DIY Volkswagen Polo repair

In detail: DIY repair of a Volkswagen polo gur from a real master for the site my.housecope.com.

The power steering pump 1H0 422 155 was installed on cars:

Volkswagen Passat B3 / Volkswagen Passat B3 (312) 1988 - 1994
Volkswagen Passat Variant B3 / Volkswagen Passat Variant B3 (315) 1988 - 1994

Volkswagen Passat B4 / Volkswagen Passat B4 (3A2) 1994 - 1997
Volkswagen Passat Variant B4 / Volkswagen Passat Variant B4 (3A5) 1994 - 1997

Volkswagen Golf 3 / Volkswagen Golf 3 (1H1, 1H5) 1992 - 1998
Volkswagen Vento (1H2) 1992 - 1998

the information is applicable for repairs and other cars

There is a 1995 VW Passat B4 car, on which a TRW steering rack is installed with a 1H0 422 155C pump made in the USA.
Some time ago, there was a not strong, but audible, knock in the power steering pump. At the same time, this did not affect the operation of the steering in any way.

Before starting to repair, I decided to study the materiel. After rummaging through the my.housecope.com/wp-content/uploads/ext/3141 forum, I came to the conclusion that the pump bearing had died, most likely. Since the pumps are somewhat different from each other in design, in particular with oil seals, I decided to first disassemble the pump and see what was in it, and then purchase spare parts for repair.

Having removed the drive belt of the attachments, and shaking my hand by the pump pulley, a doubt crept into me - is it a bearing? There are no power steering fluid leaks, there is no play on the pump drive shaft, when you turn your hand over the pulley, there are no characteristic sounds and sensations of a dead bearing. It was decided to remove the pump and disassemble it.
I will omit the process of how to remove the pump from the car - it has been described more than once.

Video (click to play).

Having unscrewed four bolts, remove the cover.
2.

Power steering (GUR) is the most important part of the steering of a car. The main part of modern cars is equipped with an electric power steering. Power steering provides easy driving. This primarily has a positive effect on road safety, especially at high speeds. Secondly, it makes driving the Volkswagen Polo Sedan easy and comfortable.

Image - DIY Volkswagen Polo Repair

There are three types of power steering:
  • Electric (EUR);
  • Electrohydraulic (EGUR);
  • Mechanical (power steering).

Electric is the simplest and most reliable. It lacks a hydraulic part. But it is not widely used due to the high cost of its electronic control unit. It is practically not repairable due to the high cost of restoration.

Electro-hydraulic is superior in all respects to mechanical. Has a high degree of dependence on the electrical equipment of the vehicle. Repairable.

Mechanical is the most common. Its main drawback is that it does not work when the engine is not running. Low cost, high maintainability compensate for its disadvantages.

EGUR among the considered types of power steering is considered the most economical, since it has no direct connection with the engine.

Sometimes on VW Polo you have to suffer with the problem of "heavy" steering. Most often, this trouble is visited by those who are sure that car maintenance consists of changing filters and oil. Unfortunately, not every car enthusiast knows that power steering also requires close attention.

Repair of EGUR VW Polo is not often required, since this steering booster mechanism is quite reliable and rarely fails. The main reasons for refusal to work are the following:

  • Extreme driving style;
  • DIY repair attempts;
  • Unstable operation of the car's electrical equipment;
  • Untimely maintenance of the mechanism;
  • Natural wear and tear;
  • Road accident.

Other reasons can also contribute to the failure. For example, low-quality manufacturing by the manufacturer and others. But such reasons do not belong to the main ones.

By what signs can the incorrect operation of the EGUR be determined? There are not many of them, and they are quite noticeable even for an inexperienced driver:

  • Difficulty turning the steering wheel;
  • Vibration occurs in the steering wheel;
  • The appearance of a backlash of the steering wheel;
  • Knocks in the steering column when the car is moving;
  • The on-board computer shows an error.

In the event of such deviations in the operation of the steering mechanism, it is necessary to immediately identify the cause.

Image - DIY Volkswagen Polo Repair

We are engaged in the restoration of the working capacity of the failed EGUR, regardless of the degree of their breakdown. We offer our clients the following types of work:
  • Replacement of EGUR;
  • Full MOT;
  • Major or current repairs of the unit;
  • Adjustment of mechanical and electrical parts;
  • Computer diagnostics of the entire steering mechanism.

Our experts will lucidly advise each client on the operation, maintenance and repair of the electric power steering.

