Removing and installing power steering pump - vehicles with 8-cyl. petrol engine, biturbo — AUDI

📋 Procedure

1. Remove the bumper General body repairs, exterior63Front bumper.
2. Move the lock carrier to the service position General body repairs, exterior50Body - front.
3. Unplug the connector (5) at the charge air pressure sender G31.
4. Unfasten hose clamps (3) and (4).
5. Detach the hoses from the air recirculation valves.

6. Screw out the bolts (1) and (2) and detach the air pipe.
7. Remove the air hose to the charge air cooler on the left (arrows). [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.]
8. To slacken off the poly V-belt, swivel the belt tensioner in (arrow direction).
9. Lock the tensioner in position by inserting the locking pin3204 in the locating holes (arrow).
10. Detach the poly V-belt from the power steering pump pulley.
11. Screw out the bolts (arrows) of the power steering pump poly V-belt pulley.
12. When slackening off and tightening the bolts (arrows), provide support with the pin wrench3212.
13. Take the connectors (arrows) out of the holder.
14. Remove holder for connectors.
15. Use hose clamps3094 to pinch off the hydraulic hoses. [Note: Place a cloth under the unions to catch escaping hydraulic fluid.]
16. Detach the suction hose (1) and expansion hose (2) at the power steering pump.
17. Unscrew bolts (arrows).
18. Take out the power steering pump.
19. 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.
20. Clean off fluid in engine compartment where necessary.
21. Renew seals and O-rings.
22. Secure all hose connections with the correct type of hose clips (same as original equipment): Electronic parts catalogue.
23. Insert the pump in the holder and screw in all 3 bolts (arrows).
24. Attach expansion and suction hose with new seals but do not tighten. [Note: The front side of the pulley is labelled "“Front”".Screw on the power steering pump pulley. Use a pin wrench3212 to provide support.]
25. Position aligning gauge3201 on pulley of air conditioner compressor.
26. Use shims of 0.5, 1.0 and 1.5 mm thickness to even out the distance between the poly V-belt pulleys for the power steering pump and the air conditioner compressor. For part no., refer to Electronic parts catalogue.
27. Then check the alignment of the poly V-belt pulleys again using the alignment gauge3201. Repeat adjustment if necessary.
28. Align expansion hose and tighten.
29. Align suction hose and tighten.
30. Remove hose clamps3094.
31. Installation position of poly V-belt 13 [Note: Pay attention to correct positioning on pulleys when fitting the poly V-belt.]
32. Attach poly V-belt and again unload tensioning roller.
33. Replace the front air pipe O-ring.
34. Check hydraulic fluid level .
35. Bleed steering system .
36. Checking steering system for leaks
37. Start engine and check that belt runs properly.
38. Attach the bumper General body repairs, exterior63Front bumper.
39. Attach the lock carrier General body repairs, exterior50Body - front.

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