Power Steering Pump Delivery Pressure, Generation I Without SCR, Checking

Special tools and workshop equipment required

Hose Clamps - Up To 25mm 3094
Torque Wrench 1331 5-50Nm VAG1331
Power Steering Test Unit VAG1402
Adapter VAG 1402/2
Adapter VAG 1402/4
Power Steering Test Unit - Adapter Hose VAG1402/6

Test Prerequisites

Ribbed belt/ribbed belt tension OK
Sealing of system
Hoses/lines are not kinked or constricted

Checking

-- With vehicles with air suspension, place vehicle on hoist, refer to POSITIONING VEHICLE ON HOIST AND WHEELS .

-- Carefully pull off engine cover from 4 retainers -arrows-.

Fig 1: Removing Engine Cover

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CAUTION:

The Hose Clamps - Up To 25mm 3094 must not be secured on return hose in check valve area. Otherwise, check valve will be damaged.
The check valve is in the return hose between the cambers -A arrows- or between hose clamps -B arrows-.

Fig 2: Locating Check Valve In Return Hose

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-- Clamp the intake hose and the return line on the reservoir using Hose Clamps - Up To 25mm 3094.

Fig 3: Clamp The Intake Hose And Return Line On The Reservoir Using 3094.

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-- Only remove front noise insulation -1-.

Fig 4: Locating Front/Rear Noise Insulation

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-- Secure Power Steering Test Unit VAG1402 -3- with a cable tie -2- to stabilizer bar -1-.

Fig 5: Identifying VAG 1402 -3-, Cable Tie -2- And Stabilizer Bar -1-

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-- Remove banjo bolt -6-.

Fig 6: Identifying Power Steering Pump Delivery Pressure, V6 TDI, Generation I Without SCR, Test Assembly

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-- Install Power Steering Test Unit VAG1402 as shown in illustration.

Power Steering Test Unit VAG1402
Hose from Power Steering Test Unit - Adapter Hose VAG1402/6
Adapter VAG 1402/4
Seal
Power Steering Pump
Banjo Bolt
Pressure Line
Adapter VAG 1402/2

-- Remove the Hose Clamps - Up To 25mm 3094.

-- Make sure that lever on pressure gauge stands in position -2-.

Fig 7: Ensuring Lever On Pressure Gauge Stands In Open/Closed Position

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-- Start engine and fill hydraulic fluid in reservoir if necessary.

-- Turn steering wheel from stop to stop approximately 10 times.

NOTE:

To avoid damage to pump, note the following:

Pressure gauge shut-off valve must not remained closed longer than 10 seconds during this test.

Start engine without giving gas and run at idle.

Read the pump pressure immediately after starting at idle speed (have it read by second technician, if necessary).

Because pressure falls over the course of the test, the highest pressure shown is the decisive measurement.

-- Now check delivery pressure.

-- Start engine and when at idle speed, close shut-off valve -item 1- and read pressure (do not measure longer than 10 seconds).

Fig 8: Ensuring Lever On Pressure Gauge Stands In Open/Closed Position

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Delivery pressure specified value: 110 to 128 bar

If specified value is not obtained, replace power steering pump, refer to POWER STEERING PUMP, REMOVING AND INSTALLING .

-- Switch off engine.

-- Remove Power Steering Test Unit VAG1402.

-- Install banjo bolt with new gaskets, refer to -item 8- Bolt. Note location of pressure line when doing so, refer to Figure.

-- Bleed steering system, refer to STEERING SYSTEM, BLEEDING AFTER REPLACING .

-- Check power steering fluid level, refer to POWER STEERING, CHECKING HYDRAULIC OIL LEVEL .

-- Check the steering system for leaks, refer to STEERING SYSTEM, CHECKING FOR LEAKS .

-- Clean engine, engine compartment and subframe in power steering pump area.

-- Install noise insulation, refer to Body Front .

-- On vehicles with air suspension, position vehicle on wheels, refer to POSITIONING VEHICLE ON HOIST AND WHEELS .