Image - DIY Volkswagen Polo Gur Repair

Our car service provides services for the diagnosis and repair of the electric power steering VW Polo. Computer diagnostics carried out by our specialists will allow us to accurately identify the cause of the EGUR malfunction. The steering rack will be checked at the same time. Such in-depth diagnostics will reveal any hidden defect.

If a malfunction is found, our specialists will, in the shortest possible time, carry out an EGUR repair for the VW Polo or replace the entire unit - it all depends on the degree of the malfunction. The minimum time to complete the work is ensured by the constant availability of the necessary spare parts in the workshop warehouse and by the high qualifications of our craftsmen. Many years of experience allows us to perform all operations to restore the performance of the EGUR VW Polo quickly and efficiently.

The technology for repairing an electric power steering is complex. Special stands, electronic devices, a computer, a tool are used. All this suggests that repair of EGUR of your car cannot be trusted by "garage" specialists. Everyone can replace a failed part, and even the masters of some service stations cannot adjust the entire unit.

Some car enthusiasts do not want to apply for a car service. In most cases, this happens because not everyone is familiar with the service station pricing system. Moreover, the prices for the same work at various car services differ slightly from each other. Where is the golden mean, and what can you expect from the workshop? Let's take a look at this issue using the example of our car service.

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We adhere to transparent pricing for the services provided. This is expressed in the fact that before taking the car for repair, we discuss with the client all issues related to the repair. Including its cost. It consists of factors such as:

  • The volume of work performed;
  • The brand of the car being repaired;
  • Urgency of order fulfillment;
  • Participation of the client in providing the repaired unit with spare parts.

Transparency of pricing on the face. But that's not all. The regular availability of promotions and discounts sometimes significantly reduces the cost of repairs.

The long-term experience of our service station has shown that all the repairs we carry out are assessed only positively. There are very few cases of cars returning to eliminate deficiencies. Our customers' grateful reviews confirm this. We give a guarantee for our work, regardless of the mileage of the car.

Each client is sure in advance that his car will be repaired on time and with high quality. We are trusted and we are proud of it.

The main task of Power Steering Polo Volkswagen is to ensure ease of rotation of the steering wheel while driving. To ensure the pump is functioning properly, systematic maintenance is necessary. Since in case of equipment failure, it will be extremely difficult and inconvenient to operate the machine.

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The steering wheel will turn, but it will take a lot of effort.In a busy city transport, this is impossible without creating an emergency.

The steering wheel cannot be fixed in one position during driving

A common and most common cause of failure is a broken drive belt. Systematic prevention will help you avoid serious and sudden problems along the way.

The first sign of insufficient tension is recoil, a push into the steering wheel while driving, as well as when starting from a standstill with the steering wheel turned to the extreme position.

Preparatory stage before replacement (repair):

  • comprehensive diagnostics, assessment of the general condition of the Polo Volkswagen;
  • troubleshooting of the case, detection of cracks, transmission oil leaks;
  • calculation of the required consumables, liquids;
  • preparation of a set of automotive tools, an empty container for draining the waste, rags, a medical syringe or a rubber bulb for pumping fluid from the tank.

The decision on replacement and partial repairs is made by the workshop master, in which the owner is serviced. Complete replacement is recommended and justified in case of cracks, mechanical damage on the body. In all other variants, a partial renovation is recommended.

  • We hang Volkswagen Polo with a hydraulic lift or install it on the observation channel;
  • unscrew the clamp from the hydraulic fluid return pipe. Do not remove the expansion tank cap. It is not necessary to break the tightness;
  • we substitute a previously prepared container for draining the mining, unscrew the lid, the mining is drained into the container;
  • start the Volkswagen Polo engine, turn the steering wheel from side to side to drain the oil;
  • we loosen the standard fastening of the roller - the belt tensioner of the drive mechanisms. Remove the belt;
  • using the key on "19" we unscrew the two pipes from the pump body;
  • by mechanical rotation of the power steering pulley, we expose the holes "for the bolts". Unscrew the upper and lower bolts with the head and ratchet;
  • we remove the worn out pump, in its place we install a new, original production with the marking (96837813);
  • we fix the supply and return pipes. Don't forget to install two brass o-rings. They prevent fluid leakage from the circuit;
  • pour the hydraulics into the tank and start pumping (MOBIL ATF Premium 220). Volume 1.0 liter;
  • fill in oil according to the level in the tank, start the engine, turn the steering wheel from side to side several times;
  • add to the top-level mark as necessary;
  • if there are air locks, bubbles, pump over until they are completely squeezed out. Otherwise, the hydraulic booster will not be able to fully function.

The process is partially repeated with the above, but has some peculiarities.

