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Home/Volkswagen/Beetle/Volkswagen Beetle A4 (1997-2005)/Repair manual/Manual & Power Steering/Steering (Hatchback): Overview
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Steering (Hatchback): Overview Volkswagen Beetle A4

Manual & Power Steering 25 illustrations ~2576 words

DESCRIPTION AND OPERATION

1.8L, 2.0L, 1.9L TDI and TDI PD

1.8L, 2.0L, and 1.9L TDI and TDI PD without A/C

1.9L TDI and TDI PD with A/C

1.9L TDI and TDI PD with A/C

1.8L with A/C, 1.9L TDI without A/C and 2.0L

1.8L without A/C and 2.0L with A/C

1.9L TDI PD

1.8L with manual transmission 02M

1.9L TDI PD with DSG transmission 02E

1.8L, 2.0L and 1.9L TDI with automatic transmission 01M

1.8L, 2.0L, 1.9L TDI, and TDI PD with manual transmission 02J

1.8L, 2.0L and 2.5L with automatic transmission 09G

2.5L

2.5L with manual transmission 0A4

2.5L with automatic transmission 09G

POWER STEERING GEAR ASSEMBLY OVERVIEW

The power steering gear is not serviceable. If a customer has reported a problem, determine cause via pressure test and leak test. If there is a malfunction, replace power steering gear.

Note. Always replace self-locking nuts and bolts. Welding or straighten work on any steering components is not permitted. To grease the rack, only use steering gear grease AOF 063 000 04. Oil type: Hydraulic fluid G 002 000 Oil capacity in system: 0.7 to 0.9 L

Scheme 1

Scheme 1: POWER STEERING GEAR ASSEMBLY OVERVIEW
Scheme 1: POWER STEERING GEAR ASSEMBLY OVERVIEW
  1. Tie rod end Checking: «SECURING BOOTS AND CHECKING TIE ROD END PLAY»(ref-492756-S00020884492012080600000) . Modification: Modified tie rod ends «TIE ROD ENDS, MODIFIED VERSION»(ref-492756-S11522728422012080600000) .
  2. Hex nut M14 x 1.5 Tightening specification, «Steering Gear»(ref-492756-S18446853532012080600000) .
  3. Clamp Replace Tightening «TIE ROD BOOT, INSTALLING»(ref-492756-S27520024022012080600000) .
  4. Boot Must not be twisted after toe is adjusted To replace, remove steering gear
  5. Clamp Replace Tensioning «TIE ROD BOOT, INSTALLING»(ref-492756-S27520024022012080600000) .
  6. Tie rod Tightening specification, «Steering Gear»(ref-492756-S18446853532012080600000) . Modification: Modified tie rods «TIE RODS, MODIFIED VERSION»(ref-492756-S02454389352012080600000) . Removing and installing «TIE ROD»(ref-492756-S19191845892012080600000) . Is preset when supplied as replacement part Adjusting toe «DIAGNOSIS AND TESTING»(ref-492815-S28343957352012080600000) . Various versions
  7. Hex bolt M8 x 25 Tightening specification, «Steering Gear»(ref-492756-S18446853532012080600000) .
  8. Gasket Note assembly instructions. Use new O-rings for hose/line connections.
  9. Hydraulic line
  10. Banjo fitting M16 x 1.5 Tightening specification, «Steering Gear»(ref-492756-S18446853532012080600000) .
  11. Banjo fitting M14 x 1.5 Tightening specification, «Steering Gear»(ref-492756-S18446853532012080600000) .
  12. Seals Replace
  13. Return line
  14. Steering gear Removing and installing «POWER STEERING GEAR»(ref-492756-S17110911242012080600000) .
  15. Clamp with rubber bushing Replace weld nut if there is damage in thread
  16. Heat shield
  17. Self-locking hex nut M12 x 1.5 Tightening specification, «Steering Gear»(ref-492756-S18446853532012080600000) .
  18. Hex nut M8 Tightening specification, «Steering Gear»(ref-492756-S18446853532012080600000) .

