Steering: Overview Audi A8 D2 facelift

Description of function

Automatic adjustment causes simultaneous adjustment of seatbelt and steering column (height/depth).

Servotronic, assembly overview

Note. The following list refers to see scheme 50.

1. Power steering gear with tie rods Removing and installing. See «POWER STEERING GEAR, ASSEMBLY OVERVIEW»(ref-196877-S32256000022005100900000) .
2. Strainer
3. Sealing ring Always replace
4. Sealing ring Always replace
5. Servotronic solenoid valve -N119- Different versions Replacement of Servotronic solenoid valve -N119- involves removing power steering gear Checking. See «SERVOTRONIC SOLENOID VALVE -N119-, CHECKING»(ref-196877-S21295306852005100900000) .
6. Servotronic solenoid valve -N119- Different versions Replacement of Servotronic solenoid valve -N119- involves removing power steering gear. Checking. See «SERVOTRONIC SOLENOID VALVE -N119-, CHECKING»(ref-196877-S21295306852005100900000) .
7. Hex socket head bolt, 3 Nm (27 in lb)
8. 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. Both versions (square plug/round plug) are fully interchangeable in relation to the power steering gear. When replacing the Servotronic steering gear, the Servotronic valve may have to be exchanged to match the connector.
9. Relay plate E Located in the passenger side footwell. Servotronic control module -J236- (position 12) Checking voltage supply. See «VOLTAGE SUPPLY FOR SERVOTRONIC, CHECKING»(ref-196877-S29383008472005100900000) .

General information

There is no provision for servicing the vane pump. If a malfunction occurs, establish the cause by means of the pressure test and leak test. Replace vane pump if it is malfunctioning.

Note. If reservoir fluid level is low then check steering system for leaks. In the case of leaks at the line connections first tighten connections and wipe dry then recheck for leaks. Pumps supplied as replacement parts are not filled with oil. Therefore it is essential to fill the pump with hydraulic oil G 002 000 and to rotate pump by hand, otherwise the pump may be damaged or be noisy during operation. Type of oil: Hydraulic oil G 002 000

The hydraulic fluid circuit on right-hand drive vehicles is the same as on left-hand drive vehicles, except for the fact that the hydraulic lines are extended from left to right on the power steering gear, and the pressure line/expansion hose bolted joint at the side member.

When fluid circuit has been opened always

1. Check all unions for leaks, start engine and perform visual inspections.
2. Check fluid level. See «POWER STEERING OIL LEVEL, CHECKING»(ref-196877-S15392846522005100900000)

Note. The following list refers to see scheme 56.

1. Power steering gear Assembly overview. See «POWER STEERING GEAR, ASSEMBLY OVERVIEW»(ref-196877-S32256000022005100900000) . Servicing. See «POWER STEERING GEAR, SERVICING»(ref-196877-S19293120772005100900000) .
2. Seal Always replace
3. Expansion hose Routed to power steering gear
4. Banjo bolt, 40 Nm (30 ft lb) With integrated non-return valve
5. Seal Always replace
6. Banjo bolt, 47 Nm (35 ft lb)
7. Return hose Routed to power steering gear
8. Reservoir Fill with hydraulic fluid, part no. G002 000, (1.2 liters) Installed on bracket for hydraulic unit Checking oil level. See «POWER STEERING OIL LEVEL, CHECKING»(ref-196877-S15392846522005100900000) .
9. Clamp Always replace Tightening. See «TIGHTENING CLAMP WITH VAG 1275»(ref-196877-S08435947132006060900000) . Can also be replaced by screw-type hose clamp
10. Clamp Always replace Tightening. See «TIGHTENING CLAMP WITH VAG 1275»(ref-196877-S08435947132006060900000) . Can also be replaced by screw-type hose clamp
11. Bonded rubber bushing
12. Retaining plate Installation position: Solid rubber faces towards hose
13. Retaining clip
14. Hex nut, 5 Nm (44 in. lb)
15. Return hose Fluid cooler-reservoir
16. Combi bolt, 10 Nm (7ft lb)
17. Fluid cooler Two versions with different line routing
18. Vane pump Check delivery pressure. See «VANE PUMP DELIVERY PRESSURE, CHECKING»(ref-196877-S40036579052005100900000) . Removing and installing. See «VANE PUMP, REMOVING AND INSTALLING»(ref-196877-S26596494882005100900000) .
19. Seal Always replace
20. Banjo bolt, 50 Nm (37 ft lb)
21. Suction hose
22. Banjo bolt, 47 Nm (35 ft lb)
23. Radiator
24. Strainer for reservoir Clean using solvent
25. Cap with dip stick Check oil level. See «POWER STEERING OIL LEVEL, CHECKING»(ref-196877-S15392846522005100900000) .

Assembly overview of vane pump

Note. Replace sealing rings. Do not reuse drawn off hydraulic oil. Hydraulic fluid: Part No. G 002 000 When vane pump is replaced, always check alignment of pulleys of A/C compressor and vane pump.

Note. The following list refers to see scheme 61.

1. Combi bolt, 25 Nm (18 ft lb)
2. Ribbed belt Mark belt running direction; running in opposite direction can destroy belt Check alignment of ribbed belt. See «CHECKING AND ADJUSTING ALIGNMENT OF RIBBED BELT»(ref-196877-S39219497022005100900000) .
3. Hex socket head bolt, 25 Nm (18 ft lb)
4. Belt pulley
5. Shims Select such that pulleys of A/C compressor and vane pump are aligned Check alignment of ribbed belt. See «CHECKING AND ADJUSTING ALIGNMENT OF RIBBED BELT»(ref-196877-S39219497022005100900000) .
6. Sleeve, slotted Used to offset tolerances
7. Hex bolt, 25 Nm (18 ft lb)
8. Expansion hose Make sure correct installation position; danger of chafing
9. Banjo bolt, 47 Nm (35 ft lb)
10. Seal Always replace
11. Suction hose Make sure correct installation position to reduce the risk of chafing.
12. Banjo bolt, 50 Nm (37 ft lb)
13. Seal Always replace
14. Vane pump Check delivery pressure. See «VANE PUMP DELIVERY PRESSURE, CHECKING»(ref-196877-S40036579052005100900000) . Removing and installing. See «VANE PUMP, REMOVING AND INSTALLING»(ref-196877-S26596494882005100900000) . Before installing, fill with hydraulic fluid at pump inlet and crank by hand until fluid comes out at pump outlet

Scheme 1

Scheme 2

1. Remove bolts at fan.
2. Lift off fan and set it aside.
3. Remove noise insulation beneath engine.
4. Firmly deflect ribbed belt downward.
5. Insert pin -3204- to secure. NOTE: Before removing the ribbed belt, mark the direction of rotation. If a used belt rotates in the wrong direction when reinstalled, this can result in breakage. When installing the belt, make sure it is correctly seated in the pulleys.
6. Remove ribbed belt off belt pulley.
7. Clamp off suction and return lines with hose clamps -3094
8. Unbolt pulley from tandem pump.
9. Counterhold with pin wrench 3212. NOTE: Shown with engine removed for ease of illustration.
10. Unscrew high-pressure hose -1-, expansion hose -2- and suction hose -3- from pump. NOTE: High-pressure hose is only installed in vehicles with self-levelling suspension
11. Plug connecting holes.
12. Unbolt pump from bracket and remove. NOTE: When installing, note the following points in particular: Before installing a new pump, put in hydraulic fluid at the inlet and turn pump by hand until fluid flows out at the pressure outlet. Clean any parts of the engine compartment which have become oily. Installation position of expansion and suction hose. See «ASSEMBLY OVERVIEW OF VANE PUMP»(ref-196877-S29186709172005100900000) . High pressure hose. See «INSTRUCTIONS FOR ATTACHING HIGH-PRESSURE HOSE TO TANDEM PUMP»(ref-196876-S05073761692006060900000) .
13. Insert pump in bracket and screw in all 3 bolts by hand.
14. Tighten two front bolts first and then the rear bolt.
15. Install new seals on expansion hose, high-pressure hose and suction hose.
16. Remove hose clamps -3094-.
17. Bolt on pulley.