This straightforward guide is a very useful tool, designed to make things easier for the professionals who place their trust in WAT products.
NEVER START THE PUMP DRY
- Drain the hydraulic fluid from the system, including from the steering unit.
- Do not strike the shaft or the pulley with a hammer. Use the special assembly and disassembly tools.
- Avoid handling the pump by the entry pipes or hoses.- Do not remove the protective caps until you are ready to install the system in the vehicle, so that foreign objects (debris, dirt etc.) do no enter the pump.
- Do not start the vehicle with the power steering hose disconnected.
I.- DISASSEMBLY OF THE STEERING PUMP
- Remove the belt.
- Remove the pulley, depending on the model:
- Pressed pulley on shaft: DO NOT disassemble
- Screw-fixed pulley: Loosen screws and disassemble pulley. See fig (A).
- Place a tray under the pump to collect the oil from it.
- Disconnect the power steering pressure hose.
II.- ASSEMBLY OF THE STEERING PUMP
- Fix the pump to the support with screws. See figure (B).
- Connect the return hose from the power steering unit to the pump fluid reservoir and secure with clip.
- Connect the pump pressure hose from the power steering unit and secure with clip.
- When needed, mount the power steering pressure switch on the pressure line.
- If it has an adjusting bracket, affix the bracket.
- Mount the belt to the appropriate tension. Ensure that the belt is the same size as the original. Avoid using belts of different lengths to avoid excessive tension on the pump shaft.
III.- ADDING OIL AND FLUSHING
- Raise the car's front wheels and turn them manually to the left lock and, without starting the engine, add enough oil to each power steering unit, to between the MIN and MAX marks on the cap.
- With a helper, turn the wheels to full right lock and full left lock, and repeat 20 to 40 times, depending on whether the return lines are short or long, and continue to add oil, taking care to keep the level between the MIN and MAX marks.
- Now the steering system is flushed, start the motor and leave it idling to check the oil level.
- After a couple of minutes, replace the cap, lower the wheels and turn the steering wheel to both sides to check:
- that the power steering works smoothly.
- that it makes no noise
- that the oil remains at the correct level and there are no leaks.
- the condition of the oil remains correct.
- NOTE: The level of the oil when it is hot should be between the MIN and MAX marks.
- Before proceeding with the installation of a power steering rack, it is essential to remove all the hydraulic fluid from the system (including the steering pump) and inspect it before disposal. If the removed fluid contains particles of metal or other foreign substances, inspect the pump as it may be damaged and cause untimely problems in the new rack.
- Once the system is drained, it should be completely cleaned, including the pump, to ensure there is no contamination of any type before the new rack is installed. It is advisable to use a hydraulic circuit cleaning fluid for this process (several manufacturers produce them).
- After installing the new rack, refill the system with new hydraulic fluid and flush it to eliminate any pockets of air that may have been created.
- In the case of replacing the pump, do not over-tighten the belt.
- On installing the rack, care should be taken with the bellows, which can get damaged or twisted during installation in the vehicle which will lead to an oil leak. All steering racks come with an instructions sheet containing a diagram and text explaining how to mount the rack and how the bellows should look afterwards.
- Only the proper oil for each type of steering system should be used.
Mounting in a different way from the one described may cause faults and damage for which WAT DIRECCIONES S.A. bears no responsibility, as well as invalidating the guarantee.
- Mount the system onto the vehicle's cradle.
- Connect all the cables to their corresponding connectors, enter the key or card in its box.
- Connect the diagnostic device's VDO plug to that of the vehicle and start it.
- Once the comparison has been made, parameterise the steering system, following and entering the data that corresponds to the vehicle in question.
- Once the mounting and parameterisation are complete, check that the steering system does not show up any errors in the diagnostic device.