Replaced power steering pump...

[DXX]

Is that top hose I removed from the reservoir the return? I have that hose disconnected and now flowing into an empty container when the engine is running and I've been keeping it topped up so it doesn't run low

Yes, that’s the return. If you do as you describe plus a few sweeps left to right the system should be bled, flushed and PS fluid renewed.
Once all is functioning set the oil level in the reservoir to the correct level for Cold once the system is shutdown and cold.
Not critical but if at a later date you want to check to see if you have a leak it’s an easy reference point.
Renewing the PS fluid periodically can only improve the system reliability, it’s a closed loop system without any stock filtration other than the reservoir strainer.

Ref’ previous posts - Last point is to ensure that the newly fabricated hose material is compatible with the PS fluid. I’ve had incorrectly spec’d hydraulic hoses dissolve in a few days, just to be sure that the person you went to for the new hose has got it correct.

 

[Algypan]

Yes, that’s the return. If you do as you describe plus a few sweeps left to right the system should be bled, flushed and PS fluid renewed.
Once all is functioning set the oil level in the reservoir to the correct level for Cold once the system is shutdown and cold.
Not critical but if at a later date you want to check to see if you have a leak it’s an easy reference point.
Renewing the PS fluid periodically can only improve the system reliability, it’s a closed loop system without any stock filtration other than the reservoir strainer.

Ref’ previous posts - Last point is to ensure that the newly fabricated hose material is compatible with the PS fluid. I’ve had incorrectly spec’d hydraulic hoses dissolve in a few days, just to be sure that the person you went to for the new hose has got it correct.

I've flushed 3 litres of fluid through and it's a nice clear green now, however after plugging the return hose back into the reservoir it's just rising. I had to shut it off as it nearly spilled over. I've shut it off and it's dropped about an inch over 10 minutes but it doesn't look like it's going to get any lower. Should I just Syphon some of it out to the half way mark?

I think I'm going to leave it as is and come back in a couple of hours to see if it's changed

Thanks again for all the help

 

[DXX]

I've flushed 3 litres of fluid through and it's a nice clear green now, however after plugging the return hose back into the reservoir it's just rising. I had to shut it off as it nearly spilled over. I've shut it off and it's dropped about an inch over 10 minutes but it doesn't look like it's going to get any lower. Should I just Syphon some of it out to the half way mark?

I think I'm going to leave it as is and come back in a couple of hours to see if it's changed

Thanks again for all the help

There are two marks on the cap / dipstick, Hot and Cold, hot being the higher on the dipstick due to thermal expansion. Set the level according to the oil temperature.
Ref’ my previous comments on the hose regarding correct spec’- if the hose is the incorrect material it will fail.

 

[Algypan]

There are two marks on the cap / dipstick, Hot and Cold, hot being the higher on the dipstick due to thermal expansion. Set the level according to the oil temperature.
Ref’ my previous comments on the hose regarding correct spec’- if the hose is the incorrect material it will fail.

I've let it cool down, I've emptied the reservoir to the cold line on the dipstick. I fired it up and have been turning lock to lock gently and within a about 2-3 minutes there is heat and steam/vapour coming from the reservoir. The level has risen a little and I can't see any leaks from anywhere at this point.

 

[DXX]

I've let it cool down, I've emptied the reservoir to the cold line on the dipstick. I fired it up and have been turning lock to lock gently and within a about 2-3 minutes there is heat and steam/vapour coming from the reservoir. The level has risen a little and I can't see any leaks from anywhere at this point.

How does it drive?

 

[Algypan]

I'll be honest I've not taken it out as when it started smoking I switched it off and wasn't sure what to do from that point. Obviously I'm dreading doing more damage.

However I did notice that when I was staeering lock to lock while bleeding, it wasn't as heavy as previously, although it seemed to "skip" being the only way to describe it. While turning lock to lock it would randomly be slightly heavier and then feel more free for a small section, but I'm guessing that could still be trapped air. Do you recommend taking it around the block a few times then?

I think at this point I'm more upset that I've been trying to nurse my poor old van back to health and neglected my motorcycle on a glorious day like today on the South East coast!

