Audi Workshop Service and Repair Manuals

Removing and installing power steering pump (vehicles with 6-cyl. 2.5 ltr. TDI engine)

Special tools and workshop equipment required

t	Hose clamps up to 25 mm Ø -3094-

t	Locking pin -3204-

t	Pin wrench -3212-

t	Open-end spanner -3312-

t	Torque wrench -V.A.G 1331- (measuring range: 5...50 Nm)

t	Torque wrench -V.A.G 1332- (measuring range: 40...200 Nm)

Removing –  Remove noise insulation → Rep. Gr.50. –  Remove bumper → Rep. Gr.63. –  Move lock carrier to service position → Rep. Gr.50.

–  Remove cover above hydraulic fluid reservoir (if fitted). –  Remove poly V-belt → Rep. Gr.13. –  Unscrew viscous fan.

–  2 open-end spanners (32 mm) are required. –  To release, counterhold with one spanner and turn second spanner in direction of arrow.

–  Unbolt cover for poly V-belt (3x).   Note t  Note position of spacer sleeves for belt cover. t  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.

Removing poly V-belt for A/C compressor: –  Slacken off bolt -A- on tensioning roller for air-conditioner compressor and detach poly V-belt.

Removing poly V-belt for power steering pump: –  To slacken off poly V-belt, turn in direction of arrow using 17 mm Allen key and insert a suitable pin (4 mm Ø), item -1- (e.g. centre punch). –  Take off belt. Detaching compressor for air conditioner:   Note t  The lines remain connected and must not be bent. t  After detaching, tie up compressor on longitudinal member using wire or similar; do not leave it suspended on refrigerant pipes. t  Ensure centring bush -B- is properly seated when installing compressor.

–  Remove bolts -A-.

–  Unbolt power steering pump pulley, using pin wrench 3212 to counterhold.   Note Shown with engine removed for illustration purposes.

–  Clamp off suction and return lines with hose clamps -3094-. –  Place a drip tray underneath to catch hydraulic fluid.

–  Detach hose clip from suction hose -1-. –  Disconnect suction hose and move hose to one side. –  Disconnect expansion hose -2-. –  Seal off connections with plugs.

–  Unbolt pump from bracket (items -1- and -2-) and take out pump. Installing When installing, note the following points in particular: t  Before fitting a new pump, put in hydraulic fluid at the inlet and turn pump by hand until fluid flows out at the pressure outlet. t  Clean off fluid in engine compartment where necessary. t  Tightening torques for power steering pump mountings: → 6-cyl. diesel direct injection engine (TDI), mechanics; Rep. Gr. 13; Dismantling and assembling engine

–  Bolt pump onto bracket -A- at holes marked -B-. –  Fit all bolts and tighten first the two front bolts, then the two rear bolts. –  Fit new seals on banjo bolt.

–  Tighten banjo bolt for pressure hose -2- → Item. –  Fit suction hose -1-. Installation position → Chapter. –  Marking -P- on suction hose must be aligned with seam on pump. –  Take off hose clamps -3094-. –  Bolt on power steering pump pulley. → 6-cyl. diesel direct injection engine (TDI), mechanics; Rep. Gr. 13; Dismantling and assembling engine

–  Install A/C compressor. → Air conditioning; Rep. Gr. 87: Servicing work on refrigerant circuit t  Ensure centring bush -B- is properly seated when installing compressor. Installing poly V-belt for power steering pump: –  Fit poly V-belt on crankshaft pulley and idler wheels first; fit onto tensioning roller last. Belt routing: → 6-cyl. diesel direct injection engine (TDI), mechanics; Rep. Gr. 13; Dismantling and assembling engine

–  Turn Allen key in direction of arrow and remove pin -1-. Installing poly V-belt for A/C compressor: –  Fit poly V-belt for air conditioner compressor. Belt routing: → 6-cyl. diesel direct injection engine (TDI), mechanics; Rep. Gr. 13; Dismantling and assembling engine

–  Apply torque wrench -C- as shown and pre-tension poly V-belt by turning in direction of arrow with a torque of 7 Nm (use 8 mm hexagon key). –  Tighten bolt -A- with torque wrench. → 6-cyl. diesel direct injection engine (TDI), mechanics; Rep. Gr. 13; Dismantling and assembling engine

–  Install belt cover (3x). –  Install viscous fan. → 6-cyl. diesel direct injection engine (TDI), mechanics; Rep. Gr. 19; Removing and installing parts of cooling system –  Install lock carrier → Rep. Gr.63. → Rep. Gr.63 –  Install bumper → Rep. Gr.63. → Rep. Gr.63 –  Install noise insulation → Rep. Gr.50. → Rep. Gr.50 –  Check hydraulic fluid level → Chapter. –  Bleed steering system → Chapter. –  Check steering system for leaks → Chapter.