Steering System - Power Audi A4 B5

ENGINE IDENTIFICATION

Engine can be identified by code and serial number stamped on machined surface of cylinder block. (Scheme 1)- (Scheme 4). Engine code is also identified on vehicle data label.

Scheme 1

Scheme 2

Scheme 3

Scheme 4

DESCRIPTION & OPERATION

To identify steering system (Scheme 5), (Scheme 6) or (Scheme 7).

Scheme 5

Scheme 6

Scheme 7

HYDRAULIC SYSTEM INSPECTION

Ensure fluid level is sufficient. See FLUID LEVEL CHECK under LUBRICATION. Ensure hoses are not kinked or leaking. Check power steering pump belt condition and adjustment. See POWER STEERING PUMP BELT under ADJUSTMENTS.

1.8L Turbo (Engine Codes AEB, ATM & AWM)

1. Pinch off suction and return lines using 3094 hose clamps. (Scheme 8)
2. Disconnect pressure line from power steering pump. Screw VAG1402/3 adapter into power steering pump in place of banjo bolt. (Scheme 9) Close pressure gauge shutoff valve (lever set to left). Remove 3094 hose clamps.
3. Start engine and top off fluid in reservoir (if necessary). Measure pressure reading at idle speed. Specified value should be 1595-1740 psi (110-120 bar).
4. If specified value is not attained, check hydraulic fluid level. See «FLUID LEVEL CHECK»(/audi/a4/b5-1994-1999/remont/manual-power-steering/#steering-system-power__fluid-level-check) under LUBRICATION. Check steering system for leaks. Bleed steering system. See «STEERING SYSTEM BLEEDING»(/audi/a4/b5-1994-1999/remont/manual-power-steering/#steering-system-power__steering-system-bleeding) under BLEEDING. If necessary, replace steering pump. See «POWER STEERING PUMP»(/audi/a4/b5-1994-1999/remont/manual-power-steering/#steering-system-power) under REMOVAL & INSTALLATION.

Scheme 8

Scheme 9

2.8L V6 (Engine Codes AFC, AHA & ATQ)

1. Unclip top engine cover and remove. Unbolt ribbed belt cover. Pinch off suction hose, using 3094 hose clamp. (Scheme 8) Press spring clip and disconnect harness connector from fuel injector. Counter-hold at hex on flexible hose and remove supply line from flexible hose.
2. On vehicles with 2.8L V6 (AFC) engine, screw VAG1402/3 adapter into power steering pump in place of flexible hose.
3. On vehicles with 2.8L V6 (AHA & ATQ) engine, counter-hold at hex on flexible hose and remove supply line from flexible hose.
4. On both engines, screw VAG1402 pressure gauge hose VAG1402/3 adapter. Close pressure gauge shut-off valve (lever positioned toward left). (Scheme 9) Reconnect fuel injector harness connector. Remove hose clamp from suction hose.
5. Start engine and top off fluid in reservoir (if necessary). Measure pressure reading at idle speed. Specified value should be 1595-1740 psi (110-120 bar).
6. If specified value is not attained, check hydraulic fluid level. See «FLUID LEVEL CHECK»(/audi/a4/b5-1994-1999/remont/manual-power-steering/#steering-system-power__fluid-level-check) under LUBRICATION. Check steering system for leaks. Bleed steering system. See «STEERING SYSTEM BLEEDING»(/audi/a4/b5-1994-1999/remont/manual-power-steering/#steering-system-power__steering-system-bleeding) under BLEEDING. If necessary, replace steering pump. See «POWER STEERING PUMP»(/audi/a4/b5-1994-1999/remont/manual-power-steering/#steering-system-power) under REMOVAL & INSTALLATION.

CAPACITY

Hydraulic system fluid capacity is about 12-15 oz. (0.7-0.9 L).

FLUID TYPE

Recommended fluid type is hydraulic oil or power steering fluid No. G 002 000.

FLUID LEVEL CHECK

Note. DO NOT re-use drained hydraulic fluid.

