Audi Workshop Service and Repair Manuals

Removing and installing power steering pump (vehicles with 6-cylinder TFSI engine, vehicles without 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 -

Bolt

q

20 Nm

q	For securing bracket to engine

q	Note different lengths of bolts

5 -

Bolt

q

20 Nm

q	For securing bracket to engine

q	Note different lengths of bolts

6 -

Hose clip

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

q	Always renew if removed

7 -	Suction hose

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

8 -

Seal

q	Always renew if removed

9 -	Pressure line

Caution Fully insert pressure line when installing.

10 -

Bolt

q

9 Nm

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	Bleeding steering system → Chapter

q	Checking hydraulic fluid level → Chapter

q	Checking steering system for leaks → Chapter

12 -	Belt pulley

13 -

Bolt

q

22 Nm

14 -

Bolt

q

20 Nm

q	For securing power steering pump to bracket

15 -

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  Ratchet -V.A.G 1331/1-

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 -1-. –  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. –  Drain coolant → Rep. gr.19.

–  Detach coolant lines -1- and -2- from coolant expansion tank. Remove nuts -arrows- and lift coolant expansion tank -3- out of retainer. –  Release and unplug connector (bottom) at coolant expansion tank -3-. Move coolant expansion tank -3- to one side.

–  Detach coolant hoses -1- and -2- from coolant pipe and swivel aside. –  Detach coolant line -3- from radiator and swivel aside.

–  Remove bolt -1- for coolant pipes (top). l  -Arrows- can be disregarded.

–  Remove bolt -1- for coolant pipes (bottom). l  -Arrows- can be disregarded.   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.

–  Slacken off poly V-belt and detach belt from power steering pump pulley. –  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.

–  If fitted, carefully cut through cable tie -1- for wiring harness -2-.

–  Remove bolts -1- and pull pressure line -2- out of power steering pump. –  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.

–  Release spring-type hose clip -arrow- for suction hose -2- at reservoir -1- and detach suction hose -2- from reservoir. –  Take power steering pump with suction hose out of bracket. Installing Installation is carried out in the reverse sequence. Note the following points: Tightening torques → Chapter Installation position of hoses → Chapter „Installation position of hoses on fluid reservoir, hydraulic fluid cooler and return line“   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. t  Due to restricted space, the hose clip cannot be tightened with the hose clip pliers -V.A.G 1275- after the power steering pump is installed, and so this must be done while the pump is still removed.

–  Before installing power steering pump, fit suction hose → Item and align marking „P“ with seam on pump. –  Secure suction hose with new hose clip. –  Note installation dimensions of hose clip. Dimension -a- should be 4 mm.

–  Fit power steering pump with suction hose into bracket -3-. l  Sleeve -2- has been driven back slightly.

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

–  Press pressure line -2- as far as it will go into power steering pump. Then tighten bolts -1-.

–  If fitted, attach wiring harness with new cable tie -4- to connection.

–  Route suction hose -2- through engine compartment so that it is free of kinks and tension, and secure hose to fluid reservoir.   Note Make sure that the suction hose is not kinked or twisted. –  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