autozoneLogo