With front wheels in straight-ahead position, run engine at idle for 2 minutes. Stop engine (switch off ignition) and remove cap with dipstick. When engine is cold, fluid level must be in area of "MIN" marking, up to 0.08" (2 mm) above or below marking. When engine is at operating temperature, fluid level must be between "MIN" and "MAX" markings.

Note. If there is too much fluid in reservoir, fluid must be extracted. If there is not enough fluid, it is not sufficient to just top off fluid; hydraulic system must also be checked for leaks.

STEERING SYSTEM BLEEDING

1. Raise vehicle until front wheels can move freely. With key on, engine off, turn steering wheel from lock-to-lock 10 times. Check hydraulic fluid level. Top off, if necessary.
2. Lower vehicle. Start engine. Turn steering wheel from lock-to-lock position 10 times. Check hydraulic fluid level. See «FLUID LEVEL CHECK»(/audi/a4/b5-1994-1999/remont/manual-power-steering/#steering-system-power__fluid-level-check) under LUBRICATION. Top off, if necessary. Any air remaining in steering system, will dissipate while driving over next 6-12 miles (10-20 km).

POWER STEERING PUMP BELT

Serpentine belt has a self-adjusting tensioner.

STEERING PLAY

Note. Two technicians are required for adjustment.

1. Ensure engine is turned off. Raise vehicle. Bring wheels to straight-ahead position. Turn steering wheel left and right (approximately 30° from center axis). Knocking noise will be heard if there is excessive play.
2. With second technician, carefully turn adjustment screw until knocking noise can no longer be heard from inside vehicle. (Scheme 10)
3. Road test vehicle. Steering must self-center when maneuvering or negotiating corners, without sticking. Re-adjust if necessary.

Scheme 10

Removal & Installation (Up To VIN 8D XA 200 000)

1. Raise and support vehicle. Remove front wheels. Remove noise insulation panel. (Scheme 11) With vehicle raised, remove Torx(R) screws at wheelhousing liner. Remove air intake duct from air filter housing.
2. Remove front bumper bolt/washer assembly (1). (Scheme 12) Disconnect all necessary electrical connectors from front of vehicle.
3. Unclip bumper from bracket (4), and pull forward. (Scheme 12) Disconnect any wiring harness attached to front bumper, and remove front bumper cover.
4. Remove bolt and install Lock Carrier Support Tool (3369) through lock carrier to chassis. (Scheme 13), (Scheme 14) and (Scheme 15). Install Lock Carrier Support Tool into bore on opposite side of vehicle. (Scheme 13) Remove lock carrier support bolts securing lock carrier to vehicle. Slide lock carrier forward onto support tool. Secure lock carrier to vehicle using holes in lock carrier and fender. (Scheme 16) This will allow servicing of front engine components.
5. To install, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1994-1999/remont/manual-power-steering/#steering-system-power__torque-specifications).

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Removal & Installation (8D XA 200 001 & Up)

1. Raise and support vehicle. Remove front wheels. Remove noise insulation panel. (Scheme 11) With vehicle raised, remove Torx(R) screws at wheelhousing liner.
2. Remove air inlet grilles, by using screwdriver to disengage clips. (Scheme 17) Remove inner end of grille first. Remove front bumper bolt/washer assembly (1). (Scheme 18)
3. Unclip bumper from bracket (9) and pull forward. (Scheme 18) Disconnect any wiring harness attached to front bumper, and remove front bumper cover.
4. Remove lower air duct hose-to-charge air cooler. (Scheme 19) Remove air duct between lock carrier and air filter housing. Disconnect harness retaining clips from left side of radiator shroud.
5. Remove bolt and install Lock Carrier Support Tool (3369) through lock carrier to chassis. (Scheme 13), (Scheme 14) and (Scheme 15). Install Lock Carrier Support Tool into bore on opposite side of vehicle. (Scheme 13) Remove lock carrier support bolts securing lock carrier to vehicle. Slide lock carrier forward onto support tool. Secure lock carrier to vehicle using holes in lock carrier and fender. (Scheme 16) This will allow servicing of front engine components.
6. To install, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1994-1999/remont/manual-power-steering/#steering-system-power__torque-specifications).