POWER STEERING SYSTEM OVERVIEW

I - Vehicles with high mounted power steering pump

II - Vehicles with low mounted power steering pump

Scheme 2

Scheme 2: POWER STEERING SYSTEM OVERVIEW
Scheme 2: POWER STEERING SYSTEM OVERVIEW
  1. Refill tank Assembly notes «POWER STEERING RESERVOIR ASSEMBLY OVERVIEW»(ref-492756-S34317818682012080600000) .
  2. Pressurized line mount Vehicles with TDI engine and A/C system Assembly notes «PRESSURIZED LINE AND INTAKE HOSE OVERVIEW»(ref-492756-S27443607912012080600000) .
  3. Pressurized line mount Vehicles with 2.0L and TDI engines without A/C system Vehicles with 1.8L engine with A/C system Assembly notes «PRESSURIZED LINE AND INTAKE HOSE OVERVIEW»(ref-492756-S21780771012012080600000) . Vehicles with 2.0L engine with A/C system Vehicles with 1.8L engine without A/C system Assembly notes «PRESSURIZED LINE AND INTAKE HOSE OVERVIEW»(ref-492756-S18465872972012080600000) .
  4. Intake hose mount
  5. Pressurized line mount On 5 speed manual transmission 02J Assembly notes «PRESSURIZED LINE MOUNT OVERVIEW»(ref-492756-S41602940452012080600000) . On 5 speed manual transmission 0A4 Assembly notes «PRESSURIZED LINE MOUNT OVERVIEW»(ref-492756-S20951115842012080600000) . On 6 speed manual transmission 02M Assembly notes «PRESSURIZED LINE OVERVIEW»(ref-492756-S40315551602012080600000) .
  6. Power steering pump Checking delivery pressure at low mounted power steering pump «LOW MOUNTED POWER STEERING PUMP, CHECKING DELIVERY PRESSURE»(ref-492756-S28465327832012080600000) . Checking delivery pressure at high mounted power steering pump «HIGH MOUNTED POWER STEERING PUMP, CHECKING DELIVERY PRESSURE»(ref-492756-S08570226172012080600000) . Before installing, fill with oil at low mounted power steering pump «LOW MOUNTED POWER STEERING PUMP»(ref-492756-S30792045742012080600000) . Before installing, fill with oil at high mounted power steering pump «HIGH MOUNTED POWER STEERING PUMP»(ref-492756-S21257051412012080600000) .
  7. Pressurized line mount On automatic transmission 01M Assembly notes «PRESSURIZED LINE OVERVIEW»(ref-492756-S10391446762012080600000) .

Scheme 3

Scheme 3: POWER STEERING RESERVOIR ASSEMBLY OVERVIEW
Scheme 3: POWER STEERING RESERVOIR ASSEMBLY OVERVIEW
  1. Cover with dipstick Oil level: Between Min. and Max. marking; engine temperature approximately 50° C -arrow A- Check oil level «POWER STEERING FLUID LEVEL, CHECKING»(ref-492756-S00183680192012080600000) . Open cap e.g. using toggle
  2. Spring clip
  3. Return hose
  4. Intake hose
  5. Bolt M6 x 45
  6. Refill tank
  7. Battery tray

Scheme 4

Scheme 4: LOW MOUNTED POWER STEERING PUMP ASSEMBLY OVERVIEW
Scheme 4: LOW MOUNTED POWER STEERING PUMP ASSEMBLY OVERVIEW
  1. Bracket
  2. Hex bolt M8 x 40 Tightening specification, «Power Steering Pump»(ref-492756-S24731125752012080600000) .
  3. Banjo fitting M16 x 1.5 Tightening specification, «Power Steering Pump»(ref-492756-S24731125752012080600000) .
  4. Pressurized line
  5. Seals Replace
  6. Intake hose
  7. Spring clip
  8. Power steering pump Checking delivery pressure «LOW MOUNTED POWER STEERING PUMP, CHECKING DELIVERY PRESSURE»(ref-492756-S28465327832012080600000) . Before installing, fill with power steering fluid, «Installing»(ref-492756-S27624869322012082700000) .
  9. Belt pulley
  10. Socket head bolt M8 x 14
  11. Ribbed belt Mark direction of travel before removing Removing and belt routing: Gas engines: [For engine(s) BDC, BEV, BGD, AVH, AZG, AEG] REMOVAL AND INSTALLATION , or refer to [For engine(s) APH, BNU, AWP, AWV, BKF] REMOVAL AND INSTALLATION , or refer to [For engine(s) ALH] REMOVAL AND INSTALLATION , or refer to [For engine(s) BEW] REMOVAL AND INSTALLATION 1.9L TDI diesel engines: [For engine(s) ALH] REMOVAL AND INSTALLATION 1.9L TDI PD diesel engines: [For engine(s) BEW] REMOVAL AND INSTALLATION Inspection of condition Maintenance ; Booklet Ribbed belt: checking condition
  12. Ribbed belt tensioner

