g4 48 Steering

Volkswagen Jetta, Golf, GTI 1999, 2000
Suspension, Wheels, Steering

48 Steering (Page GR-48)
Airbag, steering wheel and steering column
Driver's airbag unit, removing and installing
Four spoke steering wheel, servicing
Steering column, checking for damage
Steering lock housing, removing and installing
Steering column cross member, assembly overview
Steering column "A", removing and installing
Steering column "B", removing and installing
Steering column, identification
Power steering, servicing
Power steering gear, overview
Power steering gear, removing and installing
Steering gear, adjusting
Tie rod end play, mounts and boots, checking
Tie rod, removing and installing
Power steering pump, reservoir, hydraulic lines
Power steering pump (pump in lower area), removing and installing
Power steering pump (pump in upper area), removing and installing
Power steering pump with hydraulic lines/hoses, assembly overview
Power steering pump assembly, overview (pump in upper area)
Power steering pump, checking delivery pressure
Power steering assembly, overview (pump in lower area)
Pressure gauge VAG 1402, connecting

Airbag, steering wheel and steering column (Page 48-1)
Driver's airbag unit, removing and installing

Vehicles with four spoke steering wheel
1 - Steering wheel
2 - Connector
3 - Locking tab
Release from rear of steering wheel
4 - Airbag unit
Because of various engaging mechanisms, only steering wheels and airbag units
from same manufacturer can be installed
Removing
Page 48-3
Installing
Page 48-4

5 - Multi-point socket-head bolt

50 Nm (37 ft lb)
With locking compound
Can be reused up to 5 times; mark with a center punch after each installation
6 - Securing plate
7 - Spiral spring with slip ring
8 - Trim
9 - Clip

Removing
- Disconnect battery ground strap.
- Release steering column height adjustment locking lever.
- Turn steering wheel -1- until steering wheel spokes are vertical. Pull steering column
out completely and push down to lowest position.
- Secure steering column adjustment.
- Insert screwdriver, approx. 175 mm long (7 in.) from back side in hole of steering
wheel hub, insert screwdriver approx. 45 mm (1.75 in.).
Notes:
Only steering wheels and airbags of same manufacturer can be used.

- Press screwdriver in direction of arrow. Clip -10- is pressed back and locking tab -3of airbag unit is released.
- Turn steering wheel -1- 180 and release second locking tab on opposite side.
- Turn steering wheel -1- to center position (wheels straight-ahead).
- Pull connector off airbag unit.
Installing
Notes:
Only steering wheels and airbag units from same manufacturer can be installed.

- Reconnect connector to airbag unit.

- Insert airbag unit in steering wheel.
Airbag unit locking tabs must audibly engage!
- Switch ignition ON.
WARNING!
Make sure the passenger compartment is not occupied before connecting the battery
Ground (GND) strap.
- Connect battery ground strap.
- On vehicles with anti-theft radio unit, activate coding.
- Display readiness code and reset, if necessary:
Repair Manual, 2.0 Liter 4-Cyl. OBD II Fuel Injection & Ignition, Repair Group 01
Repair Manual, 1.9 Liter TDI 4-Cyl. Diesel OBD II Direct Fuel Injection & Glow Plug, Repair
Group 01
Repair Manual, 2.8 Liter VR6 OBD II Fuel Injection & Ignition, Repair Group 01

Vehicles with three spoke steering wheel

1 - Steering wheel
2 - Connector
3 - Locking tab
Release from rear of steering wheel
4 - Airbag unit
Removing
Installing
Page 48-7
Page 48-8

50 Nm (37 ft lb)
Equipped with locking compound
Can be used up to 5 times
mark with a center punch after each installation
6 - Securing plate
7 - Spiral spring with slip ring
8 - Trim
9 - Clip

Removing
- Disconnect battery ground strap.
- Release steering column adjustment.
- Turn steering wheel -1-, until steering wheel spoke is vertical. Pull out steering
column completely and push up to uppermost position.
- Secure steering column adjustment.
- Insert screwdriver approx. 175 mm long (7 in.) insert screwdriver approx. 45 mm
(1.75 in.) from back side in hole of steering wheel.

- Press screwdriver in direction of arrow. Clip -10- is pressed back and locking tab -3of airbag unit is released.
- Turn steering wheel -1- 180 and release second locking tab on opposite side.
- Turn steering wheel -1- to center position (wheels straight-ahead).
- Remove connector from airbag.
Installing
- Reconnect connector to airbag.

- Insert airbag in steering wheel.