Scheme 17

Scheme 18

Scheme 19

Note. For more information on drive belts, see COOLING SYSTEM SPECIFICATIONS & DRIVE BELT ROUTING article under COOLING SYSTEM MECHANICAL in ENGINE.

Removal & Installation (1.8L Turbo Engine Code AEB, ATM, & AWM)

1. Raise and support vehicle. Remove noise insulation panel. (Scheme 11) Remove front bumper.Move lock carrier to service position. See «FRONT BUMPER & LOCK CARRIER»(/audi/a4/b5-1994-1999/remont/manual-power-steering/#steering-system-power).
2. Use a 10 mm hex wrench, turn clockwise to loosen ribbed belt. Insert drift 3204 to lock tensioner in position. (Scheme 20) Remove ribbed belt from belt pulley.
3. To install, reverse removal procedure. Ensure drive belt is routed properly. (Scheme 21)or (Scheme 22).

Scheme 20

Scheme 21

Scheme 22

Removal & Installation (2.8L V6 Engine Code AFC, AHA & ATQ)

Unclip, and remove engine cover. Unbolt, and remove cover for drive belt. Loosen and remove drive belt. (Scheme 23)

Scheme 23

Removal (1.8L Turbo Engine Code AEB, ATM & AWM)

1. Remove noise insulation panel. (Scheme 11)
2. Remove front bumper. See «FRONT BUMPER & LOCK CARRIER»(/audi/a4/b5-1994-1999/remont/manual-power-steering/#steering-system-power). Move lock carrier to service position.
3. Using 3094 hose clamps, pinch off suction and return hoses. (Scheme 8) Place oil catch pan in position.
4. Mark drive belt in direction of rotation. Remove power steering belt. Remove water pump pulley.
5. Remove hose clamp (1) from suction hose. (Scheme 24) Remove suction hose, press out of retainer and lay to side. Remove pressure line (2). Remove power steering pump mounting bolts (1 and 2). (Scheme 25)

Scheme 24

Scheme 25

Installation

Note. Prior to installation, add hydraulic fluid to suction end of power steering pump. Turn pump by hand, until fluid emerges from discharge end.

1. Add hydraulic fluid to suction end. Turn power steering pump until fluid emerges from discharge end. Tighten bolts (1 and 2) to 15 ft. lbs. (20 N.m). (Scheme 25)
2. On model year 1997 and up, install pressure line and tighten banjo bolt (2) to 37 ft. lbs. (50 N.m). Install suction hose (1). Mark "P", on suction hose must align with seam on pump. (Scheme 26) Remove 3094 hose clamps. (Scheme 24)
3. On other model years, install pressure line, and tighten banjo bolt to 37 ft. lbs. (50 N.m). Install suction hose (1). (Scheme 24)
4. Install and tighten bolts for water pump pulley. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1994-1999/remont/manual-power-steering/#steering-system-power__torque-specifications).
5. Install fan at viscous coupling, and tighten. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1994-1999/remont/manual-power-steering/#steering-system-power__torque-specifications).

Scheme 26

Removal & Installation (2.8L Engine Code AFC, AHA & ATQ)

1. Unclip, and remove engine cover. Unbolt, and remove cover for drive belt. Loosen and remove drive belt. (Scheme 23)
2. Counter-hold belt pulley (5), using VAG1590 (if applicable) and remove. (Scheme 27) Mark position, and disconnect ignition wires from ignition coils. (Scheme 28)
3. Pinch of suction hose using 3094 hose clamp. (Scheme 24) Remove pressure and suction lines. Unbolt power steering pump bracket and remove together with pump. Remove bolts mounting pump to bracket and remove pump. (Scheme 27)
4. To install, reverse removal procedure.

Scheme 27

Scheme 28

POWER STEERING GEAR

Note. If vehicle battery is disconnected and then reconnected, radio will require anti-theft security code to be entered. Coding instructions are located in supplementary audio systems manual supplied with owners manual.

Scheme 29

Scheme 30

Scheme 31

Scheme 32

1. Remove plenum chamber cover. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM in appropriate AIR BAG RESTRAINT SYSTEMS article.
2. Disconnect battery cables, and remove battery. Remove driver's side knee bolster. (Scheme 29)
3. Center steering wheel, and remove ignition key. Move steering wheel slightly until steering lock engages.
4. Unscrew nut (1) at steering column universal joint. (Scheme 30) Release by turning eccentric Torx(R) bolt clockwise, and remove bolt.
5. Swing universal joint clear. Pull bulkhead collar inward to remove.
6. Secure steering column with safety wire before removing steering column from steering gear pinion.
7. Pinch off suction and return lines using 3094 hose clamps. (Scheme 8)
8. Raise and support vehicle. Remove front wheels. Remove wheel housing cover. Remove tie rod bolts (3 and 4). (Scheme 31) Disconnect tie rods.
9. Unscrew plastic nut (arrow). (Scheme 32) Pry out clips and remove cover.
10. Place drip tray underneath to catch hydraulic fluid. Remove 22 mm banjo bolts, and disconnect return line from steering gear.
11. Remove 19 mm banjo bolt and disconnect supply line from steering gear.
12. Second technician may be required to remove steering gear. Remove steering gear mounting bolts (1, 2 and 3). (Scheme 33) Remove steering gear through left-hand wheel housing.

Scheme 33

Note. With steering gear removed, VAG 1907 is used to hold rack in center position during installation. (Scheme 34)

Scheme 34

1. Remove bolt (1) from steering gear. (Scheme 34) Align center mark (arrow) in rack with threaded hole (2) in steering gear. Install special tool VAG 1907, and hand-tighten.
2. Position steering gear in plenum chamber.
3. Install bolts (1 and 2), but DO NOT tighten. (Scheme 33) Install bolt (3) and tighten to 48 ft. lbs. (65 N.m). Tighten bolts (1 and 2) to 48 ft. lbs. (65 N.m).
4. Install return hose and tighten 22 mm banjo bolt to 37 ft. lbs. (50 N.m). Install supply line and tighten 19 mm banjo bolt to 30 ft. lbs. (40 N.m).
5. Re-install sealing boot. Release steering column lock. Center steering wheel. Connect universal joint to steering pinion.
6. Install eccentric Torx (R) bolt, engage counterclockwise and tighten nut.
7. Remove VAG1907 centering tool from steering gear. (Scheme 34) Install socket-head bolt (1) to seal off steering gear. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1994-1999/remont/manual-power-steering/#steering-system-power__torque-specifications).
8. Tighten nut on tensioning bolt. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1994-1999/remont/manual-power-steering/#steering-system-power__torque-specifications).
9. Install driver's side knee bolster. Install wheel housing cover. Install front wheels. Tighten wheel lug bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1994-1999/remont/manual-power-steering/#steering-system-power__torque-specifications).
10. After installing steering gear, release 3094 hose clamps. Install battery and connect cables. Enter security code for radio, if necessary.
11. Check level of hydraulic fluid. See «FLUID LEVEL CHECK»(/audi/a4/b5-1994-1999/remont/manual-power-steering/#steering-system-power__fluid-level-check) under LUBRICATION.
12. Bleed steering system. See «STEERING SYSTEM BLEEDING»(/audi/a4/b5-1994-1999/remont/manual-power-steering/#steering-system-power__steering-system-bleeding) under BLEEDING. Check steering system for leaks.
13. Check wheel alignment. See «WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES»(/audi/a4/b5-1994-1999/remont/wheel-alignment/#specifications-procedures) article in SUSPENSION.

DISASSEMBLY & REASSEMBLY

Manufacturer does not supply overhaul procedures. Use exploded views, in aid to overhaul steering gear. (Scheme 35)or (Scheme 36).

Scheme 35

Scheme 36

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• COOLING SYSTEM SPECIFICATIONS & DRIVE BELT ROUTING
• WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
• FLUID LEVEL CHECK
• POWER STEERING PUMP BELT
• STEERING SYSTEM BLEEDING
• TORQUE SPECIFICATIONS