Scheme 5

Scheme 5: HIGH MOUNTED POWER STEERING PUMP ASSEMBLY OVERVIEW
Scheme 5: HIGH MOUNTED POWER STEERING PUMP ASSEMBLY OVERVIEW
  1. Bracket
  2. Hex bolt M8 x 40 Tightening specification, «Power Steering Pump»(ref-492756-S24731125752012080600000) .
  3. Power steering pump Checking delivery pressure «HIGH MOUNTED POWER STEERING PUMP, CHECKING DELIVERY PRESSURE»(ref-492756-S08570226172012080600000) . Before installing, fill with power steering fluid «HIGH MOUNTED POWER STEERING PUMP»(ref-492756-S21257051412012080600000) .
  4. Seals Replace
  5. Pressurized line
  6. Banjo fitting M16 x 1.5 Tightening specification, «Power Steering Pump»(ref-492756-S24731125752012080600000) .
  7. Intake hose
  8. Belt pulley
  9. Socket head bolt M8 x 14 Tightening specification, «Power Steering Pump»(ref-492756-S24731125752012080600000) .
  10. Ribbed belt Mark direction of travel before removing Removing and belt routing Inspection of condition Maintenance ; Booklet ; Ribbed belt: checking condition
  11. Ribbed belt tensioner

Scheme 6

Scheme 6: PRESSURIZED LINE AND INTAKE HOSE OVERVIEW (VEHICLES WITH TDI ENGINE AND A/C SYSTEM)
Scheme 6: PRESSURIZED LINE AND INTAKE HOSE OVERVIEW (VEHICLES WITH TDI ENGINE AND A/C SYSTEM)
  1. Power steering pump Checking delivery pressure «HIGH MOUNTED POWER STEERING PUMP, CHECKING DELIVERY PRESSURE»(ref-492756-S08570226172012080600000) . Before installing, fill with power steering fluid «HIGH MOUNTED POWER STEERING PUMP»(ref-492756-S21257051412012080600000) .
  2. Intake hose
  3. Spring clip
  4. Pressurized line
  5. Banjo fitting M16 x 1.5 Tightening specification, «Pressurized Line/Intake Hose TDI Engines»(ref-492756-S28491692442012080600000) .
  6. Seals Replace
  7. Socket head bolt M10 x 30 Tightening specification, «Pressurized Line/Intake Hose TDI Engines»(ref-492756-S28491692442012080600000) .
  8. Hex nut M8 Tightening specification, «Pressurized Line/Intake Hose TDI Engines»(ref-492756-S28491692442012080600000) .
  9. Clamp
  10. Cylinder block

