Removing and installing power steering pump (vehicles with 12-cylinder petrol engine) — AUDI

🧭 Before you start

Fits: Audi A8 D3 (4E, 2002–2010)

• Opens: power steering fluid
• Renewed: seals

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• Secure brake disc with 2 wheel bolts.
• Leave poly V-belt in position on the other pulleys.

📋 Procedure

1. Position vehicle on lifting platform .
2. Remove left front wheel. [Note: Secure brake disc with 2 wheel bolts.]
3. On vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of auxiliary/additional heater at noise insulation.
4. Open quick-release fasteners (arrows) on left and right at bottom of wheel housing liners.
5. Open quick-release fasteners (1) and remove noise insulation (front). [Note: Press in clamping pins on wheel housing liners only approx. 5 mm into expanding clips, and not all the way through.This releases the expanding clip so it can be pulled out.On installation, the clamping pin is pushed back and the expanding clip can be reused.]

6. Using a screwdriver, press clamping pins of expanding clips (1) on wheel housing liner (front) approx. 5 mm deep into expanding clips.
7. Pull out expanding clip.
8. Unscrew bolt (2) from wheel housing liner.
9. Unscrew two bolts (arrows) from wheel housing liner (front section).
10. Unscrew top bolt (arrow) from wheel housing liner (front). [Note: Press in clamping pins on wheel housing liners only approx. 5 mm into expanding clips, and not all the way through.This releases the expanding clip so it can be pulled out.On installation, the clamping pin is pushed back and the expanding clip can be reused.]
11. Using a screwdriver, press clamping pins of expanding clips (arrow) on wheel housing liner (front) approx. 5 mm deep into expanding clips.
12. Pull out expanding clip.
13. Remove expanding clip (arrow) in upper section of wheel housing liner (front) in the same way.
14. Remove expanding clip (arrow) in rear section of wheel housing liner (front) (1) in the same way.
15. Place drip tray for workshop hoistVAS 6208 underneath to catch hydraulic fluid.
16. Detach hose clip (4) from suction hose (3).
17. Disconnect suction hose and move hose to one side.
18. Remove banjo bolt (2) for expansion hose (1).
19. Seal off connections with plugs.
20. Disconnect both air intake hoses (arrows) at bottom of air cleaner housing (bottom section, left-side). Press release tabs together to disconnect.
21. Unplug electrical connector (3) for air mass meter 2G246.
22. Detach hose (2) from air intake hose.
23. Detach air intake hose (1) at intake manifold.
24. Unscrew bolts (arrows).
25. Detach top section of air cleaner housing (left-side).
26. Remove air duct (1).
27. Unscrew bolts (arrows).
28. Take out bottom section of air cleaner housing (left-side).
29. Carefully pull engine cover panel upwards (starting at the rear and in the centre) (arrows 1).
30. Then pull engine cover panel forwards off intake manifold (arrows 2).
31. Swivel tensioner in direction of (arrow) to slacken off poly V-belt.
32. Detach poly V-belt from power steering pump pulley, then release tensioner. [Note: Leave poly V-belt in position on the other pulleys.]
33. Unbolt pulley (1) from power steering pump (arrows).
34. Unscrew bolts (arrows) and take off power steering pump. [Note: Renew seals and O-rings.Before fitting a new pump, put in hydraulic fluid at the inlet and turn pump by hand until fluid flows out at the pressure outlet.Secure all hose connections with the correct type of hose clips (same as original equipment) Electronic parts catalogue.]
35. Turn hub by hand until fluid comes out at pump outlet.
36. Tighten bolts (arrows) and .
37. Tighten bolts (arrows) on power steering pump pulley 13.
38. Position aligning gauge3201 on pulley of air conditioner compressor.
39. Identify central position of power steering pump shaft by moving shaft backwards and forwards in axial direction.
40. Use shims (3) of appropriate thickness (as listed in Electronic parts catalogue to adjust alignment between power steering pump pulley (2) and A/C compressor pulley.
41. Then re-check alignment of poly V-belt pulleys with aligning gauge3201. Repeat adjustment if necessary.
42. Fit new seals (5) on banjo bolt.
43. Tighten banjo bolt (2).
44. Connect suction hose (3) and secure with new hose clip (4). Note correct installation position .
45. Fill up with hydraulic fluid.
46. Clean off fluid in engine compartment where necessary.
47. Fit poly V-belt 13.
48. Check hydraulic fluid level .
49. Bleed steering system .
50. Check steering system for leaks .
51. Set down vehicle on its wheels .

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