 

[DXX]

My comments in posts 2, 21 & 23 Hose specification for the non standard hose you sourced. You haven’t replied or mentioned it.

 

[Algypan]

My comments in posts 2, 21 & 23 Hose specification for the non standard hose you sourced. You haven’t replied or mentioned it.

Because I've no real way of knowing for myself. The guy does say it's fit for purpose so I didn't really question it as it's made by a specialist hydraulic company in the UK.

Don't get me wrong, I would of preferred an OEM but couldn't afford the £350 +vat dealer wanted for that pipe.

 

[DXX]

Because I've no real way of knowing for myself. The guy does say it's fit for purpose so I didn't really question it as it's made by a specialist hydraulic company in the UK.

Don't get me wrong, I would of preferred an OEM but couldn't afford the £350 +vat dealer wanted for that pipe.

The hose should have the specification marked on the outside at regular spacing, maybe NBR and hopefully not EPDM.

 

[Algypan]

The hose should have the specification marked on the outside at regular spacing, maybe NBR and hopefully not EPDM.

Got me very nervous now... I'll have a check

Edit: I've had a look and it's Semperit One wire braid hydraulic hose DIN EN 853 1SN

 

[DXX]

Got me very nervous now... I'll have a check

Edit: I've had a look and it's Semperit One wire braid hydraulic hose DIN EN 853 1SN

Here’s a link to your hose. DIN EN 853 1 SN SAE 100 R 1 S
You should be able to see the size (diameter) on the hose, make sure it’s not bent too tight (see minimum bend radius - MBR).
I’m not sure what PS fluid you are using but T6 normally uses CHF.
This hose does not list CHF in the compatibility listing, I suggest you contact the hose supplier and double check.

Synthetic rubber, resistant against hydraulic fluids (HL, HLP, HLPD, HVLP, HFA, HFAS, HFB, HFC)

 

[Algypan]

Here’s a link to your hose. DIN EN 853 1 SN SAE 100 R 1 S
You should be able to see the size (diameter) on the hose, make sure it’s not bent too tight (see minimum bend radius - MBR).
I’m not sure what PS fluid you are using but T6 normally uses CHF.
This hose does not list CHF in the compatibility listing, I suggest you contact the hose supplier and double check.

Synthetic rubber, resistant against hydraulic fluids (HL, HLP, HLPD, HVLP, HFA, HFAS, HFB, HFC)

I've used CHF, it's a T5 1.9 2004 and there is no bends or kink in the hose currently. If it was bent beyond use, wouldn't it of hindered the flush that I did?

I couldn't see a diameter on the hose. I did get under and have a look but couldn't see anything regarding size. You've got me wondering wether I should just disconnect it, f*ck it off and find an alternative... Shame as it's already cost me a new pump, £75 for that hose and over £50 in fluid I can't even find a used one on Ebay or at the local VW specialist scrappers near me.

 

[DXX]

I've used CHF, it's a T5 1.9 2004 and there is no bends or kink in the hose currently. If it was bent beyond use, wouldn't it of hindered the flush that I did?

I couldn't see a diameter on the hose. I did get under and have a look but couldn't see anything regarding size. You've got me wondering wether I should just disconnect it, f*ck it off and find an alternative... Shame as it's already cost me a new pump, £75 for that hose and over £50 in fluid I can't even find a used one on Ebay or at the local VW specialist scrappers near me.

I would just do as I suggested earlier and talk to the supplier or better still talk directly with the hose manufacturer technical support and check compatibility.

 

[Algypan]

I would just do as I suggested earlier and talk to the supplier or better still talk directly with the hose manufacturer technical support and check compatibility.

I've pinged their tech support a messege, so I'll wait to hear back.

 

[Algypan]

Ok, so I've still not had a response back yet from Semperit and I can't keep waiting around as I need to get this van back on the road asap as it's my daily. I've gone ahead and ordered a replacement pipe from here instead: VW Transporter T5 High Pressure Power Steering Hose 7H2422893G 1.9 2.0 TDi 2003-2010

I don't know if anyone has any experience with these guys? I know it's not genuine but the pipe does look like an identical fit rather than the one I had made up. I'm going to wait for this one to rock up, fit it and do another flush and bleed and see how I get on.

