Removing and installing power-assisted steering box for LHD vehicles with V6 TDI engine — AUDI

Removing

Important
Bring steering wheel to centre position and do not turn whilst performing repair work, as otherwise coil connector of airbag unit could be damaged.
Remove ignition key with steering wheel centred.

Move steering wheel slightly so that the steering lock engages.
Lever off lower surround -arrows-.

Unscrew cover -arrows-.

Unscrew nut -1- at universal joint.
Relieve tension on eccentric by turning tensioning bolt clockwise and remove bolt.

Note:

As a result of design improvements, safety guard -2- is discontinued.

Secure steering column against sliding apart => Page
48-21

Swivel the universal joint downwards out of the way.
Remove sealing boot towards inside.

Note:

If sealing boot is damaged always install a new one.

Ensure sealing boot is correctly positioned.

The coarse thread locating pin on the bulkhead must engage in the sealing boot rim aperture.

Detach front wheels.
Pinch off suction and return pipes with hose clamps -3094-.

Detach caps on engine cover panel.
Unscrew engine cover.

Remove both nuts for shield -A-.
Lift the shield from the studs.

Left and right vehicle sides:

Loosen track rod end bolts and push track rod end out of way in downwards direction.

Right side of vehicle:
Detach the engine compartment cover and remove.

Right side of vehicle:
Unscrew the right steering box securing bolt.

Left vehicle side:
Remove rear half of left front wheel housing panel.
Remove left wheel housing panel insulating mat.

Remove noise insulation (2 sections).

From below:
In order to facilitate access to the lower heat shields, detach the heat shield for the left drive shaft.

Notes:

The third securing bolt is not illustrated.
Overview of heat shields => Page
48-50

This illustration shows the vehicle from below and, for ease of illustration, without the gearbox.

Remove both lower nuts for shield -A-.
Lift the shield from the studs and push it as far as possible towards the centre of the vehicle.
Remove the nuts for shields -B and C-.
Lift the shields -B and C- until you can remove cover -D-.

Place pan underneath to catch hydraulic fluid.
Unscrew expansion hose -2- and return hose -1- from steering box (access through wheel housing).
Detach connector from Servotronic valve on vehicles equipped with Servotronic.

Remove both securing bolts from the left side of the steering box.
Free up steering box and mounting at plenum chamber lower end.
Remove steering box to left through wheel housing (second mechanic required).

When installing, pay special attention to the following:

Fix the steering box in the centred position before installation => Page
48-41
.

Ensure free movement and correct installation position of hydraulic hoses.

1 -
Return hose
2 -
Expansion hose

Insert steering box into mounting at plenum chamber lower end.

Tighten bolts in sequence A, B, C
Tightening torque: 70 Nm.

Unlock the steering wheel lock and set the steering wheel in the horizontal position.
Align the steering column free of tension to the steering rack pinion:

Detach the steering column to assembly support bolted connection -1-.

Install the steering column universal joint to the steering rack pinion.

Tension the eccentric bolt -arrow- in counter-clockwise direction and tighten the nut -2- to 40 Nm.

Re-tighten the bolted connection -1- to 20 Nm.

Remove centring device -V.A.G 1907- and tighten closure bolt to 12 Nm.
Bleed steering system => Page
48-146
Check hydraulic fluid level =>Page
48-144
Check steering system for leaks =>Page
48-149
Checking vehicle alignment => Page
44-26