  • Polo Volkswagen is in transport position, engine is inoperative;
  • in the engine compartment, unscrew the hydraulic return pipe from the power steering. Do not unscrew the expansion tank cap in order to avoid depressurization;
  • we lower the hose into an empty container, unscrew the lid, drain the mining;
  • we start the engine, turn the steering wheel from side to side until the liquid completely comes out;
  • we turn off the engine, add new oil at the maximum level, repeat the previous procedure again;
  • when the fluid has completely renewed its color, the airiness has disappeared, the procedure for replacing the hydraulics can be considered successfully completed.

The manufacturer Volkswagen Polo does not indicate the exact oil change interval in the power steering, only refers to the "change" of color to dark. The first "renewal" of the oil occurs already at 120 - 150 thousand km, depending on the operating conditions of the technical device. Given the complexity of the entire structure, it is recommended to replace the hydraulic booster only in a service station.

I will tell you how I repaired the power steering pump. But first, a little background.

The steering wheel on a cold car in summer and winter works flawlessly.But as soon as the car warms up, especially in summer, the steering wheel on the XX becomes very tight, as if the power steering is not there. In winter, this problem does not manifest itself so strongly, but it is still present. If you put it on the gas, the steering wheel immediately turns with ease (though not quite perfect, but still lighter). At the same time, the pump does not knock, does not ring, nor leaks, etc ... (do not take the snotty rail into account) the oil is fresh and perfect (especially, thanks to the state of the rail, it is updated regularly!), The cardan is lubricated and does not wedge!

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In general, on the face of the sign of the lack of performance of the power steering pump with hot oil at XX. I didn't suffer for a long time, in the end I decided to deal with this problem, spent a lot of time, rummaged through the Internet, understood the principle of the pump, found a similar description and decided to sort out my "old" pump.

And so, first of all, we remove the pump, it is necessary to drain all the slurry from it (how to remove it and drain the liquid, I think everyone will figure it out), also, on the back cover of the power steering, you need to unscrew four bolts with a 14 head.

After we begin to carefully remove the cover, try not to damage the gasket (this gasket with an internal rubber seal), in the power steering body we leave the outer part of the "working ellipse cylinder" (hereinafter simply the cylinder). There is no need to be scared when the lid moves away from the case, it may seem that it is moving away due to the influence of the spring, during reassembly it will seem to you that it does not fit into place, just continue to carefully and alternately tighten the bolts diagonally, then everything will fall into place ...

Carefully inspect the contents and remember (you can take a photo) what stood where and how (more attention should be paid to the position of the cylinder). You can twist the power steering pulley and gently check with tweezers how the blades move in the grooves of the shaft.

All parts should be pulled out without effort, since they do not have any fixations, but the central axis is fixed rigidly, it cannot be removed.

We inspect the shaft from the back side, parts (power steering body and cover wall) touching them, for scoring or grooves, everything is perfect for me.

Now we take out the entire internal economy on "clean" rags and begin to study it.

We carefully examine the shaft, all its grooves have very sharp edges on all sides. One of the end sides of each groove has a pronounced sharpening inward, which, when the blade moves inside the groove with a constant slope to this side, will greatly complicate its movement (this may be the first component of the poor operation of the power steering). The lateral parts of the grooves of the shaft are also "sharpened", this can be felt if you slide your finger in different directions along the end (outer circumference), as well as along the lateral parts of the shaft in different directions. The rest of the shaft is perfect, does not have any flaws and notches.

The faults were found, now we are starting to eliminate them.

We need a rag, white alcohol, sandpaper with a grit of P1000 / P1500 / P2000, a triangular file, a 12mm drill (or more) and an electric drill. With the shaft, everything is much simpler, you need a P1500 sandpaper and we begin to clean all the edges of the grooves on the shaft (we clean the outer and lateral on both sides) in all possible ways. We work without fanaticism, the main task is to remove only sharp burrs.

For one thing, you can immediately polish both sides of the shaft on a flat surface, it is advisable to use P2000 sandpaper.

Next, you need to check the result of our work, check it visually and by touch, everything is perfectly smooth and does not cling.

The most difficult thing will have to do with the surface of the cylinder, I personally have nothing simpler, I have not figured out how to make a spherical grinder from a skin, a drill and a thick drill (F12). To begin with, we take a P1000 skin and such a drill, which can be crammed into a drill.

Next, you need to tightly wind the skin against the rotation of the drill, in two or three turns, there should be no gaps.

Holding the tightly twisted structure, you need to insert it into the drill (clamp the skin too).

Then, in the most convenient ways for you, we carefully begin to grind the cylinder, you need to grind evenly, press the cylinder tightly and move it relative to the axis of rotation (at maximum speed). As the skin is eaten, we change it, as a result we reach the smallest skin P2000.