Scheme 7

Scheme 7: PRESSURIZED LINE AND INTAKE HOSE OVERVIEW (VEHICLES WITH 2.0L AND TDI ENGINES WITHOUT A/C SYSTEM AND
Scheme 7: PRESSURIZED LINE AND INTAKE HOSE OVERVIEW (VEHICLES WITH 2.0L AND TDI ENGINES WITHOUT A/C SYSTEM AND
  1. Power steering pump Checking delivery pressure «LOW MOUNTED POWER STEERING PUMP, CHECKING DELIVERY PRESSURE»(ref-492756-S28465327832012080600000) . Before installing, fill with power steering fluid, «Installing»(ref-492756-S27624869322012082700000) .
  2. Intake hose
  3. Spring clip
  4. Pressurized line
  5. Banjo fitting M16 x 1.5 Tightening specification 2.0L: «Pressurized Line/Intake Hose 2.0L Engines»(ref-492756-S13971442552012080600000) . Tightening specification TDI: «Pressurized Line/Intake Hose TDI Engines»(ref-492756-S28491692442012080600000) . Tightening specification 1.8L: «Pressurized Line/Intake Hose 1.8L Engines»(ref-492756-S10461367332012080600000) .
  6. Seals Replace
  7. Clamp
  8. Hex bolt M8 x 20 Tightening specification 2.0L: «Pressurized Line/Intake Hose 2.0L Engines»(ref-492756-S13971442552012080600000) . Tightening specification TDI: «Pressurized Line/Intake Hose TDI Engines»(ref-492756-S28491692442012080600000) . Tightening specification 1.8L: «Pressurized Line/Intake Hose 1.8L Engines»(ref-492756-S10461367332012080600000) .
  9. Hex bolt M10 x 25 Tightening specification 2.0L: «Pressurized Line/Intake Hose 2.0L Engines»(ref-492756-S13971442552012080600000) . Tightening specification TDI: «Pressurized Line/Intake Hose TDI Engines»(ref-492756-S28491692442012080600000) . Tightening specification 1.8L: «Pressurized Line/Intake Hose 1.8L Engines»(ref-492756-S10461367332012080600000) .
  10. Clip
  11. Bracket
  12. Cylinder block

Scheme 8

Scheme 8: PRESSURIZED LINE AND INTAKE HOSE OVERVIEW (VEHICLES WITH 2.0L ENGINE AND A/C SYSTEM & VEHICLES WITH
Scheme 8: PRESSURIZED LINE AND INTAKE HOSE OVERVIEW (VEHICLES WITH 2.0L ENGINE AND A/C SYSTEM & VEHICLES WITH
  1. Power steering pump Checking delivery pressure «LOW MOUNTED POWER STEERING PUMP, CHECKING DELIVERY PRESSURE»(ref-492756-S28465327832012080600000) . Before installing, fill with power steering fluid, «Installing»(ref-492756-S27624869322012082700000) .
  2. Intake hose
  3. Spring clip
  4. Pressurized line
  5. Banjo fitting M16 x 1.5 Tightening specification 2.0L: «Pressurized Line/Intake Hose 2.0L Engines»(ref-492756-S13971442552012080600000) . Tightening specification 1.8L: «Pressurized Line/Intake Hose 1.8L Engines»(ref-492756-S10461367332012080600000) .
  6. Seals Replace
  7. Hex nut
  8. Clamp
  9. Hex bolt M8 x 20 Tightening specification 2.0L: «Pressurized Line/Intake Hose 2.0L Engines»(ref-492756-S13971442552012080600000) . Tightening specification 1.8L: «Pressurized Line/Intake Hose 1.8L Engines»(ref-492756-S10461367332012080600000) .
  10. Hex bolt M10 x 25 Tightening specification 2.0L: «Pressurized Line/Intake Hose 2.0L Engines»(ref-492756-S13971442552012080600000) . Tightening specification 1.8L: «Pressurized Line/Intake Hose 1.8L Engines»(ref-492756-S10461367332012080600000) .
  11. Bracket
  12. Cylinder block

Scheme 9

Scheme 9: PRESSURIZED LINE AND INTAKE HOSE OVERVIEW (VEHICLES WITH TDI PUMP INJECTOR ENGINE)
Scheme 9: PRESSURIZED LINE AND INTAKE HOSE OVERVIEW (VEHICLES WITH TDI PUMP INJECTOR ENGINE)
  1. Power steering pump Checking delivery pressure «LOW MOUNTED POWER STEERING PUMP, CHECKING DELIVERY PRESSURE»(ref-492756-S28465327832012080600000) . Before installing, fill with power steering fluid, «Installing»(ref-492756-S27624869322012082700000) .
  2. Banjo fitting M16 x 1.5 Tightening specification, «Pressurized Line/Intake Hose TDI Engines»(ref-492756-S28491692442012080600000) .
  3. Seals Replace
  4. Pressurized line
  5. Spring clip
  6. Socket Only for power steering pumps manufactured by Kayaba
  7. Hex bolt M8 x 28 Tightening specification, «Pressurized Line/Intake Hose TDI Engines»(ref-492756-S28491692442012080600000) .
  8. Clamp
  9. Intake hose
  10. Cylinder block
  11. Bracket
  12. Hex bolt M10 x 25 Tightening specification, «Pressurized Line/Intake Hose TDI Engines»(ref-492756-S28491692442012080600000) .
  13. Hex bolt M8 x 20 Tightening specification, «Pressurized Line/Intake Hose TDI Engines»(ref-492756-S28491692442012080600000) .
  14. Oil filter housing
  15. Transmission
  16. Hex bolt M10 x 55 M10 x 50 (DSG transmission 02E only) Tightening specification, «Pressurized Line/Intake Hose TDI Engines»(ref-492756-S28491692442012080600000) .

Scheme 10

Scheme 10: PRESSURIZED LINE OVERVIEW - 6-SPEED MANUAL TRANSMISSION 02M
Scheme 10: PRESSURIZED LINE OVERVIEW - 6-SPEED MANUAL TRANSMISSION 02M
  1. Pressurized line
  2. Hex nut M8 Tightening specification, «Pressurized Line to Manual Transmission 02M»(ref-492756-S01745014742012080600000) .
  3. Clamp
  4. Mounting bolt on starter
  5. Hex bolt M8 Tightening specification, «Pressurized Line to Manual Transmission 02M»(ref-492756-S01745014742012080600000) .
  6. Bracket
  7. Hex nut M8 x 28 Tightening specification, «Pressurized Line to Manual Transmission 02M»(ref-492756-S01745014742012080600000) .
  8. Clamp

Assembly notes for pressurized line and intake hose on power steering pump PRESSURIZED LINE AND INTAKE HOSE TO POWER STEERING PUMP OVERVIEW .

Assembly notes for pressurized line and intake hose on DSG transmission 02E PRESSURIZED LINE AND RETURN HOSE OVERVIEW .

Scheme 11

Scheme 11: POWER STEERING SYSTEM OVERVIEW
Scheme 11: POWER STEERING SYSTEM OVERVIEW
  1. Refill tank
  2. Power steering pump Checking delivery pressure «LOW MOUNTED POWER STEERING PUMP, CHECKING DELIVERY PRESSURE»(ref-492756-S28465327832012080600000) . Before installing, fill with power steering fluid, «Installing»(ref-492756-S27624869322012082700000) .
  3. Pressurized line mount On power steering pump
  4. Intake hose mount On power steering pump
  5. Intake hose
  6. Intake hose mount On cylinder block
  7. Pressurized line
  8. Pressurized line mount On DSG transmission 02E Assembly notes «PRESSURIZED LINE AND RETURN HOSE OVERVIEW»(ref-492756-S25399543122012080600000) .
  9. Return hose mount On DSG transmission 02E
  10. Pressurized line mount On transmission bracket Assembly notes «PRESSURIZED LINE AND RETURN HOSE OVERVIEW»(ref-492756-S25399543122012080600000) .
  11. Return hose

Scheme 12

Scheme 12: PRESSURIZED LINE AND INTAKE HOSE TO POWER STEERING PUMP OVERVIEW
Scheme 12: PRESSURIZED LINE AND INTAKE HOSE TO POWER STEERING PUMP OVERVIEW
  1. Socket head bolt M8 x 14 Tightening specification, «Pressurized Line to DSG Transmission 02E»(ref-492756-S20447372042012080600000) .
  2. Belt pulley
  3. Power steering pump Checking delivery pressure «LOW MOUNTED POWER STEERING PUMP, CHECKING DELIVERY PRESSURE»(ref-492756-S28465327832012080600000) . Before installing, fill with power steering fluid, «Installing»(ref-492756-S27624869322012082700000) .
  4. Hex bolt M8 x 40 Tightening specification, «Pressurized Line to DSG Transmission 02E»(ref-492756-S20447372042012080600000) .
  5. Bracket On cylinder block
  6. Spring clip
  7. Intake line
  8. Intake hose
  9. Banjo fitting M16 x 1.5 Tightening specification, «Pressurized Line to DSG Transmission 02E»(ref-492756-S20447372042012080600000) .
  10. Seals Replace
  11. Pressurized line

