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Steering: Removal & Installation Audi A6 C5 facelift

Steering Column Switches 5 illustrations ~966 words

Installation position intake line

  1. Angle -b- : approx. 90°
  1. Align intake line and tighten.
  2. Remove 3094 hose clamps.

Scheme 5

Scheme 5: Installation position ribbed belt
Scheme 5: Installation position ribbed belt
  1. First install ribbed belt onto crankshaft pulley and idler wheel. Push belt onto tensioning roller last. NOTE: Note previously marked direction of rotation of belt and be sure that it is seated correctly on pulley.
  2. Swing tensioner in direction of (arrow).
  3. Position ribbed belt and release tensioning roller again.
  4. Install clamp for refrigerant line.
  5. Check fluid level. See «POWER STEERING FLUID LEVEL, CHECKING; STEERING SYSTEM, BLEEDING AND CHECKING FOR LEAKS»(ref-196277-S13231397802005100800000) .
  6. Bleed steering system. See «STEERING SYSTEM, BLEEDING»(ref-196277-S24095199702005100800000) .
  7. Check steering system for leaks. See «STEERING SYSTEM, CHECKING FOR LEAKS»(ref-196277-S41161247432005100800000) .
  8. Install noise insulation panel

General Information

Power steering pump is not designed to be serviced. If a customer has reported a problem, determine cause via the pressure test and leak test. If there is a problem, replace the power steering pump.

Oil circulation in Right Hand Drive (RHD) vehicles is identical to Left Hand Drive (LHD) vehicles except that the hydraulic lines are routed from left to right at the steering gear.

Note. If power steering fluid is low in the reservoir, check the steering system for leaks. In case of leaks near line connections, check lines/line connections for proper seal, if necessary tighten and wipe dry. Replacement pumps from the distribution center do not contain any fluid. Before installing, fill pump with G 002 000 hydraulic oil and turn pump by hand. Otherwise, the pump may be noisy when operating or may even get damaged. Oil type: G 002 000 hydraulic fluid

Scheme 6

Scheme 6: Special tools and equipment
Scheme 6: Special tools and equipment
  1. 10-222 A Support bar
  2. 2024 A/2 Plate
  3. V.A.G 1358 A or V.A.G 1782
  4. T40045 (plastic)
  5. T40045 (6.5 mm plastic pads for edges of wing)
  6. Bolt M10 x 15 mm

Scheme 7

Scheme 7: Removing
Scheme 7: Removing
  1. Remove rear engine cover (arrows)
  2. Extract power steering hydraulic fluid from reservoir using V.A.G 1358 A or V.A.G 1782.
  3. Attach plate 2024 A/2 to rear left engine lifting eye. Screw out bolt at plate and replace with bolt M10 x 15 mm with packing plate.
  4. Remove rubber seal at wing mounting flanges.
  5. To stop support bar from damaging edges of wing, insert special tool T40045on either side between wing mounting flange and splash panel beneath.
  6. Position support bar 10-222 A on wing mounting flanges.
  7. Engage plate 2024 A/2 at spindle of support bar.
  8. Slightly pre-tension engine with spindle of support bar, but do not lift.
  9. Unscrew left front wheel.
  10. Screw out bolts (arrows) for exhaust pipe of auxiliary/additional heater at noise insulation, on vehicles with auxiliary heater.
  11. Unfasten quick-release fasteners -1- to -3- and detach noise insulation (2 sections).
  12. Remove heat shield -1- for drive axle on left.
  13. Remove left drive axle. See «AXLE SHAFTS - FRONT & REAR»(ref-8430) .
  14. Unscrew nuts -1- to -4- for stabilizer bar mounting on left and right.
  15. Unscrew nuts -3-.
  16. Remove bolts -1- and -2- and detach engine bracket.
  17. Disconnect connector -1- at left engine mounting.
  18. Unscrew nut -2- and detach engine mounting. NOTE: Illustration shows engine removed.
  19. Remove bolts -1- and -2-.
  20. Remove return line from power steering pump (arrow).
  21. Unscrew hydraulic pressure line at power steering pump (arrow).
  22. Set aside hydraulic pressure line.
  23. Remove left engine support (arrows).
  24. Disconnect connector -2- at Speedometer Vehicle Speed Sensor (VSS) -G22-. NOTE: Ignore item -1-.
  25. Loosen lock nut -3- by several turns.
  26. Screw out as far as possible stud bolt -4-.
  27. Screw out bolts -1- and -2- and detach power steering pump.

