Audi Workshop Service and Repair Manuals

Removing and installing mounting bushes on bracket for power steering pump and oil cooler Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331- with 13 mm attachment (commercially available)

t  Assembly tool -T40104-

Removing –  Vehicles with auxiliary heater: remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Release quick-fasteners -1- and -2- and take off front noise insulation. Leave rear noise insulation in position. –  Remove front bumper cover → General body repairs, exterior; Rep. Gr.63. –  Move lock carrier into its service position → General body repairs, exterior; Rep. Gr.50.

–  Pull off engine cover panel -arrows-.

–  Remove viscous fan (32 mm).

–  Release fasteners -arrows- and remove toothed belt cover (left and right).

–  Remove poly V-belt cover -arrows-.   Note Watch position of spacer sleeves for poly V-belt cover.

–  Pry off cover from tensioning roller for air conditioner compressor. –  Slacken off bolt -arrow- of tensioning roller for air conditioner compressor and detach poly V-belt from air conditioner compressor.   WARNING The air conditioner refrigerant circuit must not be opened.

–  Unplug electrical connector -1- at air conditioner compressor regulating valve -N280-. –  Remove bolts -arrows- for air conditioner compressor.   Note To prevent damage to the refrigerant lines, ensure that the pipes and hoses are not stretched, kinked or bent.

–  Tie up air conditioner compressor onto subframe, leaving refrigerant lines connected -arrow-.

–  Unbolt bracket for A/C compressor -arrows-.

–  To slacken poly V-belt, use an Allen key to turn tensioner in direction of -arrow- and detach poly V-belt from power steering pump.   Note Disregard -item 1-.

–  Remove dowel bolt -arrow-. –  Pivot lever for tensioner to one side.

–  Pull seal -arrow- off bracket for power steering pump and oil cooler.

–  Before continuing, check whether the mounting pin -arrow- can be turned or moved in the bracket for power steering pump and oil cooler.   Note If the mounting pin is seized, it must be released by suitable means before proceeding further.

–  Screw bolt -T40104/7- into mounting pin from the front. –  Tighten bolt -T40104/7- and at the same time counterhold rear bolt using a flat ring spanner -1-. l  Continue tightening bolt -T40104/7- until the head of the rear bolt shears off. –  Remove bolt head, washer and seal. –  Pull mounting pin out of bracket. –  Clamp mounting pin in vice and unscrew bolt -T40104/7-.

Pulling out front mounting bush: –  Insert internal puller -T40104/1- into drilling in bracket for power steering pump and oil cooler until puller engages behind mounting bush in drilling. –  Screw spreader pin of internal puller -T40104/1- in just far enough by hand until the puller has a secure grip on the front mounting bush.   Note If the jaws of the internal puller are spread too far, the puller will damage the drilling in the bracket when the bush is pulled out.

–  Move internal puller to horizontal position and slide thrust sleeve -T10104/2- onto puller. –  Screw nut from -T40104/1- onto thread of spreader pin and pull front mounting bush out of bracket for power steering pump and oil cooler by screwing down nut.

Driving out rear mounting bush: –  Insert pin -T40104/3- into drilling in bracket for power steering pump and oil cooler. l  The thread of the pin points in direction of travel. –  Drive out rear mounting bush towards rear using pin -T40104/3-. –  Pull out pin -T40104/3- again (screw M8 bolt into thread of pin).

Installing –  Clean drilling and contact surfaces for seals on bracket for power steering pump and oil cooler. –  Pull in rear mounting bush -item 1- into bracket for power steering pump and oil cooler, as shown in illustration. l  Slot in mounting bush faces downwards.

–  Pull in front mounting bush -item 1- into bracket for power steering pump and oil cooler, as shown in illustration. l  Slot in mounting bush faces downwards.

Install components of mounting as shown in illustration:

1 -	Seal (front) l  Sealing lip faces in direction of travel.
2-	Mounting pin l  Do not grease l  Larger opening faces in direction of travel.
3 -	Rear seal l  Sealing lip faces in direction of travel.
4 -	Washer l  Shoulder faces in direction of travel. l  Press seal onto washer.
5 -	Rear bolt l  Hand-tighten.

Tightening rear bolt to specified torque:   Note The rear bolt on the mounting pin can only be reliably tightened to the specified torque using the method described below: –  Screw bolt with nut -T40104/4- approx. 10 turns into mounting pin. –  Lock nut -T40104/4- against mounting pin in this position (to do so, use ring spanner -1- to counterhold rear bolt).

–  Apply torque wrench -V.A.G 1331- with 13 mm attachment (commercially available) -item 2- to lock nut and tighten rear bolt to 30 Nm (counterhold rear bolt with ring spanner -1-).

–  Fit lever for tensioner onto bracket for power steering pump and oil cooler. –  Tighten dowel bolt -2- to 30 Nm (to do so, counterhold rear bolt using ring spanner -1-). Remaining installation steps are carried out in reverse sequence; note the following: –  Install poly V-belt for power steering pump, alternator and viscous fan. → Anchor –  Install air conditioner compressor → Air conditioning system; Rep. Gr.87. –  Fit poly V-belt for air conditioner compressor → Chapter. –  Install viscous fan → Chapter. –  Install lock carrier with attachments → General body repairs, exterior; Rep. Gr.50. –  Install bumper cover → General body repairs, exterior; Rep. Gr.63. Tightening torques

Component		Nm
Bracket for A/C compressor to:	Bracket for power steering pump and oil cooler	22
	Sump (top section)	22
Torque reaction support to top section of sump		40