Steering column Стр.

1 из 6

Volkswagen Phaeton
48 - 2

Steering column

„ Steering column

„ With mechanical height

adjustment

„ Can only be replaced as a

unit

„ Removing and installing

48-2, Steering column,
removing and installing

„ Multi-point socket head bolt

„ Observe tightening sequence

48-2, Steering column
tightening sequence

„ 25 Nm
Steering column Стр. 2 из 6

„ Steering column

„ With electrical height

adjustment

„ Can only be replaced as a

unit

„ Removing and installing

48-2, Steering column,
removing and installing

„ Socket head bolt

„ 30 Nm

„ Steering gear pinion

„ Cross member for steering

column

Steering column, removing and installing

Special tools, testers and auxiliary items required

„ Torque wrench V.A.G 1331

The steering column is delivered only as a complete

replacement part. Servicing is not possible.

Removing

- Remove airbag

Repair Manual, Body Interior, Repair Group 69, Airbag;

Drivers side airbag unit, removing and installing

.
Steering column Стр. 3 из 6

- Remove steering wheel

Repair Manual, Body Interior, Repair Group 68, Airbag;

Steering wheel, removing and installing

- Remove plastic cover in footwell

Repair Manual, Body Interior, Repair Group 68,

Compartments, covers and trim; Footwell (drivers side)
cover, removing and installing

- Remove fuse box plastic cover on drivers side

Repair Manual, Body Interior, Repair Group 68,

Compartments, covers and trim; Fuse box (drivers side),
removing and installing

- Remove steering column switch

Repair Manual, Electrical Equipment, Repair Group 94,

Steering column switch; Steering column switch, removing
and installing

- Remove bracket - 2 - .

- Remove universal joint from steering gear.

Steering column Стр. 4 из 6

- Secure universal joint - 2 - with cable tie - A - to steering

column.

- Disconnect connector - A - .

Vehicles with electrical height adjustment

- Disconnect both height adjustment electrical connectors

behind instrument panel.

Continued for all vehicles

- Remove steering column - 1 - .

- Remove steering column from vehicle.

Installing

Installation is in reverse order of removal, note the

following:

New replacement steering columns are secured with

transportation protection.

- Remove transportation protection after installing steering

column.

- Place steering column on crossmember.

- Install all hex socket head bolts and tighten by hand.

Steering column Стр. 5 из 6

Steering column tightening sequence

- First tighten hex socket head bolt - B - .

- Then tighten hex socket head bolts - C - and - D - .

- Finally tighten hex socket head bolt - A - to specified

torque.

- Attach universal joint on steering column pinion.

- Perform basic setting Vehicle Diagnosis, Testing and

Information System VAS 5051 for Steering Angle Sensor
G85 .

- Connect Vehicle Diagnosis, Measurement and

Information System VAS 5051 and continue switching until
"Functions/Component selection" is displayed.

Then

- Select "Body" .

- Select "Electrical components" .

- Press "01 - On Board Diagnostic (OBD)" .

- Select "Immobilizer" .

- Press "Functions" .

- Select "Adapting ELV" .

Tightening torque
Steering wheel to steering
column
Repair Manual, Body Interior, Repair Group 68, Airbag; Steering
wheel, removing and installing
Universal joint to steering 30 Nm
gear
Steering column Стр. 6 из 6

Steering column to body 25 Nm

Steering gear, assembly overview Стр. 1 из 16

48 - 3

Steering gear, assembly overview

„ Power steering gear

„ Removing and installing;

Vehicles with a 6-cyl. gasoline

engine 48-3, Power steering
gear (vehicles with 6-cyl. gasoline
engine), removing and installing

Vehicles with a 8-cyl. gasoline

engine 48-3, Power steering
gear (vehicles with 8-cyl. gasoline
engine), removing and installing

Vehicles with W12 - gasoline

engine 48-3, Power steering
gear (vehicles with W12 gasoline
engine), removing and installing
Steering gear, assembly overview Стр. 2 из 16

„ Heat shield bracket

„ No replacement part

„ Not for vehicles with V6 -

gasoline engine

„ Socket head bolt

„ 30 Nm

„ Universal joint

„ Support ring

„ Sealing boot

„ Hex bolt

„ 7 Nm

„ Square head bolt

„ Hex nut

„ 50 Nm

„ Self-locking

„ Always replace

„ Wheel bearing housing

„ Multi-point socket head bolt

„ 20 Nm

„ Nut

„ Multi-point socket head bolt

„ 90 Nm plus an additional 90
( 1 / 4 turn)

„ Always replace

„ Heat shield

„ Left

„ Ensure correct seating in

bracket
Steering gear, assembly overview Стр. 3 из 16

„ Not for vehicles with V6 -

gasoline engine

„ Support brace

„ Left

„ Hex bolt

„ 30 Nm

„ Support brace

„ Right

„ Heat shield

„ Right

„ Ensure correct seating in

bracket

„ Not for vehicles with V6 -

gasoline engine

„ Oil seal, 14 x 20

„ Always replace

„ Banjo bolt

„ 40 Nm

„ Return hose

„ Banjo bolt

„ 50 Nm

„ Oil seal, 16 x 22

„ Always replace

„ Pressure hose

Power steering gear (vehicles with 6-cyl. gasoline

engine), removing and installing
Steering gear, assembly overview Стр. 4 из 16

Special tools, testers and auxiliary items required

„ Torque wrench V.A.G 1332

„ Hose clamps up to 25 mm dia. 3094

Caution!

For all repair work, especially in the engine

compartment due to the tight working conditions,
observe the following:

„ Route lines of all types (for example for fuel,

hydraulic, EVAP canister system, coolant and
refrigerant, brake fluid, vacuum) and electrical
wiring so that the original path is followed.

„ Make sure to allow sufficient clearance for all

moving or hot components.

Removing

- Turn steering to center position and remove ignition key.

- Remove plastic cover in footwell

Steering gear, assembly overview Стр. 5 из 16

Repair Manual, Body Interior, Repair Group 68,

Compartments, covers and trim; Footwell (drivers side)
cover, removing and installing

- Remove universal joint from steering gear.

- Secure universal joint - 2 - with cable tie - A - to steering

column.

- Raise vehicle.

- Remove front wheels.

- Remove wheel housing liner

Repair Manual, Body Interior, Repair Group 66, Wheel

housing liner, removing and installing; Front wheel housing
liner

- Remove left air spring strut 40-3, Air spring strut

removing and installing .

- Clamp off return line using hose clamps up to 25 mm dia.

3094 .

- Remove tie rods from both sides of wheel bearing

housing.
Steering gear, assembly overview Стр. 6 из 16

- Remove support brace - 1 - on left side .

Vehicles with Servotronic

- Disconnect Servotronic electrical connector - 2 - and

remove bracket for connector - 3 - .

Continued for all vehicles

- Disconnect pressure line in engine compartment, while

counter-holding hex fitting.

- Disconnect return line in engine compartment, while

counter-holding hex fitting

- Remove pressure and return line from steering gear.

- Carefully cover brake lines in left wheel housing (below

left tie rod).

- Remove steering gear from body and remove from left.

Be careful not to damage surface of brake lines!

Installing

Installation is in reverse order of removal, note the

following:

Be careful not to damage surface of brake lines!

- Bleed steering system 48-5, Bleed steering system .

Steering gear, assembly overview Стр. 7 из 16

- Check power steering fluid level. 48-5, Power steering

fluid level, checking .

- Check steering system for leaks 48-5, Steering system,

checking for leaks .

- Measure vehicle after installation 44-3, Wheel

alignment .

- Perform Basic Setting for Steering Angle Sensor G85 via

Basic adjustment in "Guided Fault Finding" with VAS
5051.

Tightening torque
Universal joint to steering gear 30 Nm
Air line to air spring strut 5 Nm
Connecting link to stabilizer bar 90 Nm plus an additional 1 / 4 turn (90
1)
2)
)

Connecting link to lower link 90 Nm plus an additional 1 / 4 turn (90

1)
2)
)

Upper link to wheel bearing housing 50 Nm

Wheel acceleration sensor to air spring strut 10 Nm
Connecting link from vehicle level sensor to lower 8 Nm
link
Air spring strut to lower link 90 Nm plus an additional 1 / 4 turn (90
1)
2)
)

Mounting bracket to body 50 Nm plus an additional 1 / 4 turn (90

1)
)
Tie rod to wheel bearing housing 50 Nm
Support brace to body 30 Nm
Electrical connector bracket to steering ear 20 Nm
Pressure hose to pressure line tube 40 Nm
Return hose to return tube 40 Nm
Pressure line to steering gear 50 Nm
3)

Return line to steering gear 40 Nm

3)

Steering gear to body 90 Nm plus an additional 1 / 4 turn (90

1)
)
Steering gear, assembly overview Стр. 8 из 16

1) Always use new nuts and bolts

2) Tighten bolts/nuts in curb weight position
3) Use new seals

Power steering gear (vehicles with 8-cyl. gasoline

engine), removing and installing

Special tools, testers and auxiliary items required

„ Hose clamps up to 25 mm dia. 3094

Removing

Caution!

For all repair work, especially in the engine

compartment due to the tight working conditions,
observe the following:

„ Route lines of all types (for example for fuel,

hydraulic, EVAP canister system, coolant and
refrigerant, brake fluid, vacuum) and electrical
wiring so that the original path is followed.

„ Make sure to allow sufficient clearance for all

moving or hot components.

- Turn steering to center position and remove ignition key.

- Remove plastic cover in footwell

Repair Manual, Body Interior, Repair Group 68,

Compartments, covers and trim; Footwell (drivers side)
cover, removing and installing

.
Steering gear, assembly overview Стр. 9 из 16

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- Remove universal joint from steering gear.

- Secure universal joint - 2 - with cable tie - A - to steering

column.

- Raise vehicle.

- Remove front wheels.

- Remove wheel housing liner

Repair Manual, Body Exterior, Repair Group 66, Wheel

housing liner, removing and installing; Front wheel housing
liner

- Remove left air spring strut 40-3, Air spring strut

removing and installing .

- Clamp off return line with hose clamps up to 25 mm dia.

3094 .

- Remove tie rods from both sides of wheel bearing

housing.
Steering gear, assembly overview Стр. 10 из 16

- Remove support brace on left side - 1 - .

- Remove heat shield on both sides of vehicle.

Vehicles with Servotronic

- Disconnect Servotronic electrical connector - 2 - and

remove its bracket - 3 - for connector. .

Continued for all vehicles

- Remove pressure line - 5 - in wheel housing while

counter-holding at hex fitting - 4 - .

- Open clamps - 2 - as much as possible and remove return

hose - 3 - from return line - 1 - .

- Remove pressure and return line from steering gear.

- Carefully cover brake lines in left wheel housing (below

left tie rod).

- Remove steering gear from body and remove to the left.

Be careful not to damage surface of brake lines!

Installing

Installation is in reverse order of removal, note the

following:

Be careful not to damage surface of brake lines!

Steering gear, assembly overview Стр. 11 из 16

Note:

„ Use new seals for the union bolts.

- Ensure correct seating of heat shield in bracket at

steering gear.

- Tighten steering gear Item - 13 - .

- Bleed steering system 48-5, Bleed steering system .

- Check hydraulic fluid level 48-5, Power steering fluid

level, checking .

- Check steering system for leaks 48-5, Steering system,

checking for leaks .

- Measure vehicle after installation 44-3, Wheel

alignment .

- Perform basic setting for Steering Angle Sensor G85

Vehicle Diagnosis, Testing and Information System VAS
5051 .

Tightening torques
Universal joint to steering gear 30 Nm
Air line to air spring strut 5 Nm
Connecting link to stabilizer bar 90 Nm plus an additional 1 / 4 turn (90
1)
2)
)

Connecting link to lower link 90 Nm plus an additional 1 / 4 turn (90

1)
2)
)

Upper link to wheel bearing housing 50 Nm

1)

Wheel acceleration sensor to air spring strut 10 Nm

Connecting link from vehicle level sensor to lower 8 Nm
link
Air spring strut to lower link 90 Nm + quarter turn (+90 )
1)
2)

Mounting bracket to body 50 Nm plus an additional 1 / 4 turn (90

1)
)
Tie rod to steering knuckle 50 Nm
Support brace to body 30 Nm
Electrical connector bracket to steering ear 20 Nm
Steering gear, assembly overview Стр. 12 из 16

Pressure hose to pressure tube 40 Nm

Pressure line to steering gear 50 Nm
3)

Return line to steering gear 40 Nm

3)

Steering gear to body 90 Nm plus an additional 1 / 4 turn (90

1)
)

1) Always use new nuts and bolts

2) Tighten screws and nuts in curb weight position
3) Use new seals

Power steering gear (vehicles with W12 gasoline engine),

removing and installing

Special tools, testers and auxiliary items required

„ Torque wrench V.A.G 1332

„ Hose clamps up to 25 mm dia. 3094

Caution!

For all repair work, especially in the engine

Steering gear, assembly overview Стр. 13 из 16

compartment due to the tight working conditions,

observe the following:

„ Route lines of all types (for example for fuel,

hydraulic, EVAP canister system, coolant and
refrigerant, brake fluid, vacuum) and electrical
wiring so that the original path is followed.

„ Make sure to allow sufficient clearance for all

moving or hot components.

Removing

- Turn steering to center position and remove ignition key.

- Remove plastic cover in footwell

Repair Manual, Body Interior, Repair Group 68,

Compartments, covers and trim; Footwell (drivers side)
cover, removing and installing

- Remove universal joint from steering gear.

- Secure universal joint - 2 - with cable tie - A - to steering

column.

- Raise vehicle.

- Remove front wheels.

- Remove wheel housing liner

Repair Manual, Body Interior, Repair Group 66, Wheel

housing liner, removing and installing; Front wheel housing
liner
Steering gear, assembly overview Стр. 14 из 16

- Remove left air spring strut 40-3, Air spring strut

removing and installing .

- Clamp off return line with hose clamps up to 25 mm dia.

3094 .

- Remove tie rods from both sides of wheel bearing

housing.

- Remove support brace - 1 - on left side .

- Remove heat shield on both sides of vehicle.

Vehicles with Servotronic

- Disconnect Servotronic electrical connector - 2 - and

remove its bracket - 3 - for connector.

Continued for all vehicles

Steering gear, assembly overview Стр. 15 из 16

- Remove pressure line - 5 - in wheel housing while counter

holding at hex fitting - 4 - .

- Expand clamps - 2 - as much as possible and remove

return hose - 3 - from return line - 1 - .

- Remove pressure and return line from steering gear.

- Carefully cover brake lines in left wheel housing (below

left tie rod).

- Remove steering gear from body and remove to the left.

Be careful not to damage surface of brake lines!

Installing

Installation is in reverse order of removal, note the

following:

Be careful not to damage surface of brake lines!

- Ensure correct seating of heat shield in bracket at

steering gear.

- Tighten steering gear 48-5, Bleed steering system .

- Bleed steering system.

- Check hydraulic fluid level 48-5, Power steering fluid

level, checking .

- Check steering system for leaks 48-5, Steering system,

checking for leaks .

- Measure vehicle after installation 44-3, Wheel

alignment .

- Perform basic setting for Steering Angle Sensor G85

Vehicle Diagnosis, Testing and Information System VAS
5051 .

Tightening torques
Universal joint to steering gear 30 Nm
Steering gear, assembly overview Стр. 16 из 16

Air line to air spring strut 5 Nm

Connecting link to stabilizer bar 90 Nm plus an additional 1 / 4 turn (90
1)
2)
)

Connecting link to lower link 90 Nm plus an additional 1 / 4 turn (90

1)
2)
)

Upper link to wheel bearing housing 50 Nm

Wheel acceleration sensor to air spring strut 10 Nm
Connecting link from vehicle level sensor to lower 8 Nm
link
Air spring strut to lower link 90 Nm plus an additional 1 / 4 turn (90
1)
2)
)

Mounting bracket to body 50 Nm plus an additional 1 / 4 turn (90

1)
)
Tie rod to steering knuckle 50 Nm
Support brace to body 30 Nm
Electrical connector bracket to steering ear 20 Nm
Pressure hose to pressure tube 40 Nm
Return hose to return tube 40 Nm
Pressure line to steering gear 50 Nm
3)

Return line to steering gear 40 Nm

3)

Steering gear to body 90 Nm plus an additional 1 / 4 turn (90

1)
)

1) Always use new nuts and bolts

2) Tighten screws and nuts in curb weight position
3) Use new seals
Power steering, servicing Стр. 1 из 4

48 - 4

Power steering, servicing

„ Tie rod end

„ Check dust caps for damage

and correct seating

„ Hex nut

„ 40 Nm

„ Spring clamp

„ Boot

„ Check for damage

„ Must not be twisted when

adjusting rod
Power steering, servicing Стр. 2 из 4

„ Clamp

„ Always replace

„ Inner tie rod link

„ 100 Nm

„ O-ring

„ Always replace

„ Power steering gear

„ O-ring

„ Always replace

„ O-ring

„ Always replace

„ Servotronic solenoid valve N119

„ Can be checked in "guided

fault finding" using Vehicle
diagnosis, testing and
information system VAS 5051

„ Socket head bolt

Tie rod, removing and installing

Special tools, testers and auxiliary items required

„ Torque wrench V.A.G 1332

Power steering, servicing Стр. 3 из 4

„ Box end wrench insert V.A.G 1923

Without illustration

Hose clamp pliers V.A.G 1275

Locking pliers VAS 6199

Removing

Both tie rods on vehicle are identical.

They can be removed and installed with steering gear in

vehicle.

- Remove front wheel.

- Open clamping sleeve and spring clip - arrows - on

bellows.

- Pull boot as far out as possible.

Power steering, servicing Стр. 4 из 4

- Remove hex bolts - 1 - and - 2 - and pull tie rod ball joint
downward and out of wheel housing bearing.

- Remove tie rod using open-jaw torque wrench insert

V.A.G 1923 .

Installing

Installation is in reverse order of removal, note the

following:

Note:

„ Use only original hose clamps.

- Check boot for wear "cuts, tears" and make sure sealing
surfaces are clean.

- Measure vehicle after installation 44-3, Wheel

alignment .

Tightening torques
Tie rod to wheel bearing housing 50 Nm
Tie rod to tie rod end 4 Nm
Tie rod to steering gear 10 Nm
Power steering pump Стр. 1 из 35

48 - 5

Power steering pump

There is no provision for servicing the power steering
pump. If there are customer complaints, the cause must be
determined using a pressure and leak test. If a malfunction
is present, the power steering pump must be replaced.

Note:

„ If reservoir fluid level is low then check steering

system for leaks.

„ If there are leaks in the area of the line connections,

the lines/connections must first be inspected for
leaks, tightened as necessary and wiped dry.

„ Replacement pumps are not filled with fluid.

Therefore, before installing, always fill with hydraulic
fluid G 002 000 and turn by hand, otherwise pump
damage or noises while driving may occur.

„ Type of fluid: Hydraulic fluid G 002 000

„ Oil system capacity: 0.7 to 0.9 L.

Power steering pump supply pressure (6-cyl. gasoline

engine), checking
Power steering pump Стр. 2 из 35

Special tools, testers and auxiliary items

required

„ Hose clamps up to 25 mm dia.

3094

„ Power steering test unit V.A.G 1402

„ Adapter V.A.G 1402/2

„ Adapter V.A.G 1402/6

Special tools, testers and auxiliary items required

Power steering pump Стр. 3 из 35

„ Adapter V.A.G 1402/4

- Remove front noise insulation

Repair Manual, Body Exterior, Repair Group 50, Noise

insulation; Noise insulation, assembly overview

- Clamp off suction hose using Hose Clamps Up to 25 mm

dia. 3094 .

- Disconnect pressure line at power steering pump.

Power steering pump Стр. 4 из 35

- Assemble V.A.G adapters as shown in illustration.

1 - Power steering test unit V.A.G 1402

2 - Adapter set V.A.G 1402/2
3 - Adapter set V.A.G 1402/4
4 - Adapter set V.A.G 1402/6
5 - Banjo bolt
6 - Sealing ring

- Remove Hose Clamps Up to 25 mm dia. 3094 from

suction line.

- Make sure that lever on pressure gauge stands in position

-2-.
Power steering pump Стр. 5 из 35

- Start engine and add hydraulic fluid to reservoir if

necessary.

- Turn steering wheel back and forth about 10 times

between stops.

- Check delivery pressure.

Test Requirements:

„ Belt and belt tension OK

„ System has no leaks

„ Hydraulic hose lines not kinked or restricted.

- With engine idling, close shut-off valve (position - 1 - ) for

not longer than 5 seconds and read pressure.

Specification for delivery pressure:

110 to 120 bar

If specified value is not obtained, replace power steering

pump 48-5, Power steering pump (W12 gasoline
engine), removing and installing .

- Remove tools.

- Bleed steering system 48-5, Bleed steering system .

- Check hydraulic fluid level 48-5, Power steering fluid

level, checking .

- Check steering system for leaks 48-5, Steering system,

Power steering pump Стр. 6 из 35

checking for leaks .

Power steering pump (6-cyl. gasoline engine), assembly

overview

Note:

„ Replace sealing rings.

„ Do not reuse drained hydraulic fluid.

„ Hydraulic fluid: Part No. G 002 000

„ Banjo bolt

„ 40 Nm

„ Sealing rings, 16 x 22

„ Always replace
Power steering pump Стр. 7 из 35

„ Pressure hose

„ Suction hose

„ Spring hose clamp

„ Power steering pump

„ Check delivery pressure

48-5, Power steering pump
supply pressure (6-cyl.
gasoline engine), checking

„ Fill with fluid before

installation

„ Removing and installing

48-5, Power steering pump
(6-cyl. gasoline engine),
removing and installing

„ Belt pulley

„ Hex socket head bolt

„ Hex bolt

„ 25 Nm

„ Bracket

Power steering pump (6-cyl. gasoline engine), removing

and installing

Special tools, testers and auxiliary items required

„ Torque wrench V.A.G 1331

Power steering pump Стр. 8 из 35

„ Hose clamps up to 25 mm dia. 3094

„ Bolt M8 x 50

Caution!

For all repair work, especially in the engine

compartment due to the tight working conditions,
observe the following:

„ Route lines of all types (for example for fuel,

hydraulic, EVAP canister system, coolant and
refrigerant, brake fluid, vacuum) and electrical
wiring so that the original path is followed.

„ Make sure to allow sufficient clearance for all

moving or hot components.

Removing

- Remove front noise insulation

Repair Manual, Body Exterior, Repair Group 50, Noise

insulation; Noise insulation, assembly overview

- Mark direction of rotation of ribbed belt.

Power steering pump Стр. 9 из 35

- Install threaded bolt M8 x 50 in tensioner pulley threaded

hole - A - until ribbed belt is no longer under tension.

- Remove power steering pump belt pulley.

- Remove ribbed belt.

- Clamp off suction hose with hose clamps dia. up to 25

mm 3094 .

- Remove banjo bolt.

- Plug pressure line with a plastic bag or similar object.

- Open spring clamp and remove suction hose from power

steering pump.

- Remove power steering pump.

Installing

Installation is in reverse order of removal, note the

following:

- Fill power steering pump with hydraulic fluid.

Power steering pump Стр. 10 из 35

- Fill fluid at pump intake connection of power steering

pump.

- Turn the hub by hand until oil runs out of pressure side.

- Install power steering pump.

- Bleed steering system 48-5, Bleed steering system .

- Check hydraulic fluid level 48-5, Power steering fluid

level, checking .

- Check steering system for leaks 48-5, Steering system,

checking for leaks .

Tightening torques
Noise insulation to body

Repair Manual, Body Exterior, Repair Group 50, Noise insulation;

noise insulation - assembly overview
Belt pulley to power 25 Nm
steering pump
Banjo bolt to power 40 Nm
steering pump
1)

Power steering pump to 25 Nm

bracket

1) Use new seals

Power steering pump supply pressure (8-cyl. gasoline

engine), checking

Special tools, testers and auxiliary items required

„ Power steering test unit V.A.G 1402

Power steering pump Стр. 11 из 35

„ Hose clamps up to 25 mm dia. 3094

„ Adapter set V.A.G 1402/11 + 12 , without illustration

- Remove left front wheel.

- Remove wheelhouse liner

Repair Manual, Body Exterior, Repair Group 66,

Wheelhouse liner, removing and installing; Wheelhouse
liner front

- Clamp off return line with hose clamps up to 25 mm dia.

3094 .
Power steering pump Стр. 12 из 35

- Loosen nut - 1 - , counter-hold at hex fitting - 2 - .

- Remove pressure line from body by removing nut - arrow

-.

- Install V.A.G adapters as shown in illustration.

„ Power steering gear

„ Adapter V.A.G 1402/11
„ Power steering test unit V.A.G 1402
„ Power steering pump/power steering gear pressure
line
„ Adapter V.A.G 1402/12

- Remove Hose Clamps Up to 25 mm dia. 3094 from intake

hose.

- Make sure that lever on pressure gauge is set to position -

Power steering pump Стр. 13 из 35

2-.

- Start engine and top up hydraulic fluid in reservoir if

necessary.

- Turn steering wheel from lock to lock about 10 times.

- Check delivery pressure.

Test Requirements:

„ Ribbed belt/ribbed belt tension OK.

„ System has no leaks

„ Hoses/lines not kinked or restricted

- With engine idling, close stop valve (position - 1 - ) for no

longer than 5 seconds, and read pressure.

Specification for delivery pressure:

110 to 120 bar

If specified value is not attained, replace power steering

pump. 48-5, Power steering pump (8-cyl. gasoline
engine), removing and installing,

- Remove pressure gauge and adapter.

- Bleed steering system 48-5, Bleed steering system

- Check hydraulic fluid level 48-5, Power steering fluid

level, checking .
Power steering pump Стр. 14 из 35

- Checking steering system for leaks 48-5, Steering

system, checking for leaks

Power steering pump (8-cyl. gasoline engine), assembly

overview

Note:

„ Replace sealing rings.

„ Do not reuse hydraulic fluid that has been drained.

„ Hydraulic fluid: Replacement part No. G 002 000

„ When replacing power steering pump, always check

alignment of pulleys for AC compressor and power
steering pump.

„ Banjo bolt
Power steering pump Стр. 15 из 35

„ 35 Nm

„ Sealing rings, 16 x 22

„ Always replace

„ Pressure hose

„ Intake hose

„ Spring hose clamp

„ Power steering pump

„ Removing and installing

48-5, Power steering pump
(8-cyl. gasoline engine),
removing and installing,

„ Fill with oil prior to installation

„ Check delivery pressure

48-5, Power steering pump
supply pressure (8-cyl.
gasoline engine), checking

„ Shim

„ Belt drive pulley

„ Socket head bolt

„ 25 Nm

„ Hex bolt

„ 25 Nm

„ Bracket

Power steering pump (8-cyl. gasoline engine), removing

and installing,

Special tools, testers and auxiliary items required

Power steering pump Стр. 16 из 35

„ Torque wrench V.A.G 1331

„ Hose clamps up to 25 mm dia. 3094

Caution!

For all repair work, especially in the engine

compartment due to the tight working conditions,
observe the following:

„ Route lines of all types (for example for fuel,

hydraulic, EVAP canister system, coolant and
refrigerant, brake fluid, vacuum) and electrical
wiring so that the original path is followed.

„ Make sure to allow sufficient clearance for all

moving or hot components.

Removing
Power steering pump Стр. 17 из 35

- Remove covers - B, C - .

- Remove engine noise insulation.

Repair Manual, Body Exterior, Repair Group 50, Noise

insulation; noise insulation, assembly overview

- Loosen bolts for power steering pump belt pulley, but do

not remove them yet.

- Mark running direction of ribbed belt.

- Remove ribbed belt.

- Unclip line - 1 - from clip - 2 - .

- Unclip electrical connections from air conditioning

compressor, do not clamp off refrigerant lines.
Power steering pump Стр. 18 из 35

- Clamp off suction line with hose clamps up to 25 mm dia.

3094 .

- Remove air conditioning compressor from bracket, and

suspend from body.

- Remove power steering pump belt pulley.

- Be aware of shims between belt pulley and the power

steering pump.

- Remove left air duct, from lock carrier to lower portion of

air filter housing.

- Push refrigerant line - 1 - as far as possible toward body,

and remove union bolt - arrow - .

- Remove bolt - arrow - from bracket on rear side of power

steering pump.

- Remove bolts - arrows - and remove power steering

pump from bracket.

Installing

Installation is in reverse order of removal, note the

following:

- Fill hydraulic fluid into power steering pump.

- Fill oil at pump intake connection.

Power steering pump Стр. 19 из 35

- Turn hub by hand until fluid runs out of pressure side.

- Install power steering pump, tighten front bolts first.

- Install ribbed belt and check alignment

Repair Manual, 4.2 Liter V8 5V Engine Mechanical, Fuel

Injection Ignition, Engine Code(s): BGH, BGJ, Repair
Group 13, Engine, disassembling and assembling;
Checking alignment of ribbed belt

Note:

„ When installing, make sure ribbed V-belt is properly

seated in belt pulleys.

1 - Belt pulley - Generator

2 - Idler pulley
3 - Tensioner pulley
4 - Belt pulley - crankshaft
5 - Idler pulley
6 - Belt pulley - power steering pump
7 - Belt pulley - air conditioning compressor
8 - Ribbed belt

- Bleed steering system 48-5, Bleed steering system .

- Check power steering fluid level 48-5, Power steering

fluid level, checking .

- Checking steering system for leaks 48-5, Steering

system, checking for leaks

Torque specifications
Power steering pump Стр. 20 из 35

Noise insulation to
body
Repair Manual, Body Exterior, Repair Group 50, Noise insulation;
noise insulation, assembly overview
Ribbed belt pulley to 25 Nm
power steering pump
Air conditioning
compressor to bracket
Repair Manual, Heating Air Conditioning, Repair Group 87, Air
conditioning compressor; Air conditioning compressor with bracket,
removing and installing: Engine code BGH, BGJ
Banjo bolt to power 35 Nm
steering pump 1)
Power steering pump 25 Nm
to bracket

1) Use new seals

Power steering pump supply pressure (W12 gasoline

engine), checking

Special tools, testers and auxiliary items required

„ Power steering test unit V.A.G 1402

„ Hose clamps up to 25 mm dia. 3094

Power steering pump Стр. 21 из 35

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru

огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi

„ Adapter set V.A.G 1402/11 + 12 , without illustration

- Remove left front wheel.

- Remove wheelhouse liner

Repair Manual, Body Exterior, Repair Group 66,

Wheelhouse liner, removing and installing; Wheelhouse
liner front

- Clamp off return line with hose clamps up to 25 mm dia.

3094 .

- Loosen nut - 1 - , counter-hold at hex fitting - 2 - .

- Remove pressure line from body by removing nut - arrow

-.
Power steering pump Стр. 22 из 35

- Assemble V.A.G adapters as shown in illustration.

„ Power steering gear

„ Adapter V.A.G 1402/11
„ Power steering test unit V.A.G 1402
„ Power steering pump/power steering gear pressure
line
„ Adapter V.A.G 1402/12

- Remove Hose Clamps Up to 25 mm dia. 3094 from

suction hose.

Note:

„ Make sure that lever on pressure gauge stands to

position - 2 - .
Power steering pump Стр. 23 из 35

- Start engine and top off hydraulic fluid in reservoir if

necessary.

- Turn steering wheel from lock to lock about 10 times.

- Check delivery pressure.

Test requirements:

„ Ribbed belt/ribbed belt tension OK.

„ System has no leaks

„ Hoses/lines not kinked or restricted

- With engine at idle speed, close shut-off valve for no

longer than 5 seconds (position - 1 - ) and read pressure.

Specification for delivery pressure:

110 to 120 bar

If specified value is not obtained, replace power steering

pump 48-5, Power steering pump (W12 gasoline
engine), removing and installing .

- Remove pressure gauge and adapter.

- Bleed steering system 48-5, Bleed steering system

- Check hydraulic fluid level 48-5, Power steering fluid

level, checking .

- Checking steering system for leaks 48-5, Steering

system, checking for leaks
Power steering pump Стр. 24 из 35

Power steering pump (W12 gasoline engine), assembly

overview

Note:

„ Replace sealing rings.

„ Do not reuse drawn off hydraulic oil.

„ Hydraulic fluid: Part No. G 002 000

„ Banjo bolt

„ 40 Nm

„ Sealing rings

„ 16 x 22

„ Always replace
Power steering pump Стр. 25 из 35

„ Pressure hose

„ Intake hose

„ Spring hose clamp

„ Power steering pump

„ Check supply pressure 48-

5, Power steering pump
supply pressure (W12
gasoline engine), checking

„ Fill with fluid before

installation

„ Removing and installing

48-5, Power steering pump
(W12 gasoline engine),
removing and installing

„ Shim

„ Belt pulley

„ Socket head bolt

„ 25 Nm

„ Bracket

„ Hex head bolt

„ 8 Nm

„ Socket head bolt

„ 25 Nm

„ Socket head bolt

„ 25 Nm

„ Bracket

„ Socket head bolt

„ 25 Nm

„ Socket head bolt

„ 25 Nm
Power steering pump Стр. 26 из 35

„ Socket head bolt

„ Torque specification

Repair Manual, 6.0 Liter 12-Cyl. 4V

Engine Mechanical, Fuel Injection
Ignition, Engine Code(s): BRP, BAP,
Repair Group 13, Engine disassembling
and assembling

Power steering pump (W12 gasoline engine), removing

and installing

Special tools, testers and auxiliary items required

„ Torque wrench V.A.G 1331

„ Hose clamps up to 25 mm dia. 3094

Caution!

For all repair work, especially in the engine

compartment due to the tight working conditions,
observe the following:
Power steering pump Стр. 27 из 35

„ Route lines of all types (for example for fuel,

hydraulic, EVAP canister system, coolant and
refrigerant, brake fluid, vacuum) and electrical
wiring so that the original path is followed.

„ Make sure to allow sufficient clearance for all

moving or hot components.

Removing

- Remove engine noise insulation.

Repair Manual, Body Exterior, Repair Group 50, Noise

insulation; noise insulation, assembly overview

- Unclip retainer - 1 - for hoses.

- Unclip line - 2 - .

- Remove bracket - 3 - .

- Mark direction of rotation of ribbed belt.

- Turn tensioner in direction of - arrow - to loosen ribbed

belt.
Power steering pump Стр. 28 из 35

- Remove belt pulley for power steering pump.

- Remove ribbed belt.

Note:

„ When removing power steering pump pulley, observe

the shim located behind it. This is important for the
alignment and adjustment of the power steering
pump.

„ Do not remove adjustment shim from power steering

pump yet.

- Clamp off suction line with hose clamps up to 25 mm dia.

3094 .

- Open spring clamp and pull suction hose off power

steering pump.

- Place a hex socket 22 mm with 2 long extensions onto

union bolt from below.

- Loosen union bolt from above.

- Plug pressurized line using a plastic bag or something

similar.

- Remove power steering pump bolts from rear.

Power steering pump Стр. 29 из 35

- Unbolt power steering pump from front and remove.

- Measure dimension - a - .

The shim is included in measurement.

- Make a note of measurement.

Installing

Installation is in reverse order of removal, note the

following:

- Measure dimension - a - on new power steering pump

(without adjustment shim).

- Make a note of measurement.

Power steering pump Стр. 30 из 35

- Determine shim thickness. 48-5, Calculating shim

thickness

- Fill power steering pump with hydraulic fluid

- Fill fluid into intake end of pump.

- Turn hub by hand until oil runs out of pressure side.

- Install power steering pump and install all bolts.

- First, fasten power steering pump from front.

- Fasten power steering pump from rear.

- Check hydraulic fluid level 48-5, Power steering fluid

level, checking .

- Checking steering system for leaks 48-5, Steering

system, checking for leaks

Torque specifications
Noise insulation to body

Repair Manual, Body Exterior, Repair Group 50, Noise

insulation; noise insulation - assembly overview
Ribbed belt pulley to power 25 Nm
steering pump
Banjo bolt to power steering 40 Nm
Power steering pump Стр. 31 из 35

pump
Power steering pump to 25 Nm
bracket
Bracket to power steering 8 Nm
pump bracket

Calculating shim thickness

- Determine thickness of adjustment shim using measured

value - a - .

Example:

Measured value of old power steering pump with adjustment shim 33.65 mm
- Measured value of new power steering pump without adjustment shim 32.85 mm
Shim thickness = 0.80 mm

The following shims are available:

Thickness (mm)
0.6
0.8
1.0
1.2
1.4

Allocation of adjustment shims Parts Catalog

- Install power steering pump.

Power steering fluid level, checking

Cold fluid:

Perform following work sequence:

- Do not run engine and turn front wheels to straight ahead

position.
Power steering pump Стр. 32 из 35

- Unscrew cap with built in dipstick from reservoir.

- Wipe dipstick off with a clean cloth.

- Screw cap in hand-tight and unscrew again.

Note:

„ The valid fluid level is the one measured after

screwing in the cap.

- Check fluid level: Level must be around "MIN" mark (up to

2 mm above or below mark).

Note:

„ Fluid must be drawn off if the level is above the

specified range.

„ If the fluid level is below the range specified, the

hydraulic system must be checked for leaks. It is not
sufficient to merely top off the fluid.

„ If the hydraulic system does not leak, top off with fluid
"G 002 000" .

- Screw cap on hand-tight.

Power steering pump Стр. 33 из 35

Fluid at operating temperature (from approx. 50 C):

Perform following work sequence:

- Do not run engine and turn front wheels to straight ahead

position.

- Remove cap with built in dipstick from reservoir - arrow - .

- Wipe dipstick off with a clean cloth.

- Screw cap in hand-tight and unscrew again.

Note:

„ The cap must be fully screwed on in order to obtain

an accurate fluid level reading.

- Check fluid level: Level must be between "MIN" and

"MAX" mark.

Note:

„ Fluid must be drawn off if the level is above the MAX

mark.

„ If the fluid level is below the MIN mark, the hydraulic

system must be checked for leaks. It is not sufficient
to merely top off the fluid. If the hydraulic system
does not leak, top off with fluid "G 002 000" .
Power steering pump Стр. 34 из 35

- Screw cap in hand-tight.

Bleed steering system

- Check hydraulic fluid level and top off if necessary.

- Raise vehicle until front wheels are off the ground.

- Lower vehicle.

- Start engine and let it run at idle for approx. 5 seconds.

- Turn engine off and check fluid level.

- Repeat this sequence once more.

- Start engine again, let run at idle, and turn steering wheel
from lock to lock 3 times.

- Turn off engine and check fluid level.

- Repeat this sequence twice more.

To vent the fluid, let engine sit for 2 - 3 minutes.

- Now lower vehicle onto its wheels.

- Turn steering wheel, at idle, from lock to lock 5 times.

The steering system has been bled when no more air

bubbles rise in reservoir.

- Check hydraulic oil level and top off as needed.

Steering system, checking for leaks

Note:

„ Following installation operations and with no

hydraulic fluid in the expansion tank, the steering
system must be checked for leaks.

- Start engine.

- Turn steering wheel in both directions to full lock and hold

briefly.

This builds up maximum possible pressure.

In this position, the following components must be checked

for leaks.

„ Seal ring for steering pinion at the steering gear valve

housing.
Power steering pump Стр. 35 из 35

„ All line connections

„ Rack sealing rings

This test can only be performed with boot pushed back.

- Open clamp for boot.

- Push boot back.

If fluid is visible in steering gear housing and/or in boots,

steering gear must be replaced.