Assembly overview: Power steering/oil circuit for 6-cylinder TDI engine — AUDI

General information

Servicing of vane pump is not envisaged. In the case of complaints, determine the cause by means of a pressure test and leak test. If a fault is detected, replace the vane pump.

Notes:

Check steering system for leaks if there is a lack of fluid in the reservoir.
If a leak is found in the area of the pipe connections, first check pipes/pipe connections for leaks, re-tighten if necessary and wipe dry.
Replacement pumps are not filled with fluid. Prior to installation these must always be filled with hydraulic fluid G 002 000 and cranked by hand to avoid possible noise whilst driving or pump damage.
Type of fluid: Hydraulic fluid G 002 000

In vehicles with V6 TDI engines, additional heat shields are fitted on the left side, and an engine cover on the left and right respectively at the track rods.
The left engine compartment cover covers the securing bolts of the steering box. It can, however, only be removed once the heat shields have been detached.

Overview of heat shields => Page
48-50

Repair solution for the right engine compartment cover => Page
48-199

When fluid circuit has been opened always:

Check all unions for leaks, start engine and perform visual inspections.
Check fluid level =>Page
48-144

Power-assisted steering box
Assembly overview:

Left-hand drive => Page
48-35
Right-hand drive => Page
48-114

Servicing => Page
48-109
In vehicles with V6 TDI- engines, removal is only possible to unscrew the bolt following removal of the heat shields => Page
48-50
and the engine compartments.
Repair solution for the right engine compartment cover => Page
48-199

Sealing ring
Always replace

Banjo bolt, 47 Nm
Return hose
Steering box - hydraulic fluid cooler

Sealing ring
Always replace

Banjo bolt, 40 Nm
With integrated non-return valve

Expansion hose
Vane pump - steering box

Support panel for suspension strut holder

Note:

Items 9, 10, 11 and 12 are located in the left wheel housing and accessible from outside with vehicle raised.

Bonded rubber bush
Retaining plate
Note correct installation position:

Solid rubber faces towards hose

Retaining clip
Hexagon nut 5.6 Nm
Cap with dipstick
Check fluid level =>Page
48-144

Strainer for expansion tank
Clean using solvent

Expansion tank
Refilling with hydraulic fluid, Part No. G 002 000, filling quantity 1.2 litres
Plugged into hydraulic unit bracket
Check fluid level =>Page
48-144

Clip
Always replace
Tensioning => Page 48-113
Can also be replaced by screw-type hose clamp

Clip
Always replace
Tensioning => Page 48-113
Can also be replaced by screw-type hose clamp

Return hose
Fluid cooler - expansion tank

Clip
Always replace
Tensioning => Page 48-113
Can also be replaced by screw-type hose clamp

Combi bolt, 10 Nm
Hydraulic fluid cooler
Suction hose
Vane pump - expansion tank

Banjo bolt, 50 Nm
Sealing ring
Always replace

Vane pump
Check delivery pressure
=> Page
48-201
Assembly overview =>Page
48-204
Removing and installing
=>Page
48-208

Sealing ring
Always replace

Banjo bolt, 47 Nm

Repair solution, right engine cover:

In order to avoid detaching the track rod from the wheel bearing housing and the consequent wheel alignment, please proceed as follows in the case of a damaged cover (e.g.: marten bite):

Detach the damaged engine compartment cover and pull it out slightly.
Cut the cover open and remove it.

Cut the new cover at the pre-marked cutting line and lay it over the track rod.

Bond the cover back together again at the cutting line.

We recommend adhesive:

D 002 100

Notes:

Note the safety and useage instructions on the packaging of the adhesive.
The cover is manufactured from thermoplastic elastomere (TPE), with the constituents styrene, ethylene and butylene.
For this reason, only use adhesives which do not attack these materials.
Moreover, do not use any adhesives which attach polyethylene or styrofoam.