Audi Workshop Service and Repair Manuals

Removing and installing power steering box (RHD vehicles) Special tools and workshop equipment required

t  Hose clamps up to 25 mm Ø -3094-

t  Steering centring bolt -VAS 6224- t  Torque wrench -V.A.G 1331- t  Torque wrench -V.A.G 1332- t  Open-end ring spanner insert (19 mm and 22 mm; commercially available type) Removing –  Remove plenum chamber cover → Electrical system; Rep. Gr. 27; Battery; Removing and installing battery. –  Remove battery → Electrical system; Rep. Gr. 27; Battery; Removing and installing battery   WARNING Set steering wheel to centre position and do not turn it while performing repair work, as otherwise coil connector of airbag unit could be damaged. –  Remove ignition key with steering wheel in centre position. –  Move steering wheel slightly so that steering lock engages. –  Remove storage compartment on driver's side → Rep. Gr.68

–  Slacken off bolt -arrow-. –  Secure steering column to prevent the two sections from pulling apart → Anchor, Securing steering column prior to removal.   Note t  Always renew bulkhead seal → Item if damaged. t  Make sure bulkhead seal is properly positioned in bulkhead.

–  Clamp off suction and return lines with hose clamps -3094-. –  Remove front wheels.

–  Detach bolt connection between suspension strut and track control link. –  Place suspension strut -1- in front of track control link -2- as seen in direction of travel.

–  Loosen nut -1-, take out hexagon bolt and pull out both upper links -2- upwards. (Only on right side of vehicle.) Do not attempt to enlarge slots in wheel bearing housing using a chisel or similar. –  Remove hexagon bolt -3- and detach bolt connection -4-. –  Pull or press track rod downwards out of steering arm.   Note

t  Do not apply a chisel or similar tool between steering arm -1- and seal -2- on track rod ball joint when pressing out track rod, otherwise the seal can be damaged. t  When pressing track rod out of steering arm, apply pressure only to end of track rod ball joint, or knock out end of joint using a wooden or rubber mallet.

–  Secure wheel bearing housing -1- on right side of vehicle to suspension strut -3- with the aid of a securing strap -2-.

–  Detach speed nut -arrow-. (Illustration shows left side of vehicle) –  Lever out clips. –  Detach electrical wire. –  Take out plastic cover. –  Remove heat shield on driver's side → Chapter. –  Place a drip tray underneath to catch hydraulic fluid.   Note Banjo bolts for return hose and pressure hose are only accessible from wheel housing when disconnecting.

–  Unscrew banjo bolt (19 mm) for pressure hose from steering box. –  Unscrew banjo bolt (22 mm) for return hose from steering box. 1 -  Reversible ratchet 2 -  Open-end ring spanner insert (19 mm or 22 mm; commercially available type) 3 -  Power steering box –  For vehicles with air conditioning, unplug connector in plenum chamber. –  Detach hose bracket from steering box.

–  Remove bolts -1-, -2- and -3-.

–  Take out power steering box through right-hand wheel housing (second mechanic required). The steering pinion must point diagonally upwards. 1 -  Power steering box 2 -  Mounting bracket

Installing Before installing, centralise steering box using steering centring bolt -VAS 6224-. –  To do this, remove hexagon socket head bolt -1- on steering box. –  Move steering rack until centre marking (indentation) on rack -arrow- aligns with threaded hole -2-. –  Screw in steering centring bolt -VAS 6224- hand-tight. –  Apply lubricant G 052 745 A3 to steering box where bulkhead seal is attached. –  Position steering box on plenum chamber (2nd mechanic required). Make sure threads and contact surfaces of bolts are free from oil and grease.

–  Insert bolts -1- and -2- but do not tighten. –  Fit hose bracket on steering box. –  For vehicles with air conditioning, plug in electrical connector in plenum chamber.   Note t  Always use new seals. t  Pressure hose and return hose must not touch each other or come into contact with other parts.

–  Position hydraulic lines, fit new seals and screw in banjo bolts for return hose and pressure hose by hand. 1 -  Banjo bolt for pressure hose (19 mm) 2 -  Banjo bolt for return hose (22 mm) Tighten banjo bolts as follows:

–  Use a torque wrench -V.A.G 1331- or -V.A.G 1332--1- with an open-ended ring spanner insert (19 mm or 22 mm) -2- to tighten banjo bolts for pressure hose and return hose. 3 -  Power steering box –  Connect return hose and tighten banjo bolt (22 mm) → Item.

–  Connect pressure hose and tighten banjo bolt with non-return valve (19 mm) → Item. I -  Position of open-ended ring spanner insert on torque wrench before tightening banjo bolts (starting position). II -  Position of open-ended ring spanner insert on torque wrench after tightening banjo bolts (end position). The banjo bolts must be tightened with the open-ended ring spanner insert in such a away that the spanner insert is at an angle of 90° to the torque wrench when the torque is applied. 1 -  Torque wrench -V.A.G 1331- or -V.A.G 1332- 2 -  Open-end ring spanner insert (19 mm or 22 mm)

–  Install and tighten bolt -3- → Item. –  Now tighten bolts -1- and -2- → Item. –  Secure bracket for hoses on steering box. –  Re-fit bulkhead seal in bulkhead (note installation position). The lug on the bulkhead seal must align with the marking on the body   Note t  Always renew bulkhead seal if damaged. t  Make sure bulkhead seal is properly positioned in bulkhead. –  Release steering lock. –  Set steering wheel to centre position and then attach universal joint to steering pinion.

–  Tighten bolt -arrow- → Item. –  Remove assembly aid from steering column. –  Install driver's side storage compartment. → Rep. Gr.68 –  Install heat shield on driver's side → Chapter. –  Install plastic cover in the wheel housing liner. –  Attach electrical wire.

–  Fit joint pins of both upper links in wheel bearing housing and press down as far as possible by clamping with special tool -T40067-.

–  Install and tighten new bolt -2- and self-locking nut → Item. –  Fit fork joint of suspension strut onto track control link and tighten bolt connection -1- hand tight. Bonded rubber bushes can only be turned to a limited extent. The mountings of the suspension links must therefore only be tightened when the suspension is in the unladen position → Chapter.

–  Insert track rod as far as it will go in steering arm.   Note

Only fit the track rod into the steering arm -1- by hand; do not apply pressure to seal -2- on track rod joint.

–  Attach bolt connection -4- and tighten nut → Item. –  Insert and tighten bolt -3- → Item.

–  Now unscrew steering centring bolt -VAS 6224- from steering box. 1 -  Hexagon socket head bolt 2 -  Threaded hole in steering box –  Seal off steering box with hexagon socket head bolt -1- → Fig.. –  Remove hose clamps -3094- after completing installation of steering box. –  Install battery and plenum chamber cover. → Electrical system; Rep. Gr. 27; Battery; Removing and installing battery –  Fit and secure wheels → Wheels and tyres; Rep. Gr.44. –  Tighten bolt connection securing suspension strut/track control link to specified torque → Item. –  Check hydraulic fluid level → Chapter. –  Bleed steering system → Chapter. –  Check steering system for leaks → Chapter. –  Check and adjust wheel alignment → Chapter. Wheel alignment must always be checked and adjusted if necessary using VW/Audi-approved equipment.