The desired result is obtained,

now everything must be thoroughly wiped with a path with white alcohol. The shaft itself with blades can be rinsed in it.

After we start the assembly, everything is put in the reverse order of removal.

The device and operation of the steering rack "Volkswagen Polo" sedan, major malfunctions and do-it-yourself repairs

Good steering is the key to safe driving in any car, including the Volkswagen Polo sedan. A malfunctioning steering rack is the cause of many road traffic accidents (RTA), therefore, automakers pay a lot of attention to the reliability of this unit. Volkswagen Polo, developed by the German concern VAG, is produced in Russia, on the territory of the Kaluga Automobile Plant. The car enjoys a well-deserved popularity among Russian motorists.

The main unit of the system that controls the car is the rack that regulates the rotation of the front wheels. It is located on a subframe in the area of ​​the front axle suspension. The end part of the steering shaft of the column, on which the steering wheel is mounted, goes into the salon. The steering column also includes: an ignition switch and a lever handle that adjusts its position relative to the driver. The column is covered by a cover located below the dashboard in the cabin.

The assembly that controls the car includes the following main components:

  • steering column with steering wheel;
  • a driveshaft through which the column is connected to the rail;
  • steering rack that controls the rotation of the wheels;
  • electric amplifier with control unit.
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Image - DIY Volkswagen Polo Gur Repair

The torque from the steering wheel is transmitted to the rack-pinion that controls the rotation of the wheels

The steering column transfers the rotational force from the driver's steering wheel to the intermediate shaft, with cardan shafts at the ends. This part of the control system consists of the following parts:

  1. Upper and lower intermediate shaft driveshafts.
  2. Intermediate shaft.
  3. The bracket that secures the steering column to the body.
  4. Handle of the lever that controls the position of the steering column.
  5. Egnition lock.
  6. The shaft to which the steering wheel is attached.
  7. Electric motor with gear.
  8. Electric power steering control unit (ECU).

Image - DIY Volkswagen Polo Gur Repair

The intermediate propeller shaft allows you to change the position of the steering wheel in the cabin

An electric motor with a gearbox generates additional torque for the shaft to which the steering wheel is attached. The electronic control unit analyzes the speed of the car, the angle of rotation of the steering wheel, as well as information from the torque sensor developed on the steering wheel. Based on these data, the ECU decides to turn on the electric motor, making it easier for the driver. The steering column contains energy-absorbing elements that increase the passive safety of the driver. There is also an anti-theft device that blocks the steering shaft.

The ECU plays a special role in the operation of the system. It not only determines the direction and amount of force to be added to the torque of the steering shaft, but also reports errors in the operation of the entire steering system. As soon as a malfunction is detected, the control unit memorizes its code and turns off the electric power steering. A fault message appears on the dashboard informing the driver.

The choice of the classic steering rack is due to the fact that the car manufacturer VAG uses a McPherson-type suspension for the front-wheel drive of the car. The mechanism is simple and has a minimum number of parts. This results in a relatively low weight of the rail. The steering gear consists of the following main components:

  1. Traction tip of the left wheel.
  2. Link steering the left wheel.
  3. Anthers that protect against dirt.
  4. Drive shaft with worm gear.
  5. A housing that acts as a crankcase.
  6. Right wheel control rod.
  7. Traction tip of the right wheel.

Image - DIY Volkswagen Polo Gur Repair

The accuracy of turning the wheels directly depends on the operation of this device.

The device works as follows: the rack-pinion, located inside the housing (5), has fixed rods at the ends that control the wheels (2, 6). Rotation from the steering column is transmitted through the drive worm shaft (4). Carrying out a translational movement from the rotation of the worm gear, the rack moves the rods along its axis - to the left or to the right. At the ends of the rods, there are traction ends (1, 7), interacting through ball joints with the steering knuckles of the McPherson front suspension. To prevent dust and dirt from getting into the mechanism, the rods are covered with corrugated anthers (3). The steering rack housing (5) is attached to the front axle cross member.

The steering unit is designed for the entire period of operation of the Volkswagen Polo sedan. In the event of a malfunction or poor technical condition that does not meet safety requirements, its main components can be repaired or replaced.

Over time, any mechanism wears out. The steering is no exception. The degree of wear is influenced by the condition of the road surface in the region where the vehicle is used. In some cars, problems appear after the first 10 thousand kilometers. Others reach, without any problems in management, up to 100 thousand km. Below is a list of common Volkswagen Polo sedan malfunctions and their symptoms: