Steering: Other Audi A8 D2 facelift

Contact corrosion!

Contact corrosion can occur if non-approved fasteners are used (bolts, nuts, washers etc.).

For this reason the manufacturer installs only fasteners with a special surface coating (Dachromet). These parts can be identified by their greenish color.

Both rubber and plastic parts as well as adhesives are made of materials which are not electrically conductive.

If you are not sure whether used parts can be re-installed, always install new parts.

Please note the following

Always use genuine service replacement parts. These have been tested and are compatible with aluminum.

Accessories must be approved by AUDI AG.

Damage caused by contact corrosion is not covered by the warranty.

Note. Before removing steering wheel, wheels must be positioned in the straight-ahead position.

Note. Following procedure is for vehicles equipped with standard steering wheel. On vehicles with sport wheel, removal and installation procedure is similar.

For safetyh precautions and air bag/steering wheel removal and installation procedures, see appropriate Air Bag Restraint Systems article in RESTRAINTS.

1. Place wheels in straight-ahead position. Remove steering wheel. Pull steering column all the way down and out, and lock into place.
2. For mechanically adjustable steering column, remove steering column adjustment handle. (Scheme 9) Unscrew steering column switch trim. With electrically adjustable steering column, detach plug from switch of steering column adjuster.
3. Remove clamping screw at steering column switch, pull off plug and remove steering column switch.
4. Installation is reverse of removal procedure. Install steering wheel and tighten to: 40 Nm (30 ft lb). NOTE: For 1998 models with multi-point hex socket-head bolt, tighten to 60 Nm (44 ft lb). Always REPLACE bolt.
5. Adjust the steering column switch so that a gap of 3-4.5 mm remains between steering wheel and steering wheel column trim. see scheme 19

Scheme 9

1. The steering column is only supplied complete as a replacement part. Servicing is not possible.
2. The steering lock housing can be transferred.

Note. The following list refers to (Scheme 10).

1. Eccentric bolt Turn clockwise to loosen Turn counter-clockwise to tighten
2. Power steering gear
3. Self-locking nut, 30 Nm (22 ft lb) Always replace
4. Bolt with washer, 20 Nm (15 ft lb)
5. Transport lock Note design changes. See «STEERING COLUMN TRANSPORT LOCK»(ref-196877-S39629078672006060900000) . When removing and installing steering column, secure sliding mechanism to prevent separation. See «STEERING COLUMN TRANSPORT LOCK»(ref-196877-S39629078672006060900000) . Remove after installing steering column
6. Hex bolt, 7 Nm (62 in lb) Vehicles with automatic transmission only
7. Washer Vehicles with automatic transmission only
8. Selector lever lock cable Vehicles with automatic transmission only
9. Bracket Vehicles with automatic transmission only
10. Steering column Mechanical or electrically adjustable Illustration shows electrically adjustable steering column Vehicles with Electronic Stabilization Program (ESP) up to approx. 10.98 use a steering-angle sensor. See «STEERING ANGLE SENSOR -G85- ON VEHICLES WITH ESP»(ref-196877-S04560428182006060900000) . In case of malfunctioning electric motors or steering-angle sensor (ESP), the steering column must be replaced completely. NOTE: Never disconnect sliding mechanism between top and bottom section of steering column. Shifting by more than +/- 5 cm can damage the steering column To avoid damage, note. See «STEERING COLUMN TRANSPORT LOCK»(ref-196877-S39629078672006060900000) .
11. Tolerance adjustment screw Tightening torque: 22 Nm Only installed with electrically adjustable steering column. Before tightening tolerance adjustment screw, all 4 screws for securing the steering column to installation crossmember must be tightened to tightening torque. Do not apply any force to steering column or steering wheel while tightening tolerance adjustment screw.

1. Safety clip
2. Plastic rod
3. Steering column

Scheme 10

An assembly aid is required so that the upper and lower parts of the steering column do not pull apart when pulling off power steering gear.

IF THE UPPER AND LOWER PARTS OF THE STEERING COLUMN ARE PULLED TOO FAR APART OR PUSHED TOO CLOSE TOGETHER THE SPLINES SEPARATE.

IT IS POSSIBLE THAT RATTLING NOISES ARE CREATED LATER IF THE SPLINES ARE NOT IN THEIR ORIGINAL INSTALLATION POSITION.

New steering columns supplied as replacement parts are secured with a transport device.

This transport device must be removed after installing the steering column in the vehicle.

We recommend that this part is retained as it can be reused when removing steering columns.

Steering-angle sensor is slipped over steering column shaft.

Repair by replacing the steering column.

"Zero position compensation" must be performed for this sensor

1. If ABS control module (w/EDL) -J104- or steering angle sensor -G85- are replaced.
2. If vehicle alignment is adjusted when checking vehicle alignment.
3. If there is a fault in the fault memory of ABS control module (w/EDL) -J104- and the instructions in the DTC table require the zero position compensation to be carried out.

Zero position compensation

See DISPLAY GROUP 1: ZEROING THE STEERING ANGLE SENSOR -G85 .

Ignition lock housing, removing and installing

Note. The following list refers to see scheme 20.

1. Cover
2. Shear bolts Tighten until head shears off Drilling or chiseling. See «CHISELING OUT SHEAR BOLTS»(ref-196877-S12005407442006060900000) .
3. Steering column Mechanically or electrically adjustable Illustration corresponds to electrically adjustable steering column
4. Ignition lock housing

Chiseling out shear bolts

Note. Chiseling out shear bolts involves clamping the steering column in a vise as shown. Mounting bracket of steering column will be damaged if work is performed with steering column installed.

Scheme 11

Note (Scheme 10).

An electrical adjustable steering column is available as optional equipment.

The control module for steering column-belt height adjustment -J352- has no self-diagnosis capability.

In case of a problem, troubleshooting must be done according to the wiring diagrams.

Safety functions

To avoid overloading the vehicle battery, automatic adjustment does not engage the servo motors simultaneously, but in sequence.

Once voltage goes below 10.5 V, the motors are adjusted individually one after the other.

Lock detection (1.5 sec) and runtime error (max. 30 sec per motor) immediately switch off the relevant motor.

To aid egress and ingress for the driver, the steering column tilt and telescoping adjustment is moved all the way to the stop when opening the S - contact (ignition off) and set back to the original position when closing the S - contact (ignition on).

Turning the ingress aid switch off completely deactivates the ingress aid function and the current retracting process is stopped immediately.

Special features

If a P - button is pressed and the S - contact is off, only the belt height is adjusted. The steering column only adjusts to the memory position if "S - contact on" is actuated.

If the entry position has been changed beforehand e.g. manually, the steering column is not adjusted back upon "S - contact on" signal.

Ingress aid

The ingress aid makes entering and exiting the vehicle easier by adjusting the steering column.

1. By pressing the button-B-the ingress aid can be switched off.

Scheme 12

With ingress aid switched on (button -B- pressed), the steering column moves to the park position when the ignition key is removed (retracts forward and upward).

After entering the vehicle, the steering column moves to the memorized position, as soon as the vehicle key is turned to the ignition.

The seat memory button must be in the "ON" position (pressed) so that the memorized steering column position is retrieved.

If the ingress aid is switched off, the steering column moves to the memorized position as soon as the seat memory button is operated.

The power steering gear is removed and installed complete with tie rods and steering damper.

Note. The following list refers to see scheme 25.

1. Bolt with washer, 70 Nm (52 ft lb)
2. Connector for Servotronic Different versions To facilitate removal and installation of power steering gear on vehicles with Servotronic, Servotronic solenoid valve -N119- has been provided with an approx. 80 cm long cable. The connector for this cable now has a round plug instead of a square one. When replacing Servotronic steering gear, Servotronic valve may have to be exchanged to match the connector.
3. Phillips-head bolt, 12 Nm (9 ft lb) Screw plug for steering centering See «SCREW PLUG FOR STEERING CENTERING»(ref-196877-S39375921852006060900000) and «STEERING CENTERING»(ref-196877-S23233573742006060900000) .
4. Steering damper
5. Bolt with washer, 70 Nm (52 ft lb)
6. Power steering gear with tie rods Repairing. See «POWER STEERING GEAR, SERVICING»(ref-196877-S19293120772005100900000) . Removing and installing. See «POWER STEERING GEAR, REMOVING AND INSTALLING»(ref-196877-S18386953542005100900000) .
7. Self-locking nut, 50 Nm (37 ft lb) Always replace
8. Bolt with washer, 7 Nm (62 in lb) For setting toe-in curve, see «SPECIFICATIONS & PROCEDURES»(ref-161420) .
9. Bolt
10. Sealing boot Check for tears and chafing
11. Eccentric bolt Turn clockwise to loosen Turn counter-clockwise to tighten
12. Steering column NOTE: Never disconnect sliding mechanism between top and bottom section of steering column. Shifting by more than +/- 5 cm can damage the steering column. See «STEERING COLUMN TRANSPORT LOCK»(ref-196877-S39629078672006060900000) to avoid causing damage.
13. Self-locking nut, 40 Nm (30 ft lb) Always replace
14. Sealing ring Always replace
15. Expansion hose
16. Banjo bolt, 40 Nm (30 ft lb) With integrated non-return valve
17. Return hose
18. Banjo bolt, 47 Nm (35 ft lb)
19. Sealing ring Always replace

Arrow points in direction of travel

1. Screw plug for steering centering, 12 Nm (9 ft lb).

Cross-sectional view of power steering gear

1. 1 - Screw plug, 12 Nm (9 ft lb).
2. 2 - Screw in VAG 1907 as far as possible by hand
3. 3 - Rack
4. 4 - Power steering gear housing
5. Move steering wheel slightly around center position.
6. Have a second technician screw VAG 1907 into power steering gear until it is felt to engage in centering hole.

Removing

Scheme 13

Scheme 14

1. Disconnect battery. CAUTION: Move steering wheel to center position and not turn while performing repairs, otherwise the coil connector of the airbag unit could be damaged.
2. Remove ignition key with steering wheel centered.
3. Move steering wheel slightly so that the steering lock engages.
4. Pry off trim at bottom -arrows-.
5. Remove trim -arrows-.
6. Remove nut -1- at universal joint.
7. Turn tensioning bolt in clockwise direction to loosen eccentric and remove bolt. NOTE: Locking element -2- has been discontinued (for improved assembly in production). Securing steering column against moving apart (Scheme 13)
8. Swing universal joint away downward.
9. Remove sealing collar inward. NOTE: Always install new sealing collar if damaged. Make sure sealing collar is properly positioned. Coarse-threaded locking pin at bulkhead must be located in recess in sealing collar.
10. Remove front wheels.
11. Clamp off suction and return lines with hose clamps -3094
12. Remove bolts at tie rod end and press aside tie rod end downward.
13. Right-hand side of the vehicle
14. Remove right-hand securing bolt for power steering gear. NOTE: To facilitate access, detach fuel line from the bracket and press line slightly downward.
15. Left-hand side of the vehicle
16. Remove rear half of front wheel housing liner on left.
17. Remove insulating panel in wheel housing on left.
18. Place a drip tray underneath to catch hydraulic fluid.
19. Working through wheel housing, unscrew expansion hose -2- and return hose -1 - from power steering gear.
20. On vehicles with servotronic, unplug connector from servotronic valve.
21. Remove both securing bolts of power steering gear on left side through opening in wheel housing.
22. Detach power steering gear from locking mechanism on underside of plenum chamber.
23. Remove power steering gear to left through wheel housing (second person required).

When installing, pay special attention to the following

1. Set power steering gear in center position before installing. See «STEERING CENTERING»(ref-196877-S23233573742006060900000). Make sure clearance and correct position of hydraulic system hoses. Return hose Expansion hose
2. Engage power steering gear in locking mechanism on underside of plenum chamber.
3. Tighten bolts in sequence A, B, C
4. Tightening torque: 70 Nm (52 ft lb).
5. Release steering lock and move steering wheel to horizontal position.
6. Align the steering column free of tension to the steering rack pinion
7. Remove steering column/frame bolted joint -1-. see scheme 40
8. Attach universal joint of steering column to power steering gear pinion.
9. Tighten eccentric bolt -arrow- in counter-clockwise direction and tighten the nut -2- to 40 Nm (30 ft lb).
10. Re-tighten bolted joint -1- to 20 Nm (15 ft lb).
11. Remove centering device VAG 1907 and screw in screw plug: 12 Nm (9 ft lb).
12. Bleed steering system. See «STEERING SYSTEM, BLEEDING»(ref-196877-S37617563472005100900000).
13. Check hydraulic oil level. See «POWER STEERING OIL LEVEL, CHECKING»(ref-196877-S15392846522005100900000).
14. Check steering system for leaks. See «STEERING SYSTEM, CHECKING FOR LEAKS»(ref-196877-S28301437902005100900000).
15. Checking vehicle alignment. See «SPECIFICATIONS & PROCEDURES»(ref-161420).

Note. The following list refers to see scheme 41.

1. Clamp Always replace Tighten using VAG 1275. See «TIGHTENING CLAMP WITH VAG 1275»(ref-196877-S08435947132006060900000) .
2. Boot Check for damage Must not be twisted after adjusting toe To replace remove tie rods. See «TIE ROD, REMOVING AND INSTALLING»(ref-196877-S33996008732005100900000) .
3. Clamp Always replace Tighten using VAG 1275. See «TIGHTENING CLAMP WITH VAG 1275»(ref-196877-S08435947132006060900000) .
4. O-ring Always replace
5. Steering damper bracket
6. O-ring Always replace
7. Dished washer
8. Clamp Always replace Tighten using VAG 1275. See «TIGHTENING CLAMP WITH VAG 1275»(ref-196877-S08435947132006060900000) .
9. Boot Check for damage To replace, remove power steering gear. See «POWER STEERING GEAR, ASSEMBLY OVERVIEW»(ref-196877-S32256000022005100900000) . Do not reverse
10. Power steering gear Grease rack with power steering gear grease A0F 063 000 04
11. Tie rod end
12. Hex nut, 40 Nm (30 ft lb)
13. Inner tie rod end, 100 Nm (74 ft lb) Grease joint with power steering gear grease A0F 063 000 04
14. Hex nut, 10 Nm (7 ft lb) To loosen and tighten counter hold on steering damper piston rod hex
15. Bushing
16. Rubber mount Two piece
17. Steering damper
18. Hex bolt, 40 Nm (30 ft lb) To remove, remove intake air duct between air cleaner and throttle valve. Servotronic steering gears only
19. Hex socket head bolt, 3 Nm (27 in lb)
20. Servotronic solenoid valve -N119- Checking valve. See «SERVOTRONIC SOLENOID VALVE -N119-, CHECKING»(ref-196877-S21295306852005100900000) .
21. Servotronic solenoid valve -N119- Checking valve. See «SERVOTRONIC SOLENOID VALVE -N119-, CHECKING»(ref-196877-S21295306852005100900000) .
22. O-ring Always replace
23. O-ring Always replace
24. Strainer

Scheme 15

Note. Two mechanics are required to perform adjustment. Adjust with engine switched off.

1. Raise vehicle on hoist.
2. Wheels in straight-ahead position.
3. By turning the steering wheel to and fro (about 30 ° to center axis) a knocking noise will be heard if there is excessive play.
4. The second mechanic should carefully turn the adjustment screw (arrow) until the rattling noise can no longer be heard inside the vehicle.
5. Carry out a road test.
6. Make sure that when maneuvering or negotiating corners the steering self-centers without sticking, re-adjust if necessary.

1. Remove wheel
2. Loosen and remove bolt -1-. see scheme 44 Tightening torque: 7 Nm (62 in lb) NOTE: A protective cap may be pushed in place instead of the bolt.
3. Remove hex nut -5- and remove bolt -2-. see scheme 44 Always REPLACE self locking nut. Tightening torque: 50 Nm (37 ft lb). NOTE: The slits in the wheel bearing housing must not be widened using a chisel or similar.
4. Press away tie rod end downward.
5. Loosen hex nut -3- and remove tie rod end. see scheme 44 Hex flange -4- at axial joint is used for counter- holding Tightening torque: 40 Nm (30 ft lb)
6. Degrease tie rod end and clamping hole at wheel bearing housing.

Installing

Installation is in the reverse order of removal

Perform wheel alignment after installation

1. Checking vehicle alignment. See «SPECIFICATIONS & PROCEDURES»(ref-161420) .
2. First tighten tightening nut -5- to 50 Nm (37 ft lb).
3. Tighten hex bolt -1- to 7 Nm (62 in lb).

1. Remove tie rod end and press aside downward.
2. Open clamps on boots.
3. Pull boot as far as possible outward.
4. Remove tie rod with VAG 1923.
5. Replace boot and/or tie rod depending on respective degree of damage.

Install in reverse order of removal.

1. Checking vehicle alignment. See «SPECIFICATIONS & PROCEDURES»(ref-161420) .

Servotronic, Servicing

1. In vehicles with servotronic, steering power assistance is regulated electronically according to the driving speed.
2. In case of failure of the electronics, the steering works like a standard servo steering unit.
3. Relay for Servotronic control module -J236- is not OBD capable.

Scheme 16

Note. In see scheme 51 refer to: VOLTAGE SUPPLY FOR SERVOTRONIC, CHECKING for checking voltage supply VEHICLE SPEED SIGNAL, CHECKING for checking speed signal SERVOTRONIC SOLENOID VALVE -N119-, CHECKING for checking Servotronic valve POWER STEERING GEAR, ASSEMBLY OVERVIEW for replacing servo steering gear

Voltage supply for Servotronic, checking

1. Open electronics box in passenger side footwell.
2. Pull off Servotronic control module -J236-, position 12.
3. Switch on ignition.
4. Set digital multimeter (Fluke 83 or equivalent) to voltage measuring range, max. 20 volts.
5. Measure at relay connector between contacts 6 and 8. Specified value: approx. 12V.
6. Check wiring if specified value is not attained. See appropriate System Wiring Diagram article.

Servotronic solenoid valve -N119-, checking

1. Open electronics box in passenger side footwell.
2. Pull off Servotronic control module -J236-, position 12.
3. Set digital multimeter (Fluke 83 or equivalent) to ohm measuring range, max. 200 ohms.
4. Measure at relay connector between contacts 2 and 5. Specified value: 6 to 12 ohm.

Scheme 17

If specified value is not attained

1. Unplug connector from Servotronic valve.
2. Check wiring between relay connector and plug for Servotronic valve for short circuit and open circuit. See appropriate System Wiring Diagram article.
3. Replace Servotronic valve if wiring is OK.

Vehicle speed signal, checking

The vehicle speed signal comes from the instrument cluster.

1. Check wiring between contact -4- and instrument cluster if voltage supply, Servotronic solenoid valve -N119- and speed reading on speedometer are OK. See appropriate System Wiring Diagram article.
2. Replace Servotronic relay if wiring between contact -4- and instrument cluster is OK.

1. Do not run engine and set front wheels to straight-ahead position.

Oil cold

1. Remove cap.
2. Clean dipstick with a clean cloth.
3. Screw cap on hand tight and remove again. NOTE: The cap must be fully screwed on in order to obtain an accurate oil level reading.
4. Check oil level: Level must be around MIN. mark (up to 2 mm above or below mark).

Oil at operating temperature (above approx. 50° C)

1. Check oil level: Level must be between MIN. and MAX. mark

Note. If the oil level is above the MAX. marking, the excess oil must be extracted. If oil level is below the MIN. marking, then the hydraulic system must be checked for leaks. It is not sufficient to only top off with oil. Do not re-use hydraulic oil after draining off.

Depending on how extensive changes were on the steering system different bleeding procedures are to be employed on the steering system.

1. Check hydraulic oil level and top off if necessary.
2. Raise vehicle until front wheels are free.
3. Start engine briefly (max. 2 seconds) The pump must not draw in any air, the steering wheel must not moved under any circumstances. Waiting time between individual engine starts approx. 30 sec.
4. Check hydraulic oil level and top off if necessary.
5. Repeat procedure until the oil level remains constant.
6. Turn steering wheel from lock to lock 10 times, with engine switched off.
7. Check hydraulic oil level and top off if necessary.
8. Start engine.
9. Turn steering wheel from lock to lock 10 times.
10. Check hydraulic oil level and top off if necessary. Any remaining air in the steering system will dissipate when driving over the next 10-20 km (6-12 miles).

1. Check hydraulic oil level and top off if necessary.
2. Start engine briefly (max. 2 seconds) The pump must not draw in any air, the steering wheel must not move under any circumstances. Waiting time between individual engine starts approx. 30 sec.
3. Check hydraulic oil level and top off, if necessary.
4. Repeat this procedure until the oil level remains constant.
5. Start engine and allow to run for approx. 2-3 minutes, do not turn steering wheel.

Any residual air in the steering system will dissipate when driving over the next 10-20 km (6-12 miles).

1. Start engine.
2. Turn steering from lock to lock and hold briefly. This builds up the maximum possible pressure. NOTE: To reduce the risk damaging the pump, never run the engine for more than 10 seconds when performing this test.

In this position the following components must be checked for leaks

1. Pinion seal on power steering gear valve housing.
2. All line connections.
3. Rack seals

This check can only be carried out with the boots are pushed back.

1. Open boot hose clamp.
2. Push boot back.

Power steering gear must be replaced if oil is visible in power steering gear housing and/or in the boot

Vane pump delivery pressure, checking

Special tools and equipment

1. 3094 Hose clamp
2. VAG 1402 Power steering test unit
3. VAG 1402/3 Adapter

1. Clamp off suction and return lines with hose clamps -3094-.
2. Unbolt expansion hose on vane pump.
3. Attach seal, part-no. N 013 844 4 to adapter VAG 1402/3.
4. Screw adapter VAG 1402/3 into vane pump in place of banjo bolt.
5. Screw pressure gauge VAG 1402 hose onto adapter VAG 1402/3.
6. Close shut-off valve on gauge (lever pointing to the left).
7. Remove hose clamps -3094- and top off fluid in reservoir, if necessary.

Checking pressure

Note. To avoid damaging the pump, note the following: Do not allow the engine to run for more than 10 seconds when carrying out this test. Start the engine without pressing the accelerator and let it run at idling speed. Read off the pump pressure at idling speed immediately after starting the engine (if necessary, have a second technician read off the pressure). The pressure will drop during the test; take the highest pressure reading as the test value

Specified value: 120-130 bar of pressure.

1. Stop engine. If the test result does not meet the specification, replace vane pump. See «VANE PUMP, REMOVING AND INSTALLING»(ref-196877-S26596494882005100900000) .
2. Check hydraulic oil level. See «POWER STEERING OIL LEVEL, CHECKING»(ref-196877-S15392846522005100900000) .
3. Bleed steering system. See «STEERING SYSTEM, BLEEDING»(ref-196877-S37617563472005100900000) .
4. Check steering system for leaks. See «STEERING SYSTEM, CHECKING FOR LEAKS»(ref-196877-S28301437902005100900000) .