I also replaced my Power steering cooler as I noticed the small pipe at the back of it must have broke at some point in the past and was replaced by a peice of hose clamped on each end and this was soaking wet with oil/ fluid and felt like it was going to fall apart in my hand. Maybe this could be the culprit for the black fluid being flushed through, Thus pushing all that shite around and damaging the pump? I dunno... I'm just waffeling on again...

 

[DXX]

Ok, so I've still not had a response back yet from Semperit and I can't keep waiting around as I need to get this van back on the road asap as it's my daily. I've gone ahead and ordered a replacement pipe from here instead: VW Transporter T5 High Pressure Power Steering Hose 7H2422893G 1.9 2.0 TDi 2003-2010

I don't know if anyone has any experience with these guys? I know it's not genuine but the pipe does look like an identical fit rather than the one I had made up. I'm going to wait for this one to rock up, fit it and do another flush and bleed and see how I get on.

I also replaced my Power steering cooler as I noticed the small pipe at the back of it must have broke at some point in the past and was replaced by a peice of hose clamped on each end and this was soaking wet with oil/ fluid and felt like it was going to fall apart in my hand. Maybe this could be the culprit for the black fluid being flushed through, Thus pushing all that shite around and damaging the pump? I dunno... I'm just waffeling on again...

Have a look at the bore on that piece of repair hose and see if it has started to soften and break up.

 

[Algypan]

Ok this is actually laughable now. I've just fitted that new hose, flushed with another £60 worth of fluid and the new hose is damaged and seems to be pissing fluid from where the hose meets the metal collar.... What a circus

For your viewing pleasure...

 

[DXX]

Ok this is actually laughable now. I've just fitted that new hose, flushed with another £60 worth of fluid and the new hose is damaged and seems to be pissing fluid from where the hose meets the metal collar.... What a circus

For your viewing pleasure...

Hose manufactured incorrectly, it could be any of the following or a combination:
1. Hose not compatible with the swage fitting.
2. Hose not inserted the correct depth into the swage fitting.
3. Die press not set up correctly, final swaged diameter not within tolerance (not compressed enough of over compressed). Diameter must be measured after swaging and adjustment made.
4. Obviously not pressure tested after fabrication, normal procedure. Basic QC failure.

I strongly suspect #3, I’ve come across a few hydraulic hose providers using worn out dies and defective presses.

 

[Algypan]

Hose manufactured incorrectly, it could be any of the following or a combination:
1. Hose not compatible with the swage fitting.
2. Hose not inserted the correct depth into the swage fitting.
3. Die press not set up correctly, final swaged diameter not within tolerance (not compressed enough of over compressed). Diameter must be measured after swaging and adjustment made.
4. Obviously not pressure tested after fabrication, normal procedure. Basic QC failure.

I strongly suspect #3, I’ve come across a few hydraulic hose providers using worn out dies and defective presses.

They've sent me out another which I'm hoping to fit today, so fingers crossed...

 

[Algypan]

Hose manufactured incorrectly, it could be any of the following or a combination:
1. Hose not compatible with the swage fitting.
2. Hose not inserted the correct depth into the swage fitting.
3. Die press not set up correctly, final swaged diameter not within tolerance (not compressed enough of over compressed). Diameter must be measured after swaging and adjustment made.
4. Obviously not pressure tested after fabrication, normal procedure. Basic QC failure.

I strongly suspect #3, I’ve come across a few hydraulic hose providers using worn out dies and defective presses.

Right, thevnew replacement is leaking also. I noticed after leaving the engine running for maybe 2 minutes that the new pipe and new pump was very hot. I could maybe touch it for 2 seconds max. Pretty sure that isn't normal.

It looks like I'm going to have to try and source a genuine hose but my worry is why it's so hot in the first place? I don't want to throw £400+ for a pipe if the heat is another problem all together.

I'm stumped