Pay particular attention to the following on installation

  1. In engine compartment clean areas contaminated with fluid.
  2. Before installing new power steering pump, pour in hydraulic fluid on intake end and crank by hand until fluid emerges on discharge end.
  3. Replace O-ring on drive shaft of power steering pump.
  4. Replace oil seals.
  5. Secure all hose connections with standard hose clamps.

See Parts Catalog

  1. Install engine bracket and screw on subframe (see «SUBFRAME & SUBFRAME BUSHINGS»(ref-153103-S20265328262004110200000) ).
  2. Install stabilizer bar ( «STABILIZER BAR & BUSHINGS»(ref-153103-S35439574232003031800000) ).
  3. Install drive axle. See «AXLE SHAFTS - FRONT & REAR»(ref-8430) .
  4. Check hydraulic fluid level. See «POWER STEERING FLUID LEVEL, CHECKING; STEERING SYSTEM, BLEEDING AND CHECKING FOR LEAKS»(ref-196277-S13231397802005100800000) .
  5. Bleed power steering system. See «STEERING SYSTEM, BLEEDING»(ref-196277-S24095199702005100800000) .
  6. Check power steering system for leaks. See «STEERING SYSTEM, CHECKING FOR LEAKS»(ref-196277-S41161247432005100800000) .
  1. Before installing a new pump, fill intake side with hydraulic fluid and turn pump by hand until fluid comes out the pump side.
  2. Clean areas in engine compartment contaminated with fluid.
  3. Installation position of expansion hose, see «INSTALLATION POSITION OF RIBBED BELT»(ref-196277-S12266193932005100800000)
  4. Installation position of suction hose, see «INSTALLATION POSITION OF RIBBED BELT»(ref-196277-S12266193932005100800000)
  5. Replace oil seals and O-rings.
  6. Secure all hose connections with standard hose clamps.

See Parts Catalog

Scheme 8

Scheme 8
Scheme 8
  1. Place pump in bracket and screw in all three bolts (arrows).
  2. Install expansion and intake hoses with new seals, but do not tighten all the way. NOTE: The front of the belt pulley is marked "front".
  3. Screw on power steering pump pulley while counterholding with pin wrench - 3212-.

Installation position of ribbed belt

  1. First position ribbed belt over crankshaft pulley and other pulleys and then on tensioning roller last. NOTE: Make sure ribbed belt is properly seated on pulleys, when installing ribbed belt.
  2. Install ribbed belt and loosen tensioning roller again.

Note. Replace O-ring for front air line. Before installing hose connections and hoses for charge air system must be free from oil and grease. Never use lubricant.

  1. Check hydraulic fluid level. See «POWER STEERING FLUID LEVEL, CHECKING; STEERING SYSTEM, BLEEDING AND CHECKING FOR LEAKS»(ref-196277-S13231397802005100800000) .
  2. Bleed steering system. See «STEERING SYSTEM, BLEEDING»(ref-196277-S24095199702005100800000) .
  3. Check steering system for leaks. See «STEERING SYSTEM, CHECKING FOR LEAKS»(ref-196277-S41161247432005100800000) .
  4. Check belt routing and start engine.
  5. Install lock carrier. See «LOCK CARRIER, SERVICE POSITION»(ref-196278-S34319672162005100800000) .

Installation location

Behind glove box at center support

Scheme 9

Scheme 9: Installation location
Scheme 9: Installation location

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