Removing and installing power steering pump, vehicles with 6-cyl. 2.7 l petrol engine — AUDI

🧭 Before you start

Remove the engine cover, air duct, ignition coil bracket, viscous fan and electric fan. Mark the belt direction, pin the tensioner and remove the belt, then the pump pulley. Clamp the hoses, disconnect the expansion pipe and suction hose and remove the bracket with pump. Prime the new pump, fit it to the bracket at 22 Nm, refit the banjo at 47 Nm with new seals, refit belt and fans, then check fluid level, bleed and leak-test.

Fits: Audi A6 C5 (4B)

• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: torque wrench
• Renewed: seals

Don't miss

• The viscous fan has a left-hand thread.
• Mark the poly V-belt running direction before removal.
• Prime a new pump with fluid before fitting.
• Use new seals on the banjo bolt and tighten it to 47 Nm.
• Fit the suction hose with mark P towards the pump.
• Bleed the steering system and check for leaks.

Written for this job from the workshop steps below · TorqFix editorial.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Unclip engine top cover and remove.
2. Unscrew air duct to air filter at front end and lift out air duct.
3. Unplug 5-pin connector from ignition coils.
4. Unplug three rear connectors (A) from ignition coils.
5. Unscrew the four retaining bolts.

6. Swivel ignition coil bracket to the rear.
7. Provide support for the viscous fan pulley with the pin wrench3212 and unscrew the viscous fan with the open-ended wrench3312 (left-hand thread).
8. Lift out the viscous fan.
9. Remove the electric fan. To do so, remove bolt (1).
10. The wire of the electric fan is clipped to the viscous fan air duct. Pull off these clamps.
11. To remove, turn the electric fan slightly in (arrow direction).
12. Set down the electric fan sideways to the right. [Note: Before removing the poly V-belt, mark the direction of rotation. A used belt can break if it runs in the opposite direction. Ensure that the belt is properly seated in the pulleys when installing.]
13. Use a long torque wrench and a socket wrench attachment (w.a.f 17 mm) to turn the tensioner clockwise.
14. When the two holes coincide (arrows), secure with a locking pin3204.
15. Remove poly V-belt from belt pulley.
16. Unbolt power steering pump pulley. Use a pin wrench3212 to provide support.
17. Clamp off suction and return lines using hose clamps3094.
18. The pipe of the expansion hose is screwed to the cylinder head .
19. Unscrew this bolt.
20. Open clamp (1) and pull off suction hose.
21. Disconnect expansion hose (2).
22. Unscrew power steering pump bracket.
23. Remove bracket with pump.
24. Then screw power steering pump off bracket.
25. 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.
26. Clean off fluid in engine compartment where necessary.
27. Bolt pump to bracket (22 Nm). — 22 Nm (16 lb-ft)
28. Insert pump with bracket.
29. Tighten two front bolts first and then the rear bolt, 22 Nm. — 22 Nm (16 lb-ft)
30. Fit new seals on banjo bolt.
31. Tighten the banjo bolt for the expansion hose (2) to 47 Nm. — 47 Nm (35 lb-ft)
32. Screw the pipe of the expansion hose to the cylinder head (6 Nm) . — 6 Nm (4.4 lb-ft)
33. Fit the suction hose (1), mark (P) faces pump.
34. Remove hose clamps3094.
35. Tighten hexagon socket head bolts for power steering pump belt pulley to 22 Nm. — 22 Nm (16 lb-ft)
36. First of all fit poly V-belt over the crankshaft belt pulley and guide pulley and push it onto the tensioning roller last.
37. Installation position of poly V-belt 13 [Note: When installing the poly V-belt ensure correct running direction and correct seating of the belt in the pulley.]
38. Take out the locking pin3204.
39. Fit the electric fan and then the viscous fan.
40. Tightening torque for viscous fan 19
41. Check hydraulic fluid level .
42. Bleed steering system .
43. Checking steering system for leaks

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