Scheme 13

Scheme 13: PRESSURIZED LINE AND RETURN HOSE OVERVIEW
Scheme 13: PRESSURIZED LINE AND RETURN HOSE OVERVIEW
  1. Bracket
  2. Pressurized line
  3. Hex nut Tightening specification, «Pressurized Line to DSG Transmission 02E»(ref-492756-S20447372042012080600000) . M6
  4. Hex nut Tightening specification, «Pressurized Line to DSG Transmission 02E»(ref-492756-S20447372042012080600000) . M8
  5. Transmission bracket

PRESSURIZED LINE OVERVIEW (1.8L, 2.0L ENGINES)

Vehicles With 1.8L and 2.0L Engines

Scheme 14

Scheme 14: PRESSURIZED LINE OVERVIEW (1.8L, 2.0L ENGINES)
Scheme 14: PRESSURIZED LINE OVERVIEW (1.8L, 2.0L ENGINES)
  1. Pressurized line
  2. Clamp
  3. Hex nut M8 Tightening specification, «Pressurized Line to Automatic Transmission 01M»(ref-492756-S09541484332012080600000) .
  4. Bracket Install parallel to direction of travel
  5. Intake hose
  6. Oil filter housing
  7. Bracket
  8. Hex bolt M10 x 40 Tightening specification, «Pressurized Line to Automatic Transmission 01M»(ref-492756-S09541484332012080600000) .
  9. Hex bolt M8 x 28 Tightening specification, «Pressurized Line to Automatic Transmission 01M»(ref-492756-S09541484332012080600000) .
  10. Mounting bolt on starter
  11. Bracket

Vehicles With 1.9L TDI Engine

Scheme 15

Scheme 15
Scheme 15
  1. Mounting bolt on starter
  2. Hex nut M8 Tightening specification, «Pressurized Line to Automatic Transmission 01M»(ref-492756-S09541484332012080600000) .
  3. Bracket
  4. Hex bolt M8 x 28 Tightening specification, «Pressurized Line to Automatic Transmission 01M»(ref-492756-S09541484332012080600000) .
  5. Clamp
  6. Pressurized line

Scheme 16

Scheme 16: PRESSURIZED LINE MOUNT OVERVIEW
Scheme 16: PRESSURIZED LINE MOUNT OVERVIEW
  1. Pressurized line
  2. Speed nut
  3. Clamp
  4. Hex bolt M8 x 28 Tightening specification, «Pressurized Line to Manual Transmission 02J»(ref-492756-S24569394112012080600000) .
  5. Clamp
  6. Pressure hose
  7. Hex bolt M8 x 28 Tightening specification, «Pressurized Line to Manual Transmission 02J»(ref-492756-S24569394112012080600000) .
  8. Bracket
  9. Intake hose

Assembly notes for pressurized line and intake hose on power steering pump PRESSURIZED LINE AND INTAKE HOSE TO POWER STEERING PUMP OVERVIEW .

Assembly notes for pressurized line and intake hose on automatic transmission PRESSURIZED LINE AND RETURN HOSE OVERVIEW .

Assembly notes for pressurized line and intake hose automatic transmission, with 2.5L engine PRESSURIZED LINE AND RETURN HOSE OVERVIEW .

Scheme 17

Scheme 17: POWER STEERING SYSTEM OVERVIEW
Scheme 17: POWER STEERING SYSTEM OVERVIEW
  1. Refill tank
  2. Power steering pump Checking delivery pressure «LOW MOUNTED POWER STEERING PUMP, CHECKING DELIVERY PRESSURE»(ref-492756-S28465327832012080600000) . Before installing, fill with power steering fluid, «Installing»(ref-492756-S27624869322012082700000) .
  3. Pressurized line mount On power steering pump
  4. Intake hose mount On power steering pump
  5. Intake hose
  6. Intake hose mount On cylinder block
  7. Pressurized line
  8. Pressurized line mount On automatic transmission 09G Assembly notes «PRESSURIZED LINE AND INTAKE HOSE TO POWER STEERING PUMP OVERVIEW»(ref-492756-S40628891622012080600000) .
  9. Return hose mount On automatic transmission 09G Assembly notes «PRESSURIZED LINE AND INTAKE HOSE TO POWER STEERING PUMP OVERVIEW»(ref-492756-S40628891622012080600000) .
  10. Return hose

