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Power Steering Pump Overview Audi A4 B8

Steering (sedan) 8 illustrations ~2481 words

Power Steering Pump Overview

Note. Always replace seals. Do not reuse fluid you have drained. Only use hydraulic oil.

  1. Bracket
  2. Sleeve Drive the sleeve back slightly to install the power steering pump.
  3. Bolt 20 Nm
  4. Clamp Tension using hose clamp pliers V.A.G 1275 Always replace if removed.
  5. Intake Hose The marking "P" on the suction hose -arrow- must align with the formed seam -arrow- on the power steering pump.
  6. Power Steering Pump Control Valve -V119- The power steering pump and the control valve are one component and can only be replaced together.
  7. Steering Hydraulic Pump -V119- With power steering pump control valve -- The power steering pump and the control valve, see item 6 are one component and can only be replaced together. Fill with hydraulic oil before installation Checking delivery pressure, refer to «POWER STEERING PUMP DELIVERY PRESSURE, CHECKING»(/audi/a4/b8-2007-2012/remont/manual-power-steering/#steering-sedan__power-steering-pump-delivery-pressure-checking) Bleed the steering, refer to «STEERING, BLEEDING AFTER REPLACING»(/audi/a4/b8-2007-2012/remont/manual-power-steering/#steering-sedan__steering-bleeding-after-replacing) . Check hydraulic fluid level, refer to «POWER STEERING FLUID LEVEL, CHECKING»(/audi/a4/b8-2007-2012/remont/manual-power-steering/#steering-sedan__power-steering-fluid-level-checking) . Steering system, checking for leaks, refer to «STEERING, CHECKING FOR LEAKS»(/audi/a4/b8-2007-2012/remont/manual-power-steering/#steering-sedan__steering-checking-for-leaks)
  8. Seal Always replace if removed.
  9. Union Nut 38 Nm 36 Nm, this tightening specification applies only with the 17 mm ring spanner insert, open V.A.G 1331/10
  10. Pressure Line CAUTION: Insert the pressure line completely when installing. Observe installation position: The angle between the line connection and power steering pump axle is approximately 59°
  11. Bolt 22 Nm
  12. Belt Pulley
  13. Bolt 20 Nm For securing the bracket to the engine. note the different bolt lengths.
  14. Bolt 20 Nm For securing the bracket to the engine. Note the different bolt lengths.
  15. Bolt 20 Nm For securing the power steering pump to the bracket
  16. Bolt 20 Nm For securing the bracket to the engine.

Removing

Special tools and workshop equipment required

  1. Hose Clamps Up to 25 mm Dia. 3094
  2. Spanner Wrench 3212
  3. Hose Clamp Pliers V.A.G 1275
  4. Torque Wrench 5-50 Nm V.A.G 1331
  5. Ratchet, Reversible V.A.G 1331/1
  6. Flared Ring Spanner Tool Insert AF17 V.A.G 1331/10
  7. Used Oil Collection and Extraction Device V.A.G 1782
  8. Drip Tray for VAS 6100 VAS 6208
  9. Engine Bung Set VAS 6122

General Information

Vane pump is not designed to be serviced. If there are customer complaints, the cause must be determined using a pressure and leak test. If there is a malfunction, replace the vane pump.

  1. If power steering fluid is low in reservoir, check steering system for leaks.
  2. If there are leaks in the area of the line connections, the lines/connections must first be inspected for leaks, tightened as necessary and wiped dry.
  3. Power steering pump is delivered without oil. Therefore, hydraulic oil must be filled before installation and turned by hand. Otherwise, noises when driving or damage to power steering pump may occur.

Place the vehicle on a hoist.

Remove the engine cover -1-.

Scheme 106

Scheme 106
Scheme 106

Extract hydraulic oil from reservoir using V.A.G 1782.

Clamp off the suction hose -1- and return hose -2- using the 3094.

CAUTIONThe 3094 must not be secured on the return hose -2- in the check valve area. Otherwise, check valve will be damaged. The check valve is located in the return hose -2- between the hose clamps -arrows-.

Remove noise insulation. Refer to Description and Operation .

Drain the coolant. Refer to General Information .

Disconnect the coolant lines -1 and 2- from the coolant reservoir. Remove the nuts -arrows- and remove the coolant reservoir -3- from its mount.

Scheme 107

Scheme 107
Scheme 107

Disconnect the connector on the bottom of the coolant reservoir -3-. Move the coolant reservoir -3- to the side.

Remove the coolant hose -1 and 2- from the coolant pipe and move it to the side.

Scheme 108

Scheme 108
Scheme 108

Remove the coolant line -3- from the radiator and move it to the side.

Remove the screw -1- on the upper coolant pipes.

Scheme 109

Scheme 109
Scheme 109
  1. Ignore the -arrows

Remove the bolt -1- on the lower coolant pipes.

Scheme 110

Scheme 110
Scheme 110
  1. Ignore the -arrows

Note. Identify direction of travel before removing ribbed belt. Reversed direction of travel with a used belt can lead to malfunctions. When installing ribbed belt, make sure it is seated correctly on pulleys.

Release the tension on the ribbed belt and remove it from the power steering pump belt pulley.

Scheme 111

Scheme 111
Scheme 111

Move the tensioner in the direction of the -arrow- to release the tension on the ribbed belt.

Remove the ribbed belt from the power steering pump belt pulley.

Release the tensioner and remove the tool.

Mark the position of the belt pulley to the hub. Make a marking -arrow-.

Note. If the power steering pump will be replaced, transfer the marking from the hub on the old pump to the new one. Because of space restrictions, it is not possible to see the position of the belt pulley holes to the holes in the hub when installing.

Remove bolts -arrows-. Use 3212 as counter hold.

Remove belt pulley for vane pump.

Place the VAS 6208 under the power steering pump.

Release and disconnect the connector -2-.

Remove the union nut -1- and pull the pressure line out of the power steering pump.

Seal the power steering pump and line connections using clean sealing plugs.

Remove the power steering pump from the bracket. Remove the front bolts -1- and rear bolt -2-.

Note. The bolt -2- cannot be seen in the bracket. The illustration shows it unscrewed.

Release the tension on the intake hose spring clamp -arrow- -2- on the reservoir -1- and remove the hose -2- from the reservoir.

Scheme 112

Scheme 112
Scheme 112

Remove the power steering pump and intake hose form the bracket.

Installing

Install in reverse order of removal. Note the following

Tightening specifications, refer to POWER STEERING PUMP, VEHICLES WITH DYNAMIC STEERING

Note. Replace seals and gaskets. Before installing the new power steering pump on the intake side, fill the hydraulic oil and install it by hand until oil drains out on the high pressure side. Secure all hose connections with new hose clamps. Due to a lack of space, it is not possible to tension the clamp with the V.A.G 1275 when the power steering pump is installed. Therefore perform this step when the pump is removed.

Mount the intake hose, see item 5 before installing. The "P" must align with the seam.

Secure suction hose with new hose clamp.

Note the installation dimension of the clamp. Dimension -a- must be 4 mm.

Install the power steering pump and intake hose into the bracket -3-.

  1. The sleeve -2- is driven back slightly.

First install the bolts -1- loosely.

Then install the rear bolt -2- loosely.

Install and tighten the bolts -1- and -2-.

Press the pressure line into the power steering pump as far as the stop. Then install the union nut -1-.

Connect the connector -2-.

Tighten the union nut with the V.A.G 1331/10 as illustrated.

Scheme 113

Scheme 113
Scheme 113
  1. Torque wrench 5 - 50 Nm V.A.G 1331 with extension
  2. Flared Ring Spanner Tool Insert AF17 V.A.G 1331/10
  3. Pressure line with union nut
  4. Air Conditioning (A/C) compressor

Route the intake hose -2- inside the engine compartment so that it is free of tension and not bent and attach it to the reservoir.

Note. Make sure the hose is not bent or twisted.

Clean oiled places in engine compartment.

Align the marking -arrow- made on the belt pulley to the marking made on the hub.

Tighten the belt pulley bolts -arrows-. Refer to Removal and Installation .

Install power steering pump ribbed belt. Refer to Removal and Installation .

Check power steering fluid level. Refer to POWER STEERING FLUID LEVEL, CHECKING .

Bleed the steering. Refer to STEERING, BLEEDING AFTER REPLACING .

Check the steering for leaks. Refer to STEERING, CHECKING FOR LEAKS .

Install noise insulation. Refer to Description and Operation .

Install ribbed belt and check alignment of ribbed belt. Refer to Removal and Installation .

Note. When installing ribbed belt, ensure it is correctly seated in ribbed belt pulley.

  1. Generator
  2. Idler pulley
  3. Coolant pump
  4. Power Steering Pump
  5. A/C Compressor
  6. Tensioner pulley
  7. Crankshaft

Note. Always replace seals. Do not reuse fluid you have drained. Only use hydraulic oil.

  1. Bracket
  2. Sleeve Drive the sleeve back slightly to install the power steering pump.
  3. Bolt 20 Nm
  4. Bolt 20 Nm For securing the bracket to the engine. Note the different bolt lengths.
  5. Bolt 20 Nm For securing the bracket to the engine. Note the different bolt lengths.
  6. Clamp Tension using hose clamp pliers V.A.G 1275 Always replace if removed.
  7. Intake Hose The marking "P" on the suction hose -arrow- must align with the formed seam -arrow- on the power steering pump.
  8. Seal Always replace if removed.
  9. Pressure Line CAUTION: Insert the pressure line completely when installing.
  10. Bolt 9 Nm
  11. Power Steering Pump Fill with hydraulic oil before installation Checking delivery pressure, refer to «POWER STEERING PUMP DELIVERY PRESSURE, CHECKING»(/audi/a4/b8-2007-2012/remont/manual-power-steering/#steering-sedan__power-steering-pump-delivery-pressure-checking) Bleed the steering, refer to «STEERING, BLEEDING AFTER REPLACING»(/audi/a4/b8-2007-2012/remont/manual-power-steering/#steering-sedan__steering-bleeding-after-replacing) . Check hydraulic fluid level, refer to «POWER STEERING FLUID LEVEL, CHECKING»(/audi/a4/b8-2007-2012/remont/manual-power-steering/#steering-sedan__power-steering-fluid-level-checking) . Steering system, checking for leaks, refer to «STEERING, CHECKING FOR LEAKS»(/audi/a4/b8-2007-2012/remont/manual-power-steering/#steering-sedan__steering-checking-for-leaks)
  12. Belt Pulley
  13. Bolt 22 Nm
  14. Bolt 20 Nm For securing the power steering pump to the bracket
  15. Bolt 20 Nm For securing the bracket to the engine.

Removing

Special tools and workshop equipment required

  1. Hose Clamps Up to 25 mm Dia. 3094
  2. Spanner Wrench 3212
  3. Hose Clamp Pliers V.A.G 1275
  4. Torque Wrench 5-50 Nm V.A.G 1331
  5. Ratchet, Reversible V.A.G 1331/1
  6. Flared Ring Spanner Tool Insert AF17 V.A.G 1331/10
  7. Used Oil Collection and Extraction Device V.A.G 1782
  8. Drip Tray for VAS 6100 VAS 6208
  9. Engine Bung Set VAS 6122

General Information

Vane pump is not designed to be serviced. If there are customer complaints, the cause must be determined using a pressure and leak test. If there is a malfunction, replace the vane pump.

  1. If power steering fluid is low in reservoir, check steering system for leaks.
  2. If there are leaks in the area of the line connections, the lines/connections must first be inspected for leaks, tightened as necessary and wiped dry.
  3. Power steering pump is delivered without oil. Therefore, hydraulic oil must be filled before installation and turned by hand. Otherwise, noises when driving or damage to power steering pump may occur.

Place the vehicle on a hoist.

Remove the engine cover -1-.

Extract hydraulic oil from reservoir using V.A.G 1782.

Clamp off the suction hose -1- and return hose -2- using the 3094.

CAUTIONThe 3094 must not be secured on the return hose -2- in the check valve area. Otherwise, check valve will be damaged. The check valve is located in the return hose -2- between the hose clamps -arrows-.

Remove noise insulation. Refer to Description and Operation .

Drain the coolant. Refer to General Information .

Disconnect the coolant lines -1 and 2- from the coolant reservoir. Remove the nuts -arrows- and remove the coolant reservoir -3- from its mount.

Disconnect the connector on the bottom of the coolant reservoir -3-. Move the coolant reservoir -3- to the side.

Remove the coolant hose -1 and 2- from the coolant pipe and move it to the side.

Remove the coolant line -3- from the radiator and move it to the side.

Remove the bolt -1- on the upper coolant pipes.

  1. Ignore the -arrows

Remove the bolt -1- on the lower coolant pipes.

  1. Ignore the -arrows

Note. Identify direction of travel before removing ribbed belt. Reversed direction of travel with a used belt can lead to malfunctions. When installing ribbed belt, make sure it is seated correctly on pulleys.

Release the tension on the ribbed belt and remove it from the power steering pump belt pulley.

Move the tensioner in the direction of the -arrow- to release the tension on the ribbed belt.

Remove the ribbed belt from the power steering pump belt pulley.

Release the tensioner and remove the tool.

Mark the position of the belt pulley to the hub. Make a marking -arrow-.

Note. If the power steering pump will be replaced, transfer the marking from the hub on the old pump to the new one. Because of space restrictions, it is not possible to see the position of the belt pulley holes to the holes in the hub when installing.

Remove bolts -arrows-. Use 3212 as counter hold.

Remove belt pulley for vane pump.

Place the VAS 6208 under the power steering pump.

Carefully cut through the cable ties -1- for the wiring harness -2- if applicable.

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

Seal the power steering pump and line connections using clean sealing plugs.

Remove the power steering pump from the bracket. Remove the front bolts -1- and rear bolt -2-.

Note. The bolt -2- cannot be seen in the bracket. The illustration shows it unscrewed.

Release the tension on the intake hose spring clamp -arrow- -2- on the reservoir -1- and remove the hose -2- from the reservoir.

Remove the power steering pump and intake hose form the bracket.

Installing

Install in reverse order of removal. Note the following

Tightening specifications, refer to POWER STEERING PUMP, VEHICLES WITHOUT DYNAMIC STEERING

Note. Replace seals and gaskets. Before installing the new power steering pump on the intake side, fill the hydraulic oil and install it by hand until oil drains out on the high pressure side. Secure all hose connections with new hose clamps. Due to a lack of space, it is not possible to tension the clamp with the V.A.G 1275 when the power steering pump is installed. Therefore perform this step when the pump is removed.

Mount the intake hose, see item 7 before installing. The "P" must align with the seam.

Secure suction hose with new hose clamp.

Note the installation dimension of the clamp. Dimension -a- must be 4 mm.

Install the power steering pump and intake hose into the bracket -3-.

  1. The sleeve -2- is driven back slightly.

First install the bolts -1- loosely.

Then install the rear bolt -2- loosely.

Install and tighten the bolts -1 and 2-.

Press the pressure line -2- into the power steering pump as far as the stop. Then tighten bolts -1-.

Secure the wiring harness on the supports using a new cable tie -4-, where applicable.

Route the intake hose -2- inside the engine compartment so that it is free of tension and not bent and attach it to the reservoir.

Note. Make sure the hose is not bent or twisted.

Clean oiled places in engine compartment.

Align the marking -arrow- made on the belt pulley to the marking made on the hub.

Tighten the belt pulley bolts -arrows-. Refer to Removal and Installation .

Install power steering pump ribbed belt. Refer to Removal and Installation .

Check power steering fluid level. Refer to POWER STEERING FLUID LEVEL, CHECKING .

Bleed the steering. Refer to STEERING, BLEEDING AFTER REPLACING .

Check the steering for leaks. Refer to STEERING, CHECKING FOR LEAKS .

Install noise insulation. Refer to Description and Operation .

Install ribbed belt and check alignment of ribbed belt. Refer to Removal and Installation .

Note. When installing ribbed belt, ensure it is correctly seated in ribbed belt pulley.

  1. Generator
  2. Idler pulley
  3. Coolant pump
  4. Power Steering Pump
  5. Air Conditioning (A/C) Compressor
  6. Tensioner pulley
  7. Crankshaft