Audi Workshop Service and Repair Manuals

Removing and installing power steering pump (vehicles with 4-cylinder diesel engine, vehicles with dynamic steering) Removing and installing power steering pump (vehicles with 4-cylinder diesel engine, vehicles with dynamic steering) → Anchor Exploded view of power steering pump (vehicles with dynamic steering)

t	Renew seals.

t	Do not re-use hydraulic fluid which has been drained off.

t	Use only hydraulic fluid.

1 -

Bracket

2 -

Sleeve

q	Sleeve must be driven back slightly to install power steering pump

3 -

Bolt

q

25 Nm

4 -

Union nut

q

38 Nm

5 -

Seal

q	Always renew if removed

6 -	Pressure line

Caution Fully insert pressure line when installing.

q	Note correct position: Angle between pipe connection and shaft of power steering pump is approx. 90°

7 -	Suction hose

q	Marking „P“-arrow- on suction hose must be in line with seam -arrow- on power steering pump.

8 -

Hose clip

q	Tighten using hose clip pliers -V.A.G 1275-

q	Always renew if removed

9 -

Bolt

q

22 Nm

10 -	Belt pulley

11 -	Power steering pump

q	For correct version refer to → Electronic parts catalogue

q	Fill with hydraulic fluid before installing

q	Checking delivery pressure → Chapter

q	Removing and installing → Anchor

q	Bleeding steering system → Chapter

q	Checking hydraulic fluid level → Chapter

q	Checking steering system for leaks → Chapter

12 -

Bolt

q

25 Nm

Removing Special tools and workshop equipment required

t  Hose clamps up to 25 mm Ø -3094-

t  Pin wrench -3212-

t  Hose clip pliers -V.A.G 1275-

t  Torque wrench -V.A.G 1331-

t  Tool insert (17 mm) -V.A.G 1331/6-

t  Used oil collection and extraction unit -V.A.G 1782-

t  Drip tray for workshop hoist -VAS 6208- t  Engine bung set -VAS 6122- General notes There is no provision for repairing the power steering pump. If problems are reported, trace the fault by means of a pressure test and a leakage test. Renew the power steering pump if there is a fault. t  Always check steering system for leaks if fluid level is low in reservoir. t  If leakage is visible at the pipe connections first tighten connections and wipe dry, then check for leaks again. t  The power steering pump is supplied without fluid filling. Prior to installation, the pump must therefore always be filled with hydraulic fluid and turned by hand. Otherwise, there is a possibility of pump damage or noise while driving. –  Raise vehicle on lifting platform. –  Lift off engine cover panel. –  Move lock carrier to service position → Rep. gr.50.

–  Mark position of pulley relative to hub -arrow-.   Note t  If the power steering pump is being renewed, transfer the marking on the hub from the old pump to the new pump. t  Due to limited space, it is not possible to see the positions of the holes in the pulley relative to the holes in the hub during installation.

–  First slacken (but do not remove) bolts for pulley (only 2 of the 3 bolts are accessible). If necessary, counterhold with pin wrench -3212-. –  Slacken off poly V-belt (but do not remove yet) and hold tensioning roller with tool. At the same time rotate the power steering pump pulley so that the third bolt can be slackened.   Note Before removing poly V-belt, mark direction of rotation. A used belt can break if it runs in the opposite direction. Ensure that the belt is properly seated in the pulleys when installing. –  Remove poly V-belt only from power steering pump pulley → Rep. gr.13. –  Now remove slackened bolts and detach belt pulley. –  Extract hydraulic fluid from reservoir with used oil collection and extraction unit -V.A.G 1782-.

–  Clamp off suction hose -1- and return hose -2- using hose clamps -3094-.   Caution l  Hose clamps up to Ø 25 mm  -3094- must not be applied at any point near the non-return valve in the return hose -2-. The non-return valve will otherwise be damaged. l  The non-return valve is located in the return hose -2- between the hose clips -arrows-.

–  Release hose clips -arrows- and remove air hose. –  Remove noise insulation → Rep. gr.66. –  Place drip tray underneath power steering pump.

–  If fitted, carefully cut through cable tie -1- for wiring harness -2-. –  Detach hose clip -4- from suction hose -3-. Pull off suction hose -3-. –  Place several cloths beneath power steering pump and pressure line.

–  Unscrew union nut -1- and pull pressure line out of power steering pump. –  Seal off connections of power steering pump and lines with clean plugs.

–  Remove bolts -1- (3x) and bolt -3-. –  To install power steering pump, drive back sleeve -2- for bolt -3- slightly at bracket. –  Take out power steering pump. Installing Installation is carried out in the reverse sequence. Note the following points: Tightening torques → Chapter   Note t  Renew gaskets and seals. t  Before fitting a new power steering pump, put in hydraulic fluid at the inlet and turn pump by hand until fluid flows out at the pressure outlet. t  Secure all hose connections with new hose clips → Electronic parts catalogue. –  Note correct position of suction hose on power steering pump.

–  Note installation dimensions of hose clip. Dimension -a- should be 4 mm. –  Turn hub by hand until fluid comes out at pump outlet.

–  Fit power steering pump into bracket. l  Sleeve -2- has been driven back slightly. –  First screw in front bolts -1- (3x) loosely. –  Then screw in rear bolt -3- loosely. –  First tighten bolts -1- and then bolt -2-.

–  Press pressure line into power steering pump as far as stop. Then tighten union nut -1-.   Note When fitting the pressure line -4-, make sure the angle between the pipe connection and the shaft of the power steering pump is approx. 90°. –  Push suction hose onto connection and attach a new hose clip -3-. –  Clean off fluid in engine compartment where necessary.

–  Align marking on pulley -arrow- (made previously) with marking on hub.

–  Tighten bolts -arrows- for belt pulley. Install poly V-belt for power steering pump → Rep. gr.13. –  Check hydraulic fluid level → Chapter. –  Bleed steering system → Chapter. –  Check steering system for leaks → Chapter. –  Fit noise insulation → Rep. gr.66. –  Install poly-V-belt and make sure that belt runs straight → Rep. gr.13.   Note Ensure that the belt is properly seated in the pulleys when installing.

1 -  Vibration damper 2 -  Air conditioner compressor 3 -  Power steering pump pulley 4 -  Idler roller 5 -  Tensioner for poly V-belt 6 -  Alternator –  Start engine and check that belt runs properly.