Airbag locking tabs must audibly engage!
- Switch ignition ON.
WARNING!
Make sure the passenger compartment is not occupied before connecting the battery
Ground (GND) strap.
- Connect battery ground strap.
- On vehicles with anti-theft radio unit, activate coding.
- Display readiness code and reset, if necessary:
Repair Manual, 2.0 Liter 4-Cyl. OBD II Fuel Injection & Ignition, Repair Group 01
Repair Manual, 1.9 Liter TDI 4-Cyl. Diesel OBD II Direct Fuel Injection & Glow Plug, Repair
Group 01
Repair Manual, 2.8 Liter VR6 OBD II Fuel Injection & Ignition, Repair Group 01

Four spoke steering wheel, servicing (Page 48-10)
1 - Steering wheel
Observe installation position when installing
50 Nm (37 ft lb)
Equipped with locking compound
Can be used up to 5 times
Mark with center punch after each assembly
3 - Torx bolt
4 - Vibration damper
On TDI engine with automatic transmission
Page 48-28

5 - Torx bolt
5 Nm (44 in. lb)
6 - Airbag unit
7 - Securing plate


Removing
Airbag and steering column removed
Page 48-1 or
page 48-6.
Upper and lower steering column trim removed;
Page 48-19.
- Remove steering column switch bolt and steering column switch.

- Remove plastic cover over shear bolts.
Ignition lock cable must also be disconnected on vehicles with automatic transmission
48-21
- Chisel off shear bolts with chisel.

Removing and installing ignition switch / lock cylinder
Repair Manual, Electrical Equipment, Repair Group 94
Page

Installing
- Attach ignition lock cable if equipped with automatic transmission
Page 48-27.
- Install new shear bolts.
- Tighten shear head bolts until head shears off.
- Install steering column switch.
- Adjust distance between steering column switch and steering wheel,
Page 4828.
Continue installation in reverse sequence

Steering column, checking for damage

Visual check
- Check all steering column parts for damage.
- Replace complete steering column if damaged.
Functional check
Requirements:
Steering column universal joint pulled off steering gear.
- Check steering column for ease of turning without catching.
- Check steering column for height and reach adjustment.
- Check gap -dimension a-.

Dimension a; Maximum 23 mm (0.9 in.)
If out of specification steering column is damaged.
- Replace steering column.

Steering column cross member, assembly overview (Page 48-15)
1 - Cross member for steering column

2 - Adjustment bracket
3 - Bolt
25 Nm (18 ft lb)
4 - Strut, right
5 - Bolt
6 - Speed nut
7 - Strut, left
8 - Steering column
2 versions
Indentifying
page 48-16
9 - Steering lock housing
10 - Plug
11 - Bulkhead reinforcement
12 - Socket head multi-point bolt
10 Nm (89 ft lb)

Steering column, identification

From february 2000 a new steering column manufactured by Krupp Presta is installed in left-hand
drive vehicles. Steering column from Nacam is not installed any more.
The reach height and adjustment functions are the same for both steering columns.
Both are supplied as replacement parts.
When replacing a steering column, always use one from the same manufacturer as the original.
Before removing the steering column, be sure to identify which one was originally installed in the
vehicle.
Identifying the steering column
A - Steering column
Manufacturer: Nacam
1 - Transportation device
Remove first after steering column is installed

2 - Steering column
Column is not visible in area -23 - Steering column universal joint shaft
4 - Hex bolt
25 Nm
Installed without locking fluid
B - Steering column
Manufacturer: Krupp Presta
1 - Transportation device
Remove first after steering column is installed
2 - Steering column
Column is visible in area -23 - Steering column universal joint shaft
4 - Hex bolt
25 Nm
Installed with locking fluid D 000 600

Steering column "A", removing and installing

Removing
Steering column is supplied complete, less steering lock housing.
Steering lock housing comes as a replacement part.
Servicing is not possible.
Steering lock housing can be transferred.
Page 48-12
WARNING!
Before removing steering wheel the following conditions must be met:
Ground strap removed from battery.
Wheels straight ahead.
If instructions are not observed airbag system could become inoperative!
Removing airbag unit for four spoke steering wheel
Page 48-1.
Removing airbag unit for three spoke steering wheel
Page 48-6.
- Turn wheels to straight ahead position.
- Remove steering wheel.
- Remove lower storage compartment.

- Remove carpeting
Removing trim for steering column
Remove bolts -1-.

