Removing and installing vane pump; models with low mounted vane pumps — VW

Removing and installing vane pump; models with low mounted vane pumps for the New Beetle RSi is fundamentally similar to the Golf 1998 ä, Bora 1999 ä; Running gear, axles, steering front and four-wheel drive.

The following additional information and deviations must be observed:

Removing and installing ribbed belt:

=> Repair group 13
Running gear, axles, steering

The remaining information and work sequence for the New Beetle RSi are fundamentally the same as for the Golf 1998 ä, Bora 1999 ä:

The following description deals with the Golf 1998 ä, Bora 1999 ä. Therefore differences must be considered, if necessary.

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

3094 Hose clamps
V.A.G 1331 Torque wrench
VAS 5024 Assembly tool for spring-type clip

It is not intended that repair work be carried out on the vane pump. If complaints are received determine cause with the help of pressure tests, leakage test and fault finding programme running gear No. 10. If a fault exists renew vane pump.

Notes:

Pumps supplied as replacement parts are not filled with oil. Therefore it is essential to fill the pump with hydraulic oil Part No. G 002 000 and to rotate it by hand, otherwise the 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.

Removing

Remove noise insulation.

Loosen belt pulley hexagon socket head bolt.

Counter-hold with a hexagon key if necessary.

Turn tensioning device in direction of arrow to relieve tension on ribbed belt.
Mark direction of rotation of ribbed belt.
Remove ribbed belt.
Unscrew belt pulley hexagon socket head bolt.

Clamp off suction hose with hose clamps -3094-.
Open spring-type clip -3- and pull off suction hose.

Use special tool V.A.S 5024 for this.

Unscrew banjo bolt -4-.
Seal pressure pipe/hose with a plastic bag or similar.

Unscrew hexagon bolts -1- and -2-.
Take out pump.

Installing

Fill vane pump with hydraulic oil.

Fill pump with oil via suction union.

Turn hub by hand until oil emits from pressure side.
Fit vane pump into bracket and tighten bolts to 25 Nm.

Fit suction hose and install spring-type clip.

The mark -arrow A- must align with casting seam -arrow-.
The spring-type clip must close off mark -arrow B-.

Fit new sealing rings onto banjo bolt.
Tighten banjo bolt to 38 Nm.

Installation is continued in reverse sequence