Power Steering Issues...

**MeinS4** · 03-06-2016 05:48 PM

I am finishing up my stage 3 build and running into an issue that is keeping me from running the car for more than a couple of minutes. My power steering pump is overheating/smoking almost as if it is not circulating. It was a brand new "OEM" pump. Not a factory pump. I did pre-prime the pump before installing. Figuring the pump was just a crap OEM unit, I ordered a new ZF pump and installed it today. Here are the steps I took:

1. Pre-primed pump by filling supply side with CHF-11S fluid and rotating the shaft clockwise until it was difficult to turn and fluid came out the pressure side.
2. Installed pump and then filled reservoir with CHF-11S.
3. Performed 10 lock to lock turns of the steering wheel with car off.
4. Started car and let run for 10 seconds.
5. Turned off car and checked fluid level. Didn't seem different.
6. Started car and did 10 lock-locks of the steering wheel.

At this point the pump started making the "empty" grinding sound and actually started smoking. I shut the car off immediately. Thinking maybe I had a blocked line I uninstalled the pump again and did the following:

1. Disconnected Supply line from pump and applied 20in/hg vacuum and sucked the PS reservoir dry. This confirms the supply line is flowing fine all the way to the pump (no blockages).<script id="gpt-impl-0.009641701299033911" src="http://partner.googleadservices.com/gpt/pubads_impl_81.js"></script>
2. Disconnected high pressure line at back of motor and pressurized the pump side of the line with air. Lots of air and fluid came out indicating no restrictions on the high pressure line.
3. Disconnected the return line at the PS cooler and verified coolant drained out of the return side of the reservoir indicating no blockages (other than the inline restrictor) on the return line.
4. Both sides of rack are dead ends and hold vacuum.

Some additional information. The PS system worked fine before taking the car apart. I replaced the pump as a precautionary measure. I capped all lines during the build. All caps were removed prior to reinstalling all parts. I replaced all supply hoses but left the return and high pressure hoses alone. At this point I'm kind of at a loss. Was hoping someone could chime in and give me some suggestions. I would really like to get this car on the road. Thanks!!!

**vavJETTAw36** · 03-06-2016 05:54 PM

Are you talking about the sound you get when the fluid runs low?

If so, Check the reservoir while car is running and check that the fluid is not foamy. If it foamy, you are pulling in air somewhere or maybe the return filter in the reservoir shifted and its aerating the fluid.

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**MeinS4** · 03-06-2016 06:00 PM

Yes it is the same noise as the pump running empty/low fluid. The fluid was not foamy. I don't see any fluid leaks of any kind. All clamps are very tight. I appreciate the reply.

**01nogaro** · 03-07-2016 09:48 AM

Bump, for any help or experiences?

**vavJETTAw36** · 03-07-2016 01:36 PM

Did you jack the car up when you bled the rack (lock to lock)? Using the correct fluid?

I recently did my pump a couple of weeks ago and I had an airlock in the pump itself. I cracked the high pressure line at the pump and the airlock went away. still made noise. repeated lock-to-lock to get air out, "turkey basted" the fluid out from the reservoir, refilled, and all was good.

**LightningLou** · 03-07-2016 02:29 PM

Make sure your lines going to the reservoir aren't crossed. Just sounds like the pump isn't getting any fluid if it's smoking like that and making noise. Are there bubbles in the tank when it's running and making noise?

NVM on the hoses being crossed... Looks like you covered that base

**MeinS4** · 03-07-2016 07:35 PM

Car was on jack stands when performing lock to lock turns. CHF-11S used. I don't understand how you can cross the supply and return line on the reservoir as they are different diameters.

I filled the reservoir and turned the pump by hand which pulled fluid out of the reservoir and into the pump. I would then refill the reservoir (before getting too low) and then turn the wheel lock to lock. The fluid level would raise about 1/2 inch. Turn the pump by hand again and the level drops back down. This repeats over and over again.

**Seerlah** · 03-08-2016 05:08 AM

1.8t, but what I did when I had to replace my high pressure hose. Car was on ground the whole time. Having it suspended just makes it easier.

-filled reservoir
-chocked wheels left and right till level dropped in reservoir
-topped off
-repeated above till I could add no more fluid
-chocked wheels more for good measure

Blead my system so well, when I started the car fluid level never dropped. Flushed with CH fluid first, then placed amsoil power steering fluid in.

*can't recall if I used the starter to assist at times or not. but never let the engine fire, because rpms would be too much. just unplugged injectors.

**MeinS4** · 03-09-2016 08:43 AM

When turning the wheel left or right there are constantly bubbles in the reservoir (about 1/8" diameter bubbles). You can also see the bubbles coming into the reservoir just past the return line. With the engine off you can hear the bubbles and also hear the rack "sloshing". I never get any foam and when the car is running there is zero movement in the PS reservoir. I went ahead and cracked the PS Pump banjo bolt and I am definitely getting fluid to the pump. I cracked the line at the rear of the engine and I definitely have fluid there. I'm guessing the rack is air locked although I have never encountered this before in all of my years wrenching on cars. I'm going to drain the reservoir again and pull the return line off of it. Cap the reservoir at the bottom at the return line and then refill the reservoir. I am going to try and use a vacuum to draw fluid through the entire power steering system. I'm hoping this works because I am getting really tired of power steering stopping me from driving my newly built Stage 3 Avant. Any other suggestions would be welcome. Thanks!

**MeinS4** · 03-12-2016 11:43 PM

Got it solved. Not sure what fixed it. First I disconnected the return line at the power steering cooler. I used a hand vacuum bleed tool to pull vacuum on the return side of the rack. I turned the wheel to the left and the vacuum would drop. With vacuum applied I cranked the car over a few times (no start). At this point the container on the bleed system was filling up and the PS reservoir was going empty. I figured this was a good sign as I hadn't seen the fluid complete the circuit. I ordered and replaced both return lines and then repeated the standard bleed. Car fired up and the level dropped a bit. FINALLY. I added fluid and it stayed rock steady. Car ran for 30 minutes with no PS problems.

**Samataras** · 03-13-2016 06:29 AM

Been following this thread since the beginning. I am having a similar issue where the pump simply won't prime. The pump is new.

I did however replace the return line w random heater hose and a brass elbow to mimic the bend. The oem hose that goes there was a stupid amount of money. Do you think this could be part of my issue?

Assuming you're a power steering expert by now you may have the answer lol

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**MeinS4** · 03-13-2016 01:45 PM

Originally Posted by Samataras

Been following this thread since the beginning. I am having a similar issue where the pump simply won't prime. The pump is new.

I did however replace the return line w random heater hose and a brass elbow to mimic the bend. The oem hose that goes there was a stupid amount of money. Do you think this could be part of my issue?

Assuming you're a power steering expert by now you may have the answer lol

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I assume you are referring to the short hose that runs from the PS reservoir to the PS cooler. There is a restrictor valve inline that is held in place by two clamps. That is definitely necessary. That could be part of your problem. Also, don't overlook air lock. I think that was a big part of my problem.

**Samataras** · 03-13-2016 01:54 PM

Originally Posted by MeinS4

I assume you are referring to the short hose that runs from the PS reservoir to the PS cooler. There is a restrictor valve inline that is held in place by two clamps. That is definitely necessary. That could be part of your problem. Also, don't overlook air lock. I think that was a big part of my problem.

Nope, not that tube. The one that goes from the pump through the manifold to the rack (I think)

Thst little tube that goes to the hard line