Note. Repair work for the vane pump is not provided. In the event of complaints, the cause must be determined by means of a pressure test and a leak test. If there is a malfunction, the vane pump should be replaced. If there is no working fluid in the reservoir, it is necessary to check the tightness of the steering. If there is no seal near the line connections, first check the lines/line connections for leaks, tighten if necessary and wipe dry. The vane pump is supplied unprimed. Therefore, before installation, be sure to fill the pump with hydraulic fluid and turn it by hand. Otherwise, operating noise or damage to the vane pump may occur.
Vehicles with 6-cyl. diesel engine, vehicles with dynamic steering system installation
I 1. Bandage; 2. Expansion tank. Take into account the installation position; 3. Locking cap with measuring probe; 4/5/10. Bolt. 9 Nm; 6. Spring clamp. Remove and install using hose clamp pliers -VAG 1921-; 7. Return hose from the hydraulic fluid radiator to the reservoir; there should be no traces of oil and grease at the connection points; clean if necessary. Observe the installation position on the tank. Observe the installation position on the hydraulic oil cooler; 8. Clamp; 9. Clamp. Press together using clamp pliers -VAG 1275-. After installation, ensure correct fixation. Replace each time when removed; 11. Seal ring. Replace each time when removed; 12. Return line from the power steering to the hydraulic fluid radiator; there should be no traces of oil and grease at the connection points; clean if necessary. Insert the return line completely during installation; 13. The hydraulic oil cooler at the connection points should be free of traces of oil and grease; clean if necessary. Fixed on the capacitor using a clip; 14. Power steering; 15. Pressure line from the vane pump to the power steering gear. Insert the pressure line completely during installation; 16. Rubber cushion. 6 Nm; 17. Nut. 6 Nm; 18. Bolt. 20 Nm; 19. Union nut. 40 Nm; 20. Pressure line from the vane pump to the power steering gear. Insert the pressure line all the way during installation. Observe the installation position: the angle between the line connection and the axis of the vane pump is approx. 88°; 21. Return line from the power steering to the hydraulic fluid radiator; there should be no traces of oil and grease at the connection points; clean if necessary. Insert the pressure line all the way during installation. Observe the installation position on the hydraulic oil cooler; 22. Nut. 9 Nm; 23. Bolt. 23 Nm; 24. Vane pump. Before installation, fill with hydraulic oil; 25. Bolt. 23 Nm. 20 Nm, this tightening torque only applies when using the door adjustment key -3320-. To unfasten and tighten, use the door adjustment key -3320- and the corresponding bit -3320/2-; 26. Suction hose. There should be no traces of oil or grease at the connection points; clean if necessary. Observe the installation position on the tank. Observe the installation position on the vane pump
Mounting position of the clamping clamp
Tighten the clamp completely using pliers -VAG 1275-. Make sure that dimension -A- does not exceed 1 mm; if necessary, tighten the clamp using pliers -VAG 1275-.
Vehicles with 6-cyl. diesel engine, vehicles without dynamic steering system installation 1. Bandage; 2. Expansion tank. Take into account the installation position; 3. Locking cap with measuring probe; 4/5/8/14. Bolt. 9 Nm; 6. Spring clamp. Remove and install using hose clamp pliers -VAG 1921-; 7. Engine bracket connecting element; 9. Mounting bracket; 10. Nut. 9 Nm; 11. Seal ring. Replace each time when removed; 12. Pressure line from the vane pump to the power steering gear. Insert the pressure line completely during installation; 13. Clamp; 15. Return hose from the hydraulic fluid radiator to the reservoir; there should be no traces of oil and grease at the connection points; clean if necessary. Observe the installation position on the tank. Observe the installation position on the hydraulic oil cooler; 16. Clamp. Press together using clamp pliers -VAG 1275-. After installation, ensure correct fixation. Replace each time when removed; 17. Return line from the power steering to the reservoir; there should be no traces of oil and grease at the connection points; clean if necessary. Insert the return line completely during installation; 18. Power steering; 19. Seal ring. Replace each time when removed; 20. Bolt. 20 Nm; 21. Rubber cushion. 9 Nm; 22. Pressure line from the vane pump to the power steering gear. Insert the pressure line completely during installation; 23. Union nut. 40 Nm. Installation position of the trunk connection; 24. Nut. 6 Nm; 25. Bolt. 23 Nm; 26. Vane pump. Before installation, fill with hydraulic oil; 27. Bolt. 23 Nm. 20 Nm, this tightening torque only applies when using the door adjustment key -3320-. To unfasten and tighten, use the door adjustment key -3320- and the corresponding bit -3320/2-; 28. Clamp. Press together using clamp pliers -VAG 1275-. After installation, ensure correct fixation. Replace each time when removed; 29. Suction hose. There should be no traces of oil or grease at the connection points; clean if necessary. Observe the installation position on the tank. Observe the installation position on the vane pump
Vehicles with 6-cyl. diesel engine, vehicles with and without dynamic steering system, pipes and hoses
Parts and assemblies, fasteners for pipelines and hoses
- 1. Tank bracket on the body
- 2. Tank in bracket
- 3. Bracket bolt
- 4. Hydraulic fluid radiator to condenser
- 5. Vane pump in bracket
- 6. Pressure line on the cross brace
- 7. Installation position of the pressure line connection
- 8. Pressure line on the engine bracket
- 9. Return line on subframe
- 10. Brackets for return lines on the subframe and side member
Bracket for tank on body
The bracket -1 is attached with bolts -2- to the body. Secure the tank -4- with a bolt -3- in the bracket -2-.
Tank in bracket
Place the reservoir with the protrusion -1- into the recess on the bracket -2-.
Bracket for lines on the side member
Attach the return line -1- to the left side member using the pressure pipe -2-. Secure the return hose -5- using a clamp -4- to the return line. When doing this, pay attention to the installation position -arrows-.
Hydraulic fluid radiator to condenser
Install the hydraulic fluid cooler -1 - onto the brackets -2-, then secure it into the brackets -3-.
Pressure line on the cross brace
Screw the pressure line using a nut -3- and a rubber support -4- onto the cross connection of the braces. When screwing in the line connection, take into account the installation position of the line. Marks -1- and -2- must be located opposite each other.
Pressure line on engine bracket
Route pressure line -4- between connecting piece -2- and engine bracket -3-. Screw the mounting bracket -5- with a nut -6- onto the threaded pin -1-.
Return line holder on subframe
Secure the return line with holder -1- at the front left to the subframe -2-.
Pressure and return lines to the subframe
Secure return line -4- with holder -2- and bolt -1- to subframe -3-.
Radiator hydraulic lines to radiator frame
Place lines -5- and -6- with clips -1- (2 pcs.) on the ledges -2- (2 pcs.)
Removing the vane pump, vehicles with 6-cyl. diesel engine, vehicles with dynamic steering system
Replace seal. rings. Do not reuse drained hydraulic oil. Use only hydraulic oil.
I 1. Holder; 2. Bushing. To install the vane pump, the bushing must be moved back slightly; 3. Bolt. 23 Nm. 20 Nm, this tightening torque only applies when using the door adjustment key -3320-. To unfasten and tighten, use the door adjustment key -3320- and the corresponding bit -3320/2-; 4. Bolt; 5. Suction hose. Marking "R" -arrow- on the suction hose must be aligned with the profiled seam -arrow- on the vane pump; 6. Clamp. Press together using clamp pliers -VAG 1275-. Replace each time when removed; 7. Union nut. 38 Nm; 8. Seal ring. Replace each time when removed; 9. Pressure line. Insert the pressure line all the way during installation. Observe the installation position: the angle between the line connection and the axis of the vane pump is approx. 88°. Depending on the option, it is additionally attached to the compressor; 10. Bolt. 23 Nm; 11. Pulley; 12. Vane pump. Before installation, fill with hydraulic oil and remove air from the steering. Check the level of working fluid in the hydraulic system. Checking the tightness of the steering; 13. Bolt. 23 Nm
Removal
Repair work for the vane pump is not provided. In the event of complaints, the cause must be determined by means of a pressure test and a leak test. If there is a malfunction, the vane pump should be replaced. If there is no working fluid in the reservoir, it is necessary to check the tightness of the steering. If there is no tightness near the connections of the lines, you should first check the lines/connections for leaks, tighten if necessary and wipe dry. The vane pump is supplied unprimed. Therefore, before installation, be sure to fill the pump with hydraulic fluid and turn it by hand. Otherwise, operating noise or damage to the vane pump may occur. Place the vehicle on a lift. Pump out hydraulic fluid from the reservoir using a waste oil collection and pumping device. Carefully remove the engine cover from each of the 4 pins -arrows- one at a time.
Clamp suction hose -1- and return hose -2- using hose clamps up to 25 mm -3094-.
Do not attach hose clamps to? 25 mm -3094- on the return hose -2- next to the check valve. Otherwise, the check valve may be damaged. The non-return valve is located in the return hose -2- between the clamps -arrows-.
Remove sound insulation. Drain the coolant.
If present, release the clamp -1 - on the left side member and remove the coolant hose -2-.
Remove upper part of intake manifold -1-. To do this, remove the air hose -4- eyelet -3-, the clamp -7- and the coolant hose. Remove extension coolant reservoir -2-.
Secure the air hose -1 - using a wire -2- to the brake. highway -3-.
Before removing the poly V-belt, note the direction of rotation. Changing the direction of rotation of a used belt can lead to its destruction. When installing the poly V-belt, ensure that it is positioned correctly on the pulleys.
Turn the tensioner to release the tension on the poly V-belt in the direction of -arrow-. Use adapter -T40087- for this. Remove the poly V-belt from the vane pump pulley only.
Mark the position of the pulley in relation to the hub. To do this, mark -arrow-.
When replacing a vane pump, transfer the markings on the hub from the old pump to the new one. It is impossible to determine in what position the pulley holes are located relative to the holes in the hub during installation due to limited space.
First, simply loosen the pulley bolts -arrow-. If necessary, use counter support -T10172- with adapter -T10172/5-1- for this purpose. Remove the loosened bolts and remove the pulley from the vane pump. Place a tray under the vane pump.
Cut the binder -4-.
The illustration shows the removed vane pump. Place a rag under the vane pump and pressure line.
If the pressure line -C- is additionally secured with a bracket to the air conditioning compressor, remove the compressor mounting bolt from the front, from above.
Unscrew the union nut -1 - and remove the pressure line from the vane pump. Close the connections of the vane pump and the line with clean plugs. Unscrew bolts -1- and -3- and remove vane pump. To install the vane pump, it is necessary to slightly move back the bushing -2- of the bolt 3- in the bracket.
Installation
Install in reverse order. The following must be taken into account: Replace seals and gaskets. rings. Before installing a new vane pump, fill the suction side with hydraulic oil and turn it by hand until the oil comes out on the pressure side. Secure all hose connections with new clamps.
Pay attention to the installation size of the clamp. Dimension -a- should be 4 mm.
Before installing the vane pump, put on the suction hose -1- and align the mark "R" -3- with mark -5- on the vane pump. Secure the suction hose -1- with a new clamp -2-. Secure the wiring harness with a new cable tie -4- to the fitting.
It is not possible to clamp the clamp -2- using hose clamps when the vane pump is installed due to lack of space. Turn the hub by hand until oil comes out from the pressure side. Insert the vane pump into the bracket. The bushing -2- is slightly pushed back. First tighten the front bolts -1-. Then tighten the rear bolt -3-. Tighten bolts -1- and -3-. Press the pressure line into the vane pump as far as it will go. Finally, tighten the union nut -1 -. When installing the pressure line -4-, make sure that the angle between the line connection and the axis of the vane pump is approx. 88°. (©Picture =
If the pressure line -C- is additionally secured with a bracket to the air conditioning compressor, tighten the compressor mounting bolt from the front, from above. Clean oily areas in the motor. compartment Align the marking -arrow- on the belt pulley with the marking on the hub. Tighten the pulley bolts -arrows-. -1- counter support -T10172/5-. Install the vane pump serpentine belt. Fill with coolant and remove air. Install the upper part of the intake manifold. Check the level of working fluid in the hydraulic system. Bleed the air from the steering. Check the steering for leaks. Install sound insulation. Install the poly V-belt and check the alignment of the poly V-belt. When installing the poly V-belt, ensure that it is seated correctly in the pulleys.
- 1.Generator
- 2/3. Guide roller
- 4. Coolant pump
- 5. Vane pump
- 6. Air conditioning compressor
- 7. V-belt tensioner
- 8. Crankshaft
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