Remove height and reach adjustment handle -5-.
Remove bolts -2-, -3- and -4-.
Remove lower steering column switch trim.
- Remove upper steering column switch trim -1-.

- Release locking tabs (arrows) and pull spiral spring with slip ring off steering column
switch.
- Disconnect harness connector -1-.
- Remove bolt for steering column switch (arrow) and remove steering column switch.

- Remove plastic cover -1- over shear head bolts.

- Release tie wrap.
Vehicles with automatic transmission
Ignition lock cable must be also be disconnected on vehicles with automatic transmission.
- Move selector lever to "P".
- Turn ignition key from position "A" to position "B"(Ignition On).
- Press wire clip -1- up or down according to installation position and pull ignition lock
cable -2- out at same time.

- Remove plastic nuts -1-.
- Remove cover -A-.
- Remove bolt -1- from steering shaft joint.

- Remove universal joint from steering gear.

Steering column, securing before removal

An assembly aid is required to prevent upper and lower components of the steering column from
pulling apart while removing from the steering gear.
Notes:
If upper and lower parts of steering column are pulled too far apart or pushed too
close together the splines will separate.
Rattling noises may occur later on if splines are not in their original position.
- Push or pull steering column until hole is visible.
- Insert, for example, clip in hole -arrow-.

- Remove hex nut -3-.

- Remove hex bolt -1-.
- Remove hex bolts -2- and remove steering column.
1 - Hex bolt
2 - Hex bolts
25 Nm (18 ft lb)
3 - Hex nut
10 Nm (7 ft lb)

Installing steering column
Notes:
New (replacement) steering columns, are secured with a transportation securing
device -6-. This must be removed after installation.
When replacing with new replacement part install new shear bolt -10-.
- Install steering column with pre-assembled steering lock housing to cross member.
- Install hex bolts -5-.
- Install hex bolt -12-.
- Install hex nut -13- and tighten to 10 Nm (89 in. lb).
- Torque bolts -5- to 25 Nm (18 ft. lb).
- Remove transportation device -6-.
- Install universal joint/shaft on steering pinion -9-.
- Tighten bolt -8- to 30 Nm (22 ft. lb).


2 - Steering column
3 - Bolts
4 - Handle
5 - Hex bolts
25 Nm (18 ft lb)
6 - Transportation securing device
7 - Steering column universal joint/shaft
8 - Hex bolt
30 Nm (22 ft lb)
9 - Steering gear pinion
10 - Shear bolt
11 - Pin
12 - Hex bolt
13 - Hex nut
10 Nm (89 in. lb)


Ignition lock cable must also be disconnected on vehicles with automatic transmission.
Ignition key must be in position -B- (ignition on).
- Slide ignition lock cable -2- on steering lock housing -1- until wire clip -1- engages.
Ignition lock (with automatic transmission), checking
- Turn ignition key to position -B- (ignition on).
Must be possible to move selector lever out of park.
If selector lever will not move adjust ignition lock cable.
Repair Manual, Automatic Transmission 01M, Repair Group 37 Ignition lock cable, removing
and installing.

Notes:
Ignition key can only be removed with selector lever in park.
With ignition key in the off position selector lever must not move out of park.
Ignition switch, installing
If ignition switch has been removed, dimension -a- between steering wheel and spiral spring must
be readjusted.
1- Steering wheel
2- Spiral spring housing
3- Ignition switch bolt
a- = approx. 2.5 mm (0.10 in.)
- Install ignition switch.
- Install steering wheel so marked line (arrow A) on steering wheel and center punch
mark (arrow B) on steering column align.
Steering columns supplied as replacement parts do not have a center punch mark.
- Install steering wheel bolt and tighten.

- Align ignition switch horizontally.
Set gap -a- to approx. 2.5 mm (0.10 in.) and tighten bolt -3-.
Remove steering wheel again.
Install trim in reverse order of removal.
Install steering wheel bolt and tighten. Multi-point socket head bolt 50 Nm (37 ft lb)
Make one center punch mark on multi-point socket head bolt.
Notes:
Multi-point socket head bolts with five center punch marks must be replaced.
If a new steering column has been installed, center point can be determined via test drive.
- Install steering wheel in straight ahead position.
Mark steering column after center point has been determined.

Mark -A- on hub of steering wheel
Mark -B- on steering column
Install airbag unit.
WARNING!
When connecting battery make sure no one is in vehicle.

Steering column "B", removing and installing

Removing
Steering column is supplied complete, less steering lock housing.
Steering lock housing comes as a replacement part.
Servicing is not possible.
Steering lock housing can be transferred.
Page 48-12.
WARNING!
Before removing steering wheel the following conditions must be met:
Ground strap removed from battery.
Wheels straight ahead.
If instructions are not observed airbag system could become inoperative!
Removing airbag unit for four spoke steering wheel
Page 48-1.
Removing airbag unit for three spoke steering wheel
Page 48-6.
- Turn wheels straight ahead position.
- Remove steering wheel.
- Remove lower storage compartment.

- Remove carpeting
Removing trim for steering column
Remove bolts -1-.

Remove height and reach adjustment handle -5-.
Remove bolts -2-, -3- and -4-.
Remove lower steering column switch trim.
- Remove upper steering column switch trim -1-.

- Release locking tabs (arrows) and pull spiral spring with slip ring off steering column
switch.
- Separate connection -1-.
- Remove bolt for steering column switch (arrow) and remove steering column switch.


Ignition lock cable must be also be disconnected on vehicles with automatic transmission.
- Turn ignition key from position "A" to position "B" (Ignition On).
- Press wire clip -1- up or down according to installation position and pull ignition lock
cable -2- out at same time.
- Remove cover -A-.

- Remove bolt -1- from steering shaft joint.

- Remove universal joint from steering gear.

- Remove hex nut -4-.

- Remove hex bolt -3-.
- Remove hex bolts -2- and remove steering column.
2 - Hex bolts
25 Nm (18 ft lb)
Installed with locking fluid D 000 600
3 - Hex bolt
4 - Hex nut
10 Nm (7 ft lb)
5 - Plastic cover

Installing steering column
Notes:
New (replacement) steering columns, are secured with a transportation securing
device -6-. This must be removed after installation.
When replacing with new replacement part install new shear bolt -11- and pin -10-.
- Install steering column with pre-assembled steering lock housing to cross member.
- Install hex bolts -5-.
- Install hex bolt -12-.
- Install hex nut -13- and tighten to 10 Nm (89 in. lb).
- Torque bolts -5- to 25 Nm (18 ft. lb).
- Remove transportation device -6-.
- Install universal joint/shaft on steering pinion -8-.
- Tighten bolt -7- to 30 Nm (22 ft. lb).


2 - Steering column
3 - Bolts
4 - Handle
5 - Hex bolts
25 Nm (18 ft lb)
6 - Transportation securing device
7 - Hex bolt
30 Nm (22 ft lb)
8 - Steering gear pinion
9 - Steering column universal joint/shaft
10 - Pin
11 - Shear bolt
12 - Hex bolt
13 - Hex nut
10 Nm (89 in. lb)


Ignition lock cable must also be disconnected on vehicles with automatic transmission.
Ignition key must be in position -B- (ignition on).
- Slide ignition lock cable -2- on steering lock housing -1- until wire clip -1- engages.
Ignition lock (with automatic transmission), checking
- Turn ignition key to position -B- (ignition on).
Must be possible to move selector lever out of park.
If selector lever will not move, adjust the ignition lock cable.
Repair Manual, Automatic Transmission 01M, Repair Group 37 Ignition lock cable, removing
and installing.

Notes:
Ignition key can only be removed with selector lever in park.
With ignition key in off position, the selector lever must not move out of park.
Ignition switch, installing
If ignition switch has been removed, dimension -a- between steering wheel and spiral spring must
be readjusted.
1- Steering wheel
2- Spiral spring housing
3- Ignition switch bolt
a- = approx. 2.5 mm (0.10 in.)
- Install ignition switch.
- Install steering wheel so marked line (arrow A) on steering wheel and center punch
mark (arrow B) on steering column align.
Steering columns supplied as replacement parts do not have a center punch mark.
- Install steering wheel bolt and tighten.

- Align ignition switch horizontally.
Set gap -a- to approx. 2.5 mm (0.10 in.) and tighten bolt -3-.
Remove steering wheel again.
Install trim in reverse order of removal.
Install steering wheel bolt and tighten. Multi-point socket head bolt 50 Nm (37 ft lb)
Make one center punch mark on multi-point socket head bolt.
Notes:
Multi-point socket head bolts with five center punch marks must be replaced.
If a new steering column has been installed, center point can be determined via test drive.
- Install steering wheel in straight ahead position.
Mark steering column after center point has been determined.

Mark -A- on hub of steering wheel
Mark -B- on steering column
Install airbag unit.
WARNING!
When connecting battery make sure no one is in vehicle.