Scheme 18

Scheme 18: PRESSURIZED LINE AND INTAKE HOSE TO POWER STEERING PUMP OVERVIEW
Scheme 18: PRESSURIZED LINE AND INTAKE HOSE TO POWER STEERING PUMP OVERVIEW
  1. Banjo fitting M16 x 1.5 Tightening specification, «Pressurized Line to Automatic Transmission 09G»(ref-492756-S40953733322012080600000) .
  2. Seals Replace
  3. Pressurized line
  4. Power steering pump Checking delivery pressure «LOW MOUNTED POWER STEERING PUMP, CHECKING DELIVERY PRESSURE»(ref-492756-S28465327832012080600000) . Before installing, fill with power steering fluid, «Installing»(ref-492756-S27624869322012082700000) .
  5. Socket For power steering pumps manufactured by Kayaba
  6. Clamp
  7. Hex bolt M8 x 28 Tightening specification, «Pressurized Line to Automatic Transmission 09G»(ref-492756-S40953733322012080600000) .
  8. Spring clip
  9. Intake hose
  10. Bracket On cylinder block
  11. Bracket
  12. Hex bolt M10 x 25 Tightening specification, «Pressurized Line to Automatic Transmission 09G»(ref-492756-S40953733322012080600000) .

Scheme 19

Scheme 19: PRESSURIZED LINE AND RETURN HOSE OVERVIEW
Scheme 19: PRESSURIZED LINE AND RETURN HOSE OVERVIEW
  1. Automatic transmission
  2. Double bolt M10 x 20 - M8 x 12 Tightening specification, «Pressurized Line to Automatic Transmission 09G»(ref-492756-S40953733322012080600000) .
  3. To reservoir
  4. Hex nut M8 Tightening specification, «Pressurized Line to Automatic Transmission 09G»(ref-492756-S40953733322012080600000) .
  5. Pressurized line
  6. From steering gear
  7. From power steering pump
  8. Pressurized line
  9. Hex bolt M8 x 28 Tightening specification, «Pressurized Line to Automatic Transmission 09G»(ref-492756-S40953733322012080600000) .
  10. To steering gear

Assembly notes for pressurized line and intake hose PRESSURIZED LINE AND INTAKE HOSE OVERVIEW .

I - Vehicles with manual transmission

II - Vehicles with automatic transmission

Scheme 20

Scheme 20: POWER STEERING SYSTEM OVERVIEW
Scheme 20: POWER STEERING SYSTEM OVERVIEW
  1. Refill tank Assembly notes «POWER STEERING RESERVOIR ASSEMBLY OVERVIEW»(ref-492756-S25356039072012080600000) .
  2. Power steering pump Checking delivery pressure «HIGH MOUNT POWER STEERING PUMP, CHECKING DELIVERY PRESSURE»(ref-492756-S19461363062012080600000) . Before installing, fill with power steering fluid «HIGH MOUNT POWER STEERING PUMP»(ref-492756-S39396101552012080600000) .
  3. Pressurized line mount On power steering pump
  4. Intake hose mount On power steering pump
  5. Intake hose mount On right longitudinal member
  6. Return hose mount On longitudinal member
  7. Ribbed line cooler
  8. Pressurized line mount On cylinder block
  9. Pressurized line mount On manual transmission 0A4 Assembly notes «PRESSURIZED LINE MOUNT OVERVIEW»(ref-492756-S20951115842012080600000) .
  10. Pressurized line mount On automatic transmission 09G Assembly notes «PRESSURIZED LINE AND RETURN HOSE OVERVIEW»(ref-492756-S13291074922012080600000) .

