Audi Workshop Service and Repair Manuals

Checking delivery pressure of power steering pump (vehicles with 6-cylinder diesel engine, vehicles with and without dynamic steering) Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-

t  Hose clamps up to 25 mm Ø -3094-

t  Power steering tester -V.A.G 1402-

t  Adapter set -V.A.G 1402/6-

t  Drip tray for workshop hoist -VAS 6208-

t  Adapter -V.A.G 1402/3- is required for vehicles with connecting point in pressure line → Item t  Adapter set -V.A.G 1402/17- is required for vehicles without connecting point in pressure line → Item Test requirements: l  V-belt and V-belt tension OK. l  No leaks in system l  Hoses and pipes not kinked or constricted

Checking –  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-.

Vehicles with connecting point in pressure line → Item –  Remove noise insulation → Rep. gr.66. –  Attach tester -3- by a hook -2- to track control link -1-. –  Place drip tray for workshop hoist -VAS 6208- underneath to collect hydraulic fluid.

–  Slacken union nut -5-. Counterhold at hexagon flats. –  Remove nut -3-.

–  Connect power steering tester -V.A.G 1402- as shown. 1 -  Pressure line with connecting point 2 -  Hose from adapter set -V.A.G 1402/6- 3 -  Pressure gauge -V.A.G 1402- 4 -  Hose from adapter set -V.A.G 1402/6- 5 -  Adapter -V.A.G 1402/3- –  Screw hoses from power steering tester -V.A.G 1402- onto open lines of pressure hose at connecting point, as shown in illustration.

Vehicles without connecting point → Item –  Release hose clips -arrows- and remove air hose.

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

–  If pressure line -C- is also secured to A/C compressor by bracket, remove bolt (top) securing A/C compressor (front).

–  Connect power steering tester -V.A.G 1402- as shown. 1 -  Power steering pump 2 -  Adapter -V.A.G 1402/17-1- → Remark with angle piece -V.A.G 1402/17-3- 3 -  Bolt for securing pressure line → Item 4 -  Hose from adapter set -V.A.G 1402/6- 5 -  Power steering tester -V.A.G 1402- 6 -  Pressure line 7 -  Adapter -V.A.G 1402/17-2- with angle piece -V.A.G 1402/17-3- 1)  If the seal on adapter -V.A.G 1402/17-1- is damaged or leaking, it must be replaced with a new seal → Item → Electronic parts catalogue.   Note t  Position angle piece -V.A.G 1402/17-3- on adapter -V.A.G 1402/17-1- so that hose of adapter set -V.A.G 1402/6- does not come into contact with pulley or poly V-belt. t  Tighten union nuts on angle pieces -V.A.G 1402/17-3- and on hoses of adapter set -V.A.G 1402/6- hand-tight using an open-end spanner.

–  Install air intake hose -arrows-.

All vehicles (continued): –  Make sure lever on pressure gauge is at position -2-. –  Remove hose clamps -3094-. –  Start engine but do not press accelerator. –  Turn steering wheel approx. 10 times from lock to lock. –  Switch off engine and top up hydraulic fluid in reservoir if necessary.   Note t  To avoid damaging the power steering pump, please note the following points: t  Cut-off valve of pressure gauge must not remain closed for more than 10 seconds during this test. t  Start engine without pressing accelerator and leave it running at idling speed. t  Take pump pressure reading at idling speed immediately after starting engine (have second mechanic take reading). t  The pressure will drop during the test; the highest pressure reading is therefore the required test value. –  Then check delivery pressure. –  Start engine.

–  With engine idling, close cut-off valve (position -1-) and read off pressure (lever must face away from pressure hose). Do not perform measurement for longer than 10 seconds. Specification for delivery pressure (vehicles without dynamic steering): 115…132 bar Specification for delivery pressure (vehicles with dynamic steering): 117…131 bar Renew power steering pump if specification is not attained → Chapter „Removing and installing power steering pump (vehicles with 6-cylinder diesel engine, vehicles with dynamic steering)“ or → Chapter „Removing and installing power steering pump (vehicles with 6-cylinder diesel engine, vehicles without dynamic steering)“. –  Switch off engine. –  Remove power steering tester -V.A.G 1402-. Tightening torques → Chapter

–  Note correct positions of pipes when connecting pipe union. Markings -1- and -2- must be aligned. –  Tighten union nut -1-. Counterhold at hexagon flats. –  Tighten nut -3- and, if necessary, rubber mounting -4-. –  Bleed steering system → Chapter. –  Check hydraulic fluid level → Chapter. –  Check all opened lines for leaks → Chapter.