Power steering, servicing (Page 48-41)
Special tools and equipment

3094 Clamps
VAG 1383A Transmission jack
VAG 1332 Torque wrench

Power steering gear, instructions:

Absolute cleanliness is required when working on power steering system.
Thoroughly clean connections and immediate vicinity before loosening.
Place parts on a clean surface and cover if not re-installing immediately.
Do not use fluffy cloth.
Only unpack parts immediately prior to installation.
Only use genuine packed Volkswagen parts.

Removing
- Remove cover -A-.
- Remove steering joint bolt.

- Pull universal joint off steering gear.

- Clamp hose from reservoir with hose clamp 3094.
- Clamp hose on power steering pump with hose clamp 3094.

- Remove noise insulation tray.
- Place oil pan under vehicle.

- Press tie rod end off steering arm.

1- Ball joint puller (commercial type) e.g. Matra V 176
- Disconnect hoses from steering gear and seal with plastic wrap and adhesive tape.
Return line -1- can only be removed after lowering sub-frame.
- Seal power steering gear threaded holes with plastic plugs.

- Remove bolts -1- and -2-.

- Support sub-frame with engine/transmission jack VAG 1383A.
- Remove bolts -1-.
- Remove bolts -2- and -3-.

- Lower sub-frame with engine/transmission jack VAG 1383A.

- Remove return line clamp -1- and unscrew line fitting at steering gear -2-.
- Remove power steering gear bolts.
- Take power steering gear out to rear.
Installing
Notes:
Use new O-rings for hose/line connections.
Coat O-rings with lubricant before installing steering gear.
After connecting steering gear to universal joint shaft ensure seal lies against
assembly plate without kinking and opening to footwell is correctly sealed. Otherwise
noises or water leaks may be develop later.
Ensure sealing surfaces are clean.
- Install power steering gear on sub-frame.
Threaded sleeve -1- must seat in hole on sub-frame.

- Install return line.

A gap of approx. 10 mm (0.39 in.) must exist between return line and power steering
gear.
1- Return line
2- Nut, 22 Nm (16 ft lb)
3- Steering gear
Installation is performed in reverse sequence:

Power steering gear, overview

Power steering gear is not serviceable. Determine cause through pressure and leak tests: If
malfunctioning replace complete unit.
Notes:
Replace self-locking nuts and bolts. Do not weld or straighten steering components.
To grease rack only use steering gear grease Part No. AOF 063 000 04.
Replace self locking nuts and bolts.
Oil type: Hydraulic oil Part No. G 002 000
Oil system capacity: 0.7 ... 0.9 ltr (23 -30 oz.).

1 - Tie rod end

Checking:
Page 48-56
2 - Nut
50 Nm (37 ft lb)
3 - Clamp
Replace
Tightening
Page 48-55
4 - Boot
Must be straight, not twisted after adjusting tie rod
Remove steering gear to replace
5 - Clamp
Replace
Tensioning
Page 48-55

6 - Tie rod
75 Nm (55 ft lb)
Removing and installing
Page 48-53
Replacement parts are supplied preset
Vehicle alignment
Page 44-1
7 - Clamp with rubber sleeve
8 - Return line
9 - Nut
22 Nm (16 ft lb)
10 - Clamp with rubber sleeve
Arrow on clamp points forward
Replace if threads in welded nut are damaged
11 - Heat shield
12 - Self-locking nut
45 Nm (33 ft lb)

13 - Selector mechanism bearing bracket

Center on support (arrow A) with heat shield -11-.
14 - Bolt
24 Nm (18 ft lb)
15 - Gasket
Observe installation instructions
page 48-47
16 - Hydraulic line
17 - Banjo bolt
M 16 x 1.5, 45 Nm (33 ft lb)
18 - Banjo bolt
M 14 x 1.5, 40 Nm (30 ft lb)
19 - O-ring
Replace
20 - Steering gear
Page 48-41

Tie rod, removing and installing

VAG 1332/5 Open jaw insert, 34 mm (1.34 in.) AF
VAG 1275 Pliers

Removing
Notes:
Tie rods can only be removed/installed with steering gear removed.
Removing and installing power steering gear
Page 48-41
- Seal line connections on power steering gear, if not already done.
- Clean steering gear around boot.
- Open clamps and push boot back.
- Clamp steering gear in vice and remove tie rod.

Installing
Install in reverse sequence.
Tightening torque:
Tie rod to power steering gear 75 Nm (55 ft lb)
Installing boot
- Check boot for wear (cuts, cracks) and ensure sealing surfaces are clean.
- Install boot, but first turn tie rod so tie rod end is in installed position.
Notes:
Only use genuine clamps.
- Tension clamp with pliers VAG 1275.
- Install power steering gear.
Page 48-41

Tie rod end play, mounts and boots, checking

- With vehicle raised (wheels hanging free), check play by moving tie rods and
wheels. Play: Zero
Specification: zero play
- Check mounts.
- Ensure boots are correctly seated and not damaged
Center position on rack, determining
Rack should be centered before installing power steering gear on subframe.

- Slide rack until dimension -a- is achieved.
Dimension -a- = 30.5 mm (1.20 in.).

Steering gear, adjusting

Notes:
Two mechanics required. Adjust with engine turned off.
- Raise vehicle on hoist and with wheels straight-ahead.
- Turning steering wheel back and forth (30 from center) a knocking noise will be
heard if play is excessive.
- Second mechanic carefully turns adjustment screw in until knocking noise can no
longer be heard from inside vehicle.
- Perform road test to ensure steering returns to center without sticking.
- Secure lock nut with a punch mark (arrow).

Power steering pump, reservoir, hydraulic lines (Page 48-58)
Power steering pump, checking delivery pressure

3094 Hose clamps
VAG 1402 Pressure guage
VAG 1402/2 Adapter
VAG 1402/3 Adapter
VAG 1402/4 Adapter
VAG 1402/6 Hose from adapter set

VAS 5024 Assembly pliers
VA 1402/1 Adaptor

Vehicles with power steering pump in lower area
- Clamp return hose with hose clamp 3094.

- Remove noise insulation panel.
Clamp suction hose with hose clamp 3094.

Place oil pan under vehicle.
Disconnect pump pressure line.
Remove connector from pressure switch if necessary.

- Install adapter -1-.

Use seal.
1- VAG 1402/1
2- VAG 1402/6 Hose from adapter set
- Connect pressure gauge VAG 1402.

A- Pressure switch (n/a U.S.)
1- VAG 1402 Pressure gauge
2- VAG 1402/6 Hose from adapter set
3- Banjo bolt
4- Pressure hose banjo union
5- VAG 1402/2
6- VAG 1402 Hose from pressure gauge

Remove hose clamp 3094 from suction and return hoses.

Re-connect suction and return hoses.
Start engine and if necessary add fluid to reservoir.
Turn steering wheel approx.10 times lock to lock.
Check delivery pressure.
Requirements:
V-belt/V-belt tension OK.
System not leaking.
Hoses/lines are not kinked or restricted.
- With engine running at idle, close cut-off valve (not longer than 5 seconds) and read
pressure.
Specifications
Gasoline engines: 85...95 bar (1233-1378 psi)
Diesel engines: 96...105 bar (1392-1523psi)

Notes:
If reading is higher or lower than specified replace pump:
Power steering pump (with pump in lower area), removing and installing
Page
48-68.
If reservoir fluid level is low check steering system for leaks.
For leaks at pinion check lines/line connections and if necessary tighten and wipe
dry.
If pinion seal or rack seals in steering gear housing are leaking replace steering
gear.
To check rack seals loosen hose clip on boot and push boot to one side.
Vehicles with power steering pump in upper area
- Remove engine cover.

- Clamp return hose with hose clamp 3094.
- Clamp suction hose with hose clamp 3094.

- Place oil pan under vehicle.
- Disconnect pump pressure line.

Pressure gauge VAG 1402, connecting
1 - VAG 1402 Pressure gauge

2 - VAG 1402 Hose from pressure gauge
3 - VAG 1402/6 Hose from adapter set
4 - VAG 1402/4 Adapter
5 - O-ring
Qty. 2
6 - VAG 1402/2 Adapter
7 - Pressure line/hose with banjo union
8 - Banjo bolt

Remove hose clamp 3094 from suction and return hoses.

Start engine and if necessary add fluid to reservoir.
Turn steering wheel approx. 10 times lock to lock.
Check delivery pressure.
Requirements:
V-belt/V-belt tension OK.
System not leaking.
Hoses/lines are not kinked or restricted.
- Close cut-off valve (not longer than 5 seconds) and read pressure, with engine
idling.
Specifications
Gasoline engines: 85...95 bar (1233-1378 psi)
Diesel engines: 96...105 bar (1392-1523 psi)

Notes:
If reading is higher or lower than specified replace pump
Power steering pump (vehicles with pump in upper area), removing and installing
Page 48-72
If reservoir fluid level is low check steering system for leaks.
For leaks at pinion check lines/line connections for leaks and if necessary tighten
and wipe dry.
If pinion seal or rack seals in steering gear housing are leaking replace steering
gear.
To check rack seals loosen hose clamp on boot and push boot to one side.

Power steering pump (pump in lower area), removing and installing

Power steering pump is not serviceable. If malfunction in pump is suspected, determine cause
using pressure and leak tests; if malfunctioning replace complete unit
Notes:
Pumps supplied as replacement parts are not filled with oil. Therefore, fill pump with
hydraulic oil Part No. G 002 000 and rotate by hand, otherwise pump may be
damaged or noisy during operation.
Type of oil: hydraulic oil Part No. G 002 000
Oil system capacity: 0.7 ... 0.9 ltr (11.8-15.2 oz.).
Removing
- Remove noise insulation.

- Loosen belt pulley hex bolt.

Counter-hold with a hex key if necessary.
Turn tightening device in direction of arrow to relieve tension on ribbed belt.

Mark direction of ribbed belt rotation.
Remove ribbed belt.
Remove belt pulley hex bolt.

Clamp off suction hose with hose clamps -3094-.

Open spring clip -3- and pull off suction hose with special tool VAS 5024.
Remove banjo bolt -4-.
Seal pressure line/hose with a plastic bag or similar.
Remove hex bolts -1- and -2-.
Remove pump.
Installing
- Fill power steering pump with hydraulic oil, via suction union.
- Turn hub by hand until oil comes from pressure side.
- Install p/s pump on bracket and tighten bolts to 25 Nm (18 ft lb).
- Install suction hose and spring clip.
(Arrow A) must align with casting seam arrow.

Spring clip must close off mark -arrow B-.

- Install new O-rings on banjo bolt.

- Tighten banjo bolt to 30 Nm (22 ft lb).

Power steering pump (pump in upper area), removing and installing

Power steering pump is not serviceable. If malfunction in pump is suspected, determine cause
using pressure and leak tests; if malfunctioning replace complete unit
Notes:
Pumps supplied as replacement parts are not filled with oil. Fill pump with hydraulic
oil Part No. G 002 000 and rotate by hand, otherwise pump may be damaged or
noisy during operation.
Type of oil: hydraulic oil Part No. G 002 000
Oil system capacity: 0.7 ... 0.9 ltr. (11.8-15.2 oz.).
Removing
- Remove noise insulation.

- Loosen belt pulley hex bolt.

Counter-hold with a hex key if necessary.
- Turn tightening device in direction of arrow to relieve tension on ribbed belt.

For ease of illustration, relieving belt pulley tension is shown with out charge air line.
- Mark ribbed belt direction of rotation.
- Remove ribbed belt.
- Remove hex bolt from belt pulley.

Suction line and hose, removing

Suction line lower spring clip can only be opened with headlight removed.
Remove bumper for this.
Repair Manual, Body-Exterior, Repair Group 63
- Pull connector off intake line.
- Open spring clamps -1-, -2- and -3- with special tool VAS 5024.
- Remove suction hose -A- and suction line.

- Clamp off suction hose with hose clamps 3094.

- Open spring clip -3- and pull off suction hose with special tool VAS 5024.
- Clamp off return hose with hose clamps 3094.

- Remove banjo bolt -2-.
- Seal pressure line/hose with a plastic bag or similar.

- Remove hex bolts -1- and -2-.

- Remove pump.
Installing
- Fill power steering pump with hydraulic oil, via suction union.
- Turn hub by hand until oil comes from pressure side.
- Install power steering pump on bracket and tighten bolts to 25 Nm (18 ft lb).
- Install suction hose and spring clip.

(Arrow A) must align with casting seam -arrow-.
Spring clip must close off mark -arrow B-.
- Install new O-rings on banjo bolt.
- Tighten banjo bolt to 30 Nm (22 ft lb).

Power steering pump with hydraulic lines/hoses, assembly overview
I - Vehicles with power steering pump in upper area

II - Vehicles with power steering pump in lower area
1 - Reservoir
Page 48-79
2 - Pressure hose/line
Vehicles with TDI engine and air conditioner
Page 48-74
Page 48-80

Vehicles with /TDI engine and no air conditioning
Disassembling and assembling
Page 48-74
Vehicles with TDI engine and air conditioning
Page 48-74
On 5-speed manual transmission 02J
Page 48-74
On automatic transmission
Page 48-74
Check pressure
Page 48-58
Fill before installing
Note: Page 48-68

Reservoir, removing and installing
1 - Cap with dip stick

Oil level: between min. and max. marks; Engine temperature approx. 50 C (122 F)
Check oil level with cap screw on
With engine cold, oil level must not rise above Min. marking
Open cap with e.g. a bar
Arrow A: oil level with engine cold
2 - Hose clamp
3 - Suction hose
4 - Return hose
5 - Socket-head bolt
10 Nm (89 in. lb)
6 - Reservoir

Pressure line and suction hose (TDI engine with A/C)
1 - Power steering pump

Delivery pressure, checking
Before installing fill with oil
2 - Suction hose
3 - Mounting bracket
4 - Pressure hose
5 - Hex bolt
10 Nm (89 in. lb)
6 - Clamp
7 - Banjo bolt
30 Nm (22 ft lb)
8 - Seal
Always replace
9 - Suction hose
10 - Reservoir
Page 48-58
Note: Page 48-68

Pressure line and suction hose (TDI 2.0 liter engine without A/C)

Checking delivery pressure
Page 48-58
Fill with oil before installing
Note: Page 48-68
White or yellow ring must seat within retainer item -92 - Suction hose
3 - Pressure hose
4 - Banjo bolt
30 Nm (22 ft lb)
5 - Seal
Always replace
6 - Suction hose
White or yellow ring must seat within retainer -97 - Retainer
8 - Hex nut

Pressure line and suction hose (vehicles with A/C and 2.0 liter or VR6 engines)

Page 48-58
Note: Page 48-68
2 - Suction hose
3 - Pressure hose
4 - Banjo bolt
30 Nm (22 ft lb)
5 - Seal
Always replace
6 - Suction hose
8 - Hex nut

Pressure line and suction hose (1.8 liter engines with A/C)

2 - Suction hose
3 - Pressure hose
4 - Pressure switch
Switches at 40 bar (580 psi)
Tighten to 15 Nm (11 ft lb)
5 - Seal
Always replace
6 - Banjo bolt
30 Nm (22 ft lb)
7 - Seal
Always replace
Page 48-58
Note: Page 48-68

8 - Suction hose
10 - Hex bolt

Pressure line (5-speed manual transmission 02J), securing
1 - Pressure line
2 - Speed nut
3 - Clamp
4 - Bolt
22 Nm (16 ft lb)
5 - Nut
25 Nm (18 ft lb)
7 - Pressure hose
8 - Bolt
22 Nm (16 ft lb)

Pressure line (automatic transmission), securing
1 - Securing bolt on starter

2 - Hex bolt
22 Nm (16 ft lb)
3 - Clamp
4 - Hex nut
25 Nm (18 ft lb)
6 - Pressure hose
7 - Securing bolt on transmission

Power steering, assembly overview (pump in lower area)
1 - Bracket
2 - Bolt
25 Nm (18 ft lb)
3 - Banjo bolt
30 Nm (22 ft lb)
4 - Pressure hose
5 - Sealing ring
Always replace
6 - Suction hose
7 - Clamp
Page 48-58
Note Page 48-68

9 - Belt pulley
25 Nm (18 ft lb)
11 - Ribbed belt
CAUTION!
Using a crayon or marker, mark the direction of travel before removing the
ribbed belt. Reinstalling a used belt in the opposite direction could damage
the belt
When installing the belt, make sure that it is correctly seated in the pulleys.
Determine part number from parts catalog
Removing and belt routing
Repair Manual, Engine Mechanical, Repair Group 13
Checking condition
Reapair Manual, Maintenance
12 - Ribbed tensioner belt

Power steering pump assembly overview (pump in the upper area)

Vehicles with power steering pump in upper area
1 - Bracket
2 - Bolt
25 Nm (18 ft lb)
4 - O-ring
Always replace
5 - Banjo bolt
30 Nm (22 ft lb)
6 - Pressure hose
7 - Bolt
22 Nm (16 ft lb)
8 - Belt pulley
Page 48-58
Note: Page 48-72

25 Nm (18 ft lb)
10 - Ribbed belt
Using a crayon or marker, mark the direction of travel before removing the
ribbed belt. Reinstalling a used belt in the opposite direction could damage
the belt
When installing the belt, make sure that it is correctly seated in the pulleys.
Determine part number from parts catalog
Removing and belt routing
Repair Manual, Engine Mechanical, Repair Group 13
Checking condition
Repair Manual, Maintenance
11 - Ribbed tensioner belt

g4 48 Steering

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