Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ 3094 Hose clamps up to ø 25 mm
• ◆ V.A.G 1331 Torque wrench
• ◆ V.A.G 1332 Torque wrench
• ◆ V.A.G 1907 Screw for steering centring

Removing

• ‒ Take out plenum chamber cover.

• ‒ Remove battery.

=> Electrical System; Repair Group 27; Battery; Removing and installing battery

• ‒ → Unscrew battery bracket -arrows-.
• ‒ Remove driver's storage compartment.

=> General Body Repairs, Interior; Repair Group 68; Storage compartments/covers and trim panels; Removing driver's storage compartment

• ‒ Move steering wheel to centre position.
• ‒ Pull out ignition key with steering wheel in centre position.
• ‒ Move steering wheel slightly to engage steering lock.

Uncontrolled turning of steering wheel with steering box removed could strain and damage coil connector of airbag system.

• ‒ → Unscrew nut -1- at universal joint.
• ‒ Slacken off eccentric by turning tensioning bolt (Torx T50) clockwise and take out bolt.

• ‒ → Swivel aside universal joint.
• ‒ Pull out bulkhead collar to inside.

• ‒ → Before detaching from steering box pinion, secure steering column with wire as shown.

• ‒ Remove wheel bearing housing and mounting bracket with suspension strut .

When removing wheel bearing housing, take care not to damage track rod bellows (shield bellows if necessary).

• ‒ → Unscrew nut -1-.
• ‒ Prise out clips -2-.
• ‒ Take out cover.

• ‒ Remove air cleaner housing and air pipe for air-mass meter.
• ‒ Take out bottom part of air cleaner box.
• ‒ Unscrew nut -2- and self-tapping screws -3-.
• ‒ → Take out shield -1-.

• ‒ Remove cover from reservoir.
• ‒ → Pinch off suction and return pipe with hose clamps -3094-.

• ‒ Place drip tray in position to collect hydraulic fluid.
• ‒ → Unscrew expansion hose -1- and return hose -2- from steering box.

• ‒ → Unfasten holder -arrow- for hoses at steering box.
• => Page 48-32, Item10

• ‒ → Screw out right steering box bolt.

• ‒ → On vehicles with air conditioner, unplug connector -arrow-.
• ‒ Unscrew multi-point socket-head bolt -1- for attaching steering box.

• ‒ → Unscrew bolt -arrow- for attaching steering box.

• Bolt is located on side of servo unit.

• ‒ Pull out steering box to right (2nd mechanic required).

Installing

→ Centre steering box removed with -V.A.G 1907-.

• ‒ To do so, screw out hexagon socket-head bolt -1- at steering box.
• ‒ Move rack until centring on rack -arrow- is aligned with tapped hole -2-.
• ‒ Hand-tighten V.A.G 1907.
• ‒ Apply lubricant G 052 745 A3 to steering box in area of bulkhead collar seat.

• ‒ → Position steering box at plenum chamber (requires 2nd mechanic).

Make sure threads and contact surfaces of bolts are free from oil/grease.

To ensure compliance with wheel alignment values, repair set for South Africa contains 3 additional shims 8D0422211 (thickness 2 mm) for fitting between steering box and body (at all 3 bolted joints).

• ‒ Fit but do not tighten bolts -1- and -2-.
• ‒ Screw in bolt -3- and tighten to 68 Nm.
• ‒ Then tighten bolts -1- and -2- to 68 Nm.

• ‒ → Position holder for hoses at steering box.
• => Page 48-32, Item10

Notes:

• ◆ Always use new seals for banjo bolts.
• ◆ Pressure and return hose must not make mutual contact or come into contact with other parts.

• ‒ → Screw on return hose and tighten banjo bolt -22 mm- to 50 Nm.
• ‒ Screw on pressure hose and tighten banjo bolt -19 mm- to 40 Nm.
• ‒ Secure holder for hoses at steering box.

• Tightening torque 20 Nm

• ‒ Re-insert bulkhead collar.

Notes:

• ◆ Replace seal if damaged.
• ◆ Make sure seal is properly positioned.

• ‒ Release steering lock.
• ‒ Move steering wheel to centre position and then attach universal joint to steering pinion.

• ‒ Insert tensioning bolt (Torx T50) and pre-tension in anti-clockwise direction. Use new nut.
• ‒ Remove assembly lock from steering column.

• ‒ → Then screw tool -V.A.G 1907 out of steering box.

•     1 -    Hexagon socket-head bolt
•     2 -    Tapped hole in steering box

• ‒ Secure steering box with hexagon socket-head bolt -1- (tightening torque 13 Nm).
• ‒ Tighten hexagon nut of tensioning bolt (steering column/steering pinion) to30 Nm.
• ‒ Install driver's storage compartment.

=> General Body Repairs, Interior; Repair Group 68; Storage compartments/covers and trim panels; Removing driver's storage compartment

• ‒ Remove hose clamps -3094- on completion of steering box assembly.
• ‒ Fit wheel housing trim.
• ‒ Fit mounting bracket with suspension strut and wheel bearing housing => Page 40-85.

• ‒ Fit heat shield.
• ‒ Fit cover of reservoir.
• ‒ Fit bottom part of air cleaner box.
• ‒ Fit air cleaner housing and air pipe for air-mass meter.
• ‒ Install battery bracket, battery and plenum chamber cover.

=> Electrical System; Repair Group 27; Battery; Removing and installing battery

• ‒ Check hydraulic fluid level .
• ‒ Bleed steering system .
• ‒ Check steering system for leaks .
• ‒ Perform wheel alignment => Page 44-13.