Audi Workshop Service and Repair Manuals

Removing and installing power steering pump (vehicles with 6-cylinder FSI engine, vehicles with dynamic steering) Exploded view of power steering pump

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

20 Nm

4 -

Hose clip

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

q	Always renew if removed

5 -	Suction hose

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

6 -	Regulating valve for power steering pump -(V119)-

q	Power steering pump and regulating valve are combined as one component and can only be renewed together

7 -	Steering hydraulics pump -V119-

q	With regulating valve for power steering pump -(V119)-

q	Power steering pump and regulating valve → Item are combined as one component and can only be renewed together

q	For correct version refer to → Electronic parts catalogue

q	Fill with hydraulic fluid before installing

q	Checking delivery pressure → Chapter

q	Bleeding steering system → Chapter

q	Checking hydraulic fluid level → Chapter

q	Checking steering system for leaks → Chapter

8 -

Seal

q	Always renew if removed

9 -

Union nut

q

38 Nm

10 -	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. 59°

q	Also secured to A/C compressor, depending on version

11 -

Bolt

q

22 Nm

12 -	Belt pulley

13 -

Bolt

q

20 Nm

q	For securing bracket to engine

q	Note different lengths of bolts

14 -

Bolt

q

20 Nm

q	For securing bracket to engine

q	Note different lengths of bolts

15 -

Bolt

q

20 Nm

q	For securing power steering pump to bracket

16 -

Bolt

q

20 Nm

q	For securing bracket to engine

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  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 -arrows-. –  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-. –  Remove noise insulation → Rep. gr.66.

–  Unfasten clamp -1- on longitudinal member (left-side) and take out coolant hose -2-.

–  Remove nuts -1- and detach coolant expansion tank -2- with hoses connected. –  Release and unplug connector at coolant expansion tank -2-.   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.

–  Swivel tensioner in direction of -arrow- to slacken poly V-belt. –  Remove poly V-belt only from power steering pump pulley. –  Release tensioner and remove tool.

–  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.

–  Remove bolts -arrows-. Use pin wrench -3212- to counterhold pulley. –  Take off power steering pump pulley. –  Place drip tray underneath power steering pump.

–  Carefully cut through cable tie -1- for wiring harness -2-. –  Detach hose clip -4- from suction hose -3-. Pull off suction hose -3-.

–  If pressure line is also secured to A/C compressor, remove bolt -C- for bracket -D- from A/C compressor.

–  Unscrew union nut -1- and pull pressure line out of power steering pump. –  Release connector -2- and unplug. –  Seal off connections of power steering pump and lines with clean plugs.

–  Unbolt power steering pump from bracket. To do so, remove front bolts -1- and rear bolt -2-.   Note Bolt -2- is concealed inside the bracket and has already been unscrewed in the illustration.

–  Remove bolts -1- from bracket -3-.

–  Release connector -3- and unplug. –  Remove bolt -1- and detach bracket -2-.

–  Remove bracket -3-. –  To install power steering pump, drive back sleeve -2- slightly at bracket. –  Take out power steering pump. Installing Installation is carried out in the reverse sequence. Note the following points: Tightening torques → Chapter Tightening torques → Rep. gr.87   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. –  Insert power steering pump with bracket.

–  Fit bracket -2- and tighten bolt -1- → Rep. gr.87. –  Plug in connector -3-.

–  Note installation dimensions of hose clip. Dimension -a- should be 4 mm.

–  Before installing power steering pump, fit suction hose -1- and position marking „P“-3- opposite marking -5- on power steering pump. –  Secure suction hose -1- with new hose clip -2-. –  Secure wiring harness to connection with new cable tie -4-.   Note Due to restricted space, the hose clip -2- cannot be tightened with the hose clip pliers -V.A.G 1275- after the power steering pump has been installed.

–  Attach bracket -3- and tighten bolts -1-. l  Sleeve -2- has been driven back slightly. –  Turn hub by hand until fluid comes out at pump outlet. –  Fit power steering pump into bracket.

–  First screw in front bolts -1- loosely. –  Then screw in rear bolt -2- loosely. –  Tighten bolts -1- and -2-.

–  Press pressure line into power steering pump as far as stop. Then tighten union nut -1-. –  Plug in connector -2-.

–  If pressure line is also secured to A/C compressor, tighten bolt -C- for bracket -D- on A/C compressor. –  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 → Rep. gr.13. 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 -  Alternator 2 -  Idler roller 3 -  Coolant pump 4 -  Power steering pump 5 -  Air conditioner compressor 6 -  Tensioning roller 7 -  Crankshaft