Scheme 21

Scheme 21: HIGH MOUNT POWER STEERING PUMP ASSEMBLY OVERVIEW
Scheme 21: HIGH MOUNT POWER STEERING PUMP ASSEMBLY OVERVIEW
  1. Hex bolt M8 x 40 Tightening specification, «Power Steering Pump»(ref-492756-S24731125752012080600000) .
  2. Bracket For power steering pump, A/C compressor and generator
  3. Banjo fitting M16 x 1.5 Tightening specification, «Power Steering Pump»(ref-492756-S24731125752012080600000) .
  4. Seals Replace
  5. Pressurized line
  6. Power steering pump Checking delivery pressure «HIGH MOUNT POWER STEERING PUMP, CHECKING DELIVERY PRESSURE»(ref-492756-S19461363062012080600000) . Before installing, fill with power steering fluid «HIGH MOUNT POWER STEERING PUMP»(ref-492756-S39396101552012080600000) .
  7. Hex bolt Tightening specification, «Power Steering Pump»(ref-492756-S24731125752012080600000) .
  8. Line for intake hose
  9. Belt pulley
  10. Socket head bolt M8 x 14 Tightening specification, «Power Steering Pump»(ref-492756-S24731125752012080600000) .

Scheme 22

Scheme 22: POWER STEERING RESERVOIR ASSEMBLY OVERVIEW
Scheme 22: POWER STEERING RESERVOIR ASSEMBLY OVERVIEW
  1. Cover with dipstick Oil level: Between Min. and Max. marking; engine temperature approximately 50° C -arrow A- Check oil level «POWER STEERING FLUID LEVEL, CHECKING»(ref-492756-S00183680192012080600000) . Open cap e.g. using toggle
  2. Spring clip
  3. Nut M6 Tightening specification, «Pressurized Line/Intake Hose 2.5L Engines»(ref-492756-S39855666352012080600000) .
  4. Right longitudinal member
  5. Ribbed line cooler
  6. Bracket

Scheme 23

Scheme 23: PRESSURIZED LINE AND INTAKE HOSE OVERVIEW
Scheme 23: PRESSURIZED LINE AND INTAKE HOSE OVERVIEW
  1. Nut M6 Tightening specification, «Pressurized Line/Intake Hose 2.5L Engines»(ref-492756-S39855666352012080600000) .
  2. Refill tank
  3. Intake hose
  4. Return hose
  5. Banjo fitting M16 x 1.5 Tightening specification, «Pressurized Line/Intake Hose 2.5L Engines»(ref-492756-S39855666352012080600000) .
  6. Seals Replace
  7. Pressurized line
  8. Power steering pump Checking delivery pressure «HIGH MOUNT POWER STEERING PUMP, CHECKING DELIVERY PRESSURE»(ref-492756-S19461363062012080600000) . Before installing, fill with power steering fluid «HIGH MOUNT POWER STEERING PUMP»(ref-492756-S39396101552012080600000) .
  9. Bumper carrier
  10. Ribbed pipe cooler
  11. Radiator
  12. Longitudinal
  13. Return hose
  14. Spring clip
  15. Hex bolt M6 x 25 Tightening specification, «Pressurized Line/Intake Hose 2.5L Engines»(ref-492756-S39855666352012080600000) .

Scheme 24

Scheme 24: PRESSURIZED LINE MOUNT OVERVIEW
Scheme 24: PRESSURIZED LINE MOUNT OVERVIEW
  1. Pressurized line
  2. 5 speed manual transmission 0A4
  3. Clamp
  4. Hex bolt M8 x 28 Tightening specification, «Pressurized Line to Manual Transmission 0A4»(ref-492756-S22320284542012080600000) .
  5. Speed nut

Scheme 25

Scheme 25: PRESSURIZED LINE AND RETURN HOSE OVERVIEW
Scheme 25: PRESSURIZED LINE AND RETURN HOSE OVERVIEW
  1. Automatic transmission
  2. Pressurized line
  3. Double bolt M10 x 20 - M8 x 12 Tightening specification, «Pressurized Line to Automatic Transmission 09G»(ref-492756-S40953733322012080600000) .
  4. Clamp
  5. Hex nut M8 Tightening specification, «Pressurized Line to Automatic Transmission 09G»(ref-492756-S40953733322012080600000) .
  6. Hex bolt M8 x 28 Tightening specification, «Pressurized Line to Automatic Transmission 09G»(ref-492756-S40953733322012080600000) .
  7. Bracket Bolted to bolt for starter

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