Removing and installing power-assisted steering box (RS4) — 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 right water deflector.
Remove battery.

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

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.

An assembly lock is required to prevent top and bottom parts of steering column being pulled apart when pulling off steering box.

Mesh section will become separated if top and bottom parts of steering column are pulled too far apart or excessively telescoped.

Rattling noise may subsequently be encountered if mesh section is no longer in its original installation position.

Securing steering column prior to removal

Pull wire/cable tie through hole in bottom part of steering column
-arrow- and spring.
Wire/cable tie can also be pulled through spring and universal joint.

Steering column can also be secured with a transport lock => Page
48-158
.

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.

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.
Remove noise insulation.

Remove cover -1- of reservoir -2-.

Pinch off suction hose -1- immediately downstream of reservoir with hose clamp -3094-.

Pinch off return pipe -1- with hose clamp -3094-.

Unscrew front wheels.
Screw out hexagon bolt -3- and bolt -4-.
Pull out track rod.

Unscrew speed nut -arrow-.
Prise out clips and take out cover.
Place drip tray in position to collect hydraulic fluid.

Unscrew banjo bolt for pressure hose (19 mm) from steering box.

Screw out bolts -1- and -2-.

Left gearbox support must be removed before bolt -3- can be screwed out.

Remove left gearbox support assembly.

=> Manual Gearbox; Repair Group 34; Removing and installing gearbox
Manual Gearbox
Removing and installing gearbox

=> Automatic Gearbox; Repair Group 37; Removing and installing gearbox
Automatic Gearbox
Removing and installing gearbox

Screw out bolt -arrow- for attaching steering box.
(corresponds to Item 3 in Fig. A48-0059)

Note:

Bolt -arrow- is only accessible through recess in shield between Lambda probe -1- and front exhaust pipe -2-.

3 -
Subframe

Apply tool as shown to screw out bolt.

The following operations require two mechanics

Guide steering box as far as possible to left over wheel bearing housing and give 90° anti-clockwise turn.

Then guide steering box as far as possible to left again and give a further 90° anti-clockwise turn.
Take out steering box.

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 screw for steering centring -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.

Fit but do not tighten bolts -1- and -2-.

Screw in bolt -arrow- and tighten to 68 Nm.
(corresponds to Item 3 in Fig. A48-0059)

Note:

Bolt -arrow- is only accessible through recess in shield between Lambda probe -1- and front exhaust pipe -2-.

3 -
Subframe

Apply tool as shown to screw in and tighten bolt.

Then tighten bolts -1- and -2- to 68 Nm.
Install left gearbox support assembly.

=> Manual Gearbox; Repair Group 34; Removing and installing gearbox
Manual Gearbox
Removing and installing gearbox

=> Automatic Gearbox; Repair Group 37; Removing and installing gearbox
Automatic Gearbox
Removing and installing gearbox

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.
Re-insert bulkhead collar.

Notes:

Replace bulkhead collar if damaged.
Make sure bulkhead collar 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.
Tighten hexagon nut of tensioning bolt (steering column/steering pinion) to30 Nm.

Remove assembly lock from steering column.
Insert track rod as far as it will go in steering arm.
Fit screw connection -4- and tighten.

Tighten torques:wheel bearing housing:
wheel bearing housing steel 42 Nm
wheel bearing housing aluminium 50 Nm

Insert bolt -3- and tighten to 7 Nm.

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).
Install noise insulation.
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

Fit wheel housing trim.
Remove hose clamps -3094- on completion of steering box assembly.
Install battery.

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

Install right water deflector.
Install plenum chamber cover.
Install cover of hydraulic fluid reservoir.
Fit and secure wheels => Page
44-1
.
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
.