Removing and installing power-assisted steering box (right-hand drive) — AUDI

Special tools and workshop equipment required

3094 Hose clamps up to ø 25 mm
V.A.G 1331 Torque wrench
V.A.G 1332 Torque wrench
V.A.G 1907 Screw for steering centring

Removing

Take out plenum chamber cover.

Remove battery.

=> Electrical System; Repair Group 27; Battery; Removing and installing battery
Electrical System
Battery
Removing and installing battery

Unscrew battery bracket -arrows-.
Remove driver's storage compartment.

=> General Body Repairs, Interior; Repair Group 68; Storage compartments/covers and trim panels; Removing driver's storage compartment
General Body Repairs, Interior
Storage compartments/covers and trim panels
Removing driver's storage compartment

Attention:
Move steering wheel to centre position and do not turn it whilst performing repair work, as otherwise coil connector of airbag unit could be damaged.
Move steering wheel to centre position.
Pull out ignition key with steering wheel in centre position.
Move steering wheel slightly to engage steering lock.

Uncontrolled turning of steering wheel with steering box removed could strain and damage coil connector of airbag system.

Unscrew nut -1- at universal joint.
Slacken off eccentric by turning tensioning bolt (Torx T50) clockwise and take out bolt.

Swivel aside universal joint.
Pull out bulkhead collar to inside.

Before detaching from steering box pinion, secure steering column with wire as shown.

Attention:
Mesh section between top and bottom part of steering column is never to be separated.
Do not turn steering wheel whilst performing repair work, as otherwise coil connector of airbag unit could be damaged.

Remove wheel bearing housing and mounting bracket with suspension strut => Page
40-125
.

When removing wheel bearing housing, take care not to damage track rod bellows (shield bellows if necessary).

Unscrew nut -1-.
Prise out clips -2-.
Take out cover.

Remove air cleaner housing and air pipe for air-mass meter.
Take out bottom part of air cleaner box.
Unscrew nut -2- and self-tapping screws -3-.
Take out shield -1-.

Remove cover from reservoir.
Pinch off suction and return pipe with hose clamps -3094-.

Place drip tray in position to collect hydraulic fluid.
Unscrew expansion hose -1- and return hose -2- from steering box.

Unfasten holder -arrow- for hoses at steering box.
=> Page
48-32
, Item
10

Screw out right steering box bolt.

On vehicles with air conditioner, unplug connector -arrow-.
Unscrew multi-point socket-head bolt -1- for attaching steering box.

Unscrew bolt -arrow- for attaching steering box.

Bolt is located on side of servo unit.

Pull out steering box to right (2nd mechanic required).

Installing

Centre steering box removed with -V.A.G 1907-.

To do so, screw out hexagon socket-head bolt -1- at steering box.
Move rack until centring on rack -arrow- is aligned with tapped hole -2-.
Hand-tighten V.A.G 1907.
Apply lubricant G 052 745 A3 to steering box in area of bulkhead collar seat.

Position steering box at plenum chamber (requires 2nd mechanic).

Make sure threads and contact surfaces of bolts are free from oil/grease.

To ensure compliance with wheel alignment values, repair set for South Africa contains 3 additional shims 8D0422211 (thickness 2 mm) for fitting between steering box and body (at all 3 bolted joints).

Fit but do not tighten bolts -1- and -2-.
Screw in bolt -3- and tighten to 68 Nm.
Then tighten bolts -1- and -2- to 68 Nm.

Position holder for hoses at steering box.
=> Page
48-32
, Item
10

Notes:

Always use new seals for banjo bolts.
Pressure and return hose must not make mutual contact or come into contact with other parts.

Screw on return hose and tighten banjo bolt -22 mm- to 50 Nm.
Screw on pressure hose and tighten banjo bolt -19 mm- to 40 Nm.
Secure holder for hoses at steering box.

Tightening torque 20 Nm

Re-insert bulkhead collar.

Notes:

Replace seal if damaged.
Make sure seal is properly positioned.

Release steering lock.
Move steering wheel to centre position and then attach universal joint to steering pinion.

Insert tensioning bolt (Torx T50) and pre-tension in anti-clockwise direction. Use new nut.
Remove assembly lock from steering column.

Then screw tool -V.A.G 1907 out of steering box.

1 -
Hexagon socket-head bolt
2 -
Tapped hole in steering box

Secure steering box with hexagon socket-head bolt -1- (tightening torque 13 Nm).
Tighten hexagon nut of tensioning bolt (steering column/steering pinion) to30 Nm.
Install driver's storage compartment.

=> General Body Repairs, Interior; Repair Group 68; Storage compartments/covers and trim panels; Removing driver's storage compartment
General Body Repairs, Interior
Storage compartments/covers and trim panels
Removing driver's storage compartment

Remove hose clamps -3094- on completion of steering box assembly.
Fit wheel housing trim.
Fit mounting bracket with suspension strut and wheel bearing housing => Page
40-85
.

Fit heat shield.
Fit cover of reservoir.
Fit bottom part of air cleaner box.
Fit air cleaner housing and air pipe for air-mass meter.
Install battery bracket, battery and plenum chamber cover.

=> Electrical System; Repair Group 27; Battery; Removing and installing battery
Electrical System
Battery
Removing and installing battery

Check hydraulic fluid level =>Page
48-55
.
Bleed steering system =>Page
48-57
.
Check steering system for leaks =>Page
48-59
.
Perform wheel alignment => Page
44-13
.