Installing Hydraulic Pump (PDCC)

Information 

• The reservoir must always be replaced if individual or multiple components, such as the hydraulic pump (tandem hydraulic pump) and steering, are replaced. 
• The hydraulic system must be bled after repair work is carried out. The vehicle must be lowered onto the wheels for this. →  4890IN TEST AND ASSEMBLY WORK ON POWER STEERING  
• Only use Pentonsin CHF 202 to fill the hydraulic system. 
• Check the hydraulic fluid level. 
• Replace sealing rings. 
• Observe correct tightening torques. →  4X00IN TIGHTENING TORQUES FOR STEERING 

Information 

• Make sure not to damage the radiator grilles. 

1. Carefully fit the hydraulic pump from the side.
2. Carefully fit the three fastening screws -2-  at the front and the fastening screw -3-  at the side of the hydraulic pump and then tighten all screws to the specified tightening torque.
   Fig 1: Installing Hydraulic Pump

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3. Replace the sealing ring -1-  on the lower pressure line -2-  .
   Fig 2: Identifying Sealing Ring On Pressure Line

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4. Fit the pressure lines to the hydraulic pump.
   Fig 3: Fitting Pressure Lines To Hydraulic Pump

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   1. 4.1. Insert the lower pressure line -1-  into the hydraulic pump -2-  and fit it -A-  .
   2. 4.2. Fit the upper pressure line to the pressure supply tank -4-  (-arrow-  ) and secure with the banjo bolt -3-  .

      Use new sealing washers -5-. 

5. Replace sealing rings -1, 2-  on the intake pipes -3, 4-  .
   Fig 4: Identifying Sealing Rings On Intake Pipes

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6. Insert the intake pipes -1, 2-  into the hydraulic pump -3-  (-arrows-  ), position the holder -4-  and screw on the fastening nut -5-  .
   Fig 5: Identifying Intake Pipes, Hydraulic Pump, Fastening Nut

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7. Fit the intake pipes -1, 2-  at the cylinder head -4-  using the holder and screw on the fastening nut -3-  .
   Fig 6: Identifying Intake Pipes At Cylinder Head

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8. Fit the pulley -2-  on the hydraulic pump -3-  and screw in the fastening screws -1-  .
   Fig 7: Identifying Pulley On Hydraulic Pump And Screw

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9. Fit the drive belt at the correct position and tension it. → Installing Drive Belt
10. Fit the fastening screws -1-  on the pulley -2-  for the hydraulic pump -3-  .
11. Fit the intake manifold on the turbocharger.
12. Turbo only: 

    Connect the wastegate line at the clamp -1-  .

    Fig 8: Identifying Wastegate Line At Clamps

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13. Turbo only: 

    Attach the check valve -1-  to the air box and fit the clamp -2-  .

    Fig 9: Identifying Valve For Positive Crankcase Ventilation

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14. Turbo only: 

    Attach hoses to the check valve and fit with new clamps.

15. Fit the lift switchover hose to the intake manifold.