Removing and installing vane pump for power assisted steering and hydraulic cooler — AUDI

Special tools and workshop equipment required

Hose clamps 3094
Pin wrench 3212
Drip tray V.A.G 1306

Note:

All cable ties which are released or cut open when removing must be fitted in the same position when installing.

Removing

Removing ribbed belt.

=> 8-cyl. TDI®-Engine, Mechanical Components; Repair group 13; Dismantling and assembling engine; Removing and installing ribbed belt
8-cyl. TDI®-Engine, Mechanical Components
Dismantling and assembling engine
Removing and installing ribbed belt

Unclip and detach green electrical connector -1- for air conditioner magnetic clutch in front of the left wheel housing, move wiring clear.

Important
The air conditioner refrigerant circuit must not be opened.
Unscrew air conditioner compressor from bracket -arrows- and secure to one side on the chassis longitudinal member.

Place drip tray V.A.G 1306 under gearbox.

Clamp the two hoses on the vane pump with hose clamps 3094 and disconnect the hoses.
Unbolt the pressure pipe for power assisted steering -arrow-.

Unplug vacuum hoses -1...3- on the solenoid valves for boost pressure control.
Disconnect the solenoid valves for charge pressure control from the rubber bracket on the heat shield -arrow-.

Unscrew the heat shield for the solenoid valve from the bracket for A/C compressor and vane pump -2-.
Move vacuum hose -1- on dipstick guide tube clear.
Unscrew rear hexagon socket head bolt for vane pump.

Remove engine cover -arrows-.

Remove cover on left in engine compartment-arrows-.
Remove upper left toothed belt guard.

=> 8-cyl. TDI®-Engine, Mechanical Components; Repair group 13; Dismantling and assembling engine; Toothed belt covers
8-cyl. TDI®-Engine, Mechanical Components
Dismantling and assembling engine
Toothed belt covers

Clamp the pressure pipe to the hydraulic fan with pipe clamp 3094.
Unbolt pressure pipe -1-.
Disconnect electrical connector -2- on the vane pump and moving wiring clear.
Unscrew bracket for pressure control valve for crankcase breather -3- on the body.

Note:

The pressure control valve for crankcase breather remains installed.

Unbolt dipstick guide tube on cylinder head -arrow- and remove upwards.

Unscrew the bolts -arrows- of the ribbed belt pulley for the vane pump.

Notes:

Use pin wrench 3212 as a counterhold when slackening and tightening bolts.
Installation position: The word "vorne" ("front") on the ribbed belt pulley indicates direction of travel

Unscrew the 2 nuts -arrows-.
Lift out the vane pump.

Installing

Installation is carried out in the reverse order; note the following:

Note:

Replace seals and gaskets.

Installing air conditioner compressor

=> 8-cyl. TDI®-Engine, Mechanical Components; Repair group 13; Dismantling and assembling engine; Ribbed belt drive for vane pump, alternator and AC compressor
8-cyl. TDI®-Engine, Mechanical Components
Dismantling and assembling engine
Ribbed belt drive for vane pump, alternator and AC compressor

Install ribbed belt

=> 8-cyl. TDI®-Engine, Mechanical Components; Repair group 13; Dismantling and assembling engine; Removing and installing ribbed belt
8-cyl. TDI®-Engine, Mechanical Components
Dismantling and assembling engine
Removing and installing ribbed belt

Inspect alignment of ribbed belt.

=> 8-cyl. TDI®-Engine, Mechanical Components; Repair group 13; Dismantling and assembling engine; Checking alignment of ribbed belt
8-cyl. TDI®-Engