Removing and installing power steering pump - vehicles with 6-cyl. Diesel engine — AUDI

🧭 Before you start

Remove noise insulation and bumper, move the lock carrier to service position, then unscrew the viscous fan and the belt cover. Release both belts, hang the A/C compressor on the longitudinal member, take off the pump pulley, clamp and disconnect suction and expansion hoses, and unbolt the pump. Prime the new pump, bolt it on front pair then rear, tighten the pressure banjo with new seals, refit belts and pretension, then fill, bleed and leak-check.

Fits: Audi A6 C5 (4B)

• Opens: power steering fluid
• Special tools named: torque wrench
• Renewed: seals

Don't miss

• Mark the belt's direction of rotation before removal; a used belt run backwards can break.
• Do not let the A/C compressor hang on its refrigerant lines; tie it up and do not bend them.
• Fill the new pump with fluid and turn it by hand until fluid comes out at the pressure outlet.
• Banjo bolt for the pressure hose takes new seals and 47 Nm.
• Align marking P on the suction hose with the seam on the pump.
• Pretension the A/C belt to 7 Nm with the torque wrench, then tighten the tensioner bolt to 25 Nm.

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. Detach the noise insulation.
2. Remove the bumper General body repairs, exterior63Front bumper.
3. Move the lock carrier to the service position General body repairs, exterior50Body - front.
4. Remove the cover over the reservoir.
5. Detach green plug for solenoid clutch/air conditioning compressor and detach bottom part of connector from retainer.

6. Move wiring to compressor clear.
7. Unscrew the viscous fan.
8. 2 open-end spanners (32 mm) are required.
9. To unfasten, provide support with one wrench and turn in (arrow direction) with the other.
10. Unbolt cover for poly V-belt (3x). [Note: Note position of spacer sleeves for belt cover.Mark the direction of rotation before removing the poly V-belt. A used belt can break if it runs in the opposite direction. Ensure that the belt is properly seated in the pulleys when installing.]
11. Removing poly V-belt for A/C compressor:
12. Slacken off bolt (A) on tensioning roller for air-conditioner compressor and detach poly V-belt.
13. Removing poly V-belt for power steering pump:
14. To slacken off the poly V-belt, turn in (arrow direction) with an Allen key (17 mm) and insert a pin ∅ 4 mm (1) (e. g. pin punch).
15. Take off belt.
16. Detaching compressor for air conditioner: [Note: The lines remain connected and must not be bent.After detaching, tie up compressor on longitudinal member using wire or similar; do not leave it suspended on refrigerant lines.Ensure centring bush (B) is properly seated when installing compressor.]
17. Remove the bolts (A) (tightening torque 25 Nm). — 25 Nm (18 lb-ft)
18. Unscrew the poly V-belt sprocket of the hydraulic pump. Use pin wrench3212 to counterhold pulley. [Note: Shown with engine removed for illustration purposes.]
19. Clamp off suction and return lines using hose clamps3094.
20. Place a drip tray underneath to catch hydraulic fluid.
21. Detach hose clip from suction hose (1).
22. Disconnect suction hose and move hose to one side.
23. Disconnect expansion hose (2).
24. Seal off connections with plugs.
25. Unbolt pump from bracket (1) and (2) and take out pump.
26. 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.
27. Clean off fluid in engine compartment where necessary.
28. Bolt pump onto bracket (A) at holes marked (B).
29. Fit all bolts and tighten first the two front bolts, then the two rear bolts.
30. Fit new seals on banjo bolt.
31. Tighten banjo bolt for pressure hose (2) to 47 Nm. — 47 Nm (35 lb-ft)
32. Fit suction hose (1).
33. Marking (P) on suction hose must be aligned with seam on pump.
34. Remove hose clamps3094.
35. Screw on the pulley.
36. Screw the air conditioner compressor to the holder (25 Nm). — 25 Nm (18 lb-ft)
37. Fit poly V-belt on crankshaft pulley and idler wheels first; fit onto tensioning roller last.
38. Installation position of poly V-belt 13
39. Turn Allen key in direction of arrow and remove pin (1).
40. Fit poly V-belt for air conditioner compressor.
41. Apply the torque wrench (C) as shown and pretension the poly V-belt to 7 Nm by turning in arrow direction (Allen key w.a.f 8 mm). — 7 Nm (5.2 lb-ft)
42. Tighten the bolt (A) with a torque wrench (tightening torque 25 Nm). — 25 Nm (18 lb-ft)
43. Unscrew cover of poly V-belt (3x).
44. Screw in the viscous fan.
45. Install lock carrier.
46. Fit bumper.
47. Check hydraulic fluid level .
48. Bleed steering system .
49. Checking steering system for leaks

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