Power steering pump, 10-cyl. diesel engine

Transcription

1 Volkswagen Touareg - Power steering pump, 10-cyl. diesel engine Page 1 / Power steering pump, 10-cyl. diesel engine It is not intended that repair work be performed on the power steering pump. If complaints are received determine cause with the help of pressure tests and leakage test. If a malfunction exists replace power steering pump. Note: If reservoir fluid level is low then check steering system for leaks. In the case of leaks at the line connections first tighten connections and wipe dry then recheck for leaks. Power steering pumps supplied as spare parts and are not filled with oil. Therefore it is essential to fill the pump with hydraulic fluid G and to rotate pump by hand, otherwise the power steering pump may be damaged or be noisy during operation. Type of fluid: Hydraulic fluid G Delivery pressure of power steering pump 10-cyl. diesel engine, checking

2 Page 2 / 11 Special tools, testers and auxiliary items required Hose clamp 3094 Power steering test unit V.A.G 1402 Adapter V.A.G 1402/2 Hose from adapter set V.A.G 1402/6 Special tools, testers and auxiliary items required

3 Page 3 / 11 Adapter V.A.G 1402/4 - Remove sound insulation for engine Repair Manual, Body Exterior, Repair Group 50, Sound insulation, installation overview - Clamp off intake hose with hose clamp Remove pressure line at the power steering pump.

4 Page 4 / 11 - Assemble adapters as shown in illustration. 1 - Power steering test unit V.A.G Adapter V.A.G 1402/2 3 - Adapter V.A.G 1402/4 4 - Hose from adapter set V.A.G 1402/6 5 - Banjo bolt 6 - Seal ring - Remove hose clamp 3094 from intake line. Make sure that the lever on pressure gauge is in position

5 Page 5 / 11 - Start engine and if necessary top off hydraulic fluid in reservoir. - Turn steering wheel from lock to lock about 10 times. - Check delivery pressure. Requirements: V-belt/V-belt tension OK. System has no leaks Hoses/lines not kinked or restricted - With engine idling, close shut-off valve (position for no longer than 5 seconds and note pressure. Specifications: 110 to 120 bar If pressure is not to specification, replace power steering pump 48-6, Power steering pump, 10-cyl. diesel engine, removing and installing. - Remove pressure gauge and adapter. - Bleed steering system 48-7, Bleeding steering system. - Inspect hydraulic oil level and top off as needed Repair Manual, Maintenance

6 Page 6 / Check steering system for leaks 48-7, Steering system, checking for leaks. Power steering pump, 10-cyl. diesel engine, assembly overview Note : Replace sealing rings Do not reuse drawn off hydraulic oil. Hydraulic fluid: G Cylinder block Allen head bolt

7 Page 7 / Nm Hex bolt 20 Nm Power steering pump Fill with fluid before instating Removing and installing 48-6, Power steering pump, 10-cyl. diesel engine, removing and installing Check delivery pressure of power steering pump 48-6, Delivery pressure of power steering pump 10-cyl. diesel engine, checking During 2004 model year, the power steering pump with hard rubber disc clutch was replaced with one with a torsion-elastic clutch. O-ring Always replace Lubricate before assembling O-ring Always replace Lubricate before assembling Sealing rings, 16 x 22 Always replace Pressure hose Banjo bolt, 35 Nm Power steering pump Fill with fluid before installing

8 Page 8 / 11 Removing and installing 48-6, Power steering pump, 10-cyl. diesel engine, removing and installing Check delivery pressure of power steering pump 48-6, Delivery pressure of power steering pump 10-cyl. diesel engine, checking During 2004 model year, the power steering pump with hard rubber disc clutch was replaced with one with a torsion-elastic clutch. Torsion-elastic clutch Drive flange Hard rubber disc clutch Hex bolt 14 Nm plus and additional 1 / 8 turn 45 Hex bolt 9 Nm Intake line Spring clamp Intake hose Power steering pump, 10-cyl. diesel engine, removing and installing Special tools, testers and auxiliary items required

9 Page 9 / 11 Hose clamp 3094 Torque wrench V.A.G 1331 Removing - Clamp off intake hose with hose clamp Remove engine and transmission Repair Manual, 5.0 Liter V10 2V TDI PD Engine Mechanical, Fuel Injection Glow Plug, Engine Code(s)

10 Page 10 / 11 BKW, Repair Group 10, Engine Removal and Installation. - Remove air-conditioning compressor Repair Manual, Heating Air Conditioning, Repair Group 87, Air-conditioning Compressor. - Unbolt charge line at cylinder block - Arrow -. - Unbolt charge pipe at turbocharge - Arrows - and lay aside. - Remove pressure line at power steering pump. - Seal pressure line/hose with a plastic bag or similar. - Remove intake line at the power steering pump. - Remove power steering pump from cylinder block. Installing Installation is reverse of removal, with special attention to

11 Page 11 / 11 the following: - Fill power steering pump with hydraulic fluid. Fill power steering pump with fluid through intake line. - Turn hub by hand until oil runs out of pressure side. - Install power steering pump. After installing engine: - Bleed steering system 48-7, Bleeding steering system. - Check hydraulic fluid level. Repair Manual, Maintenance - Check steering system for leaks 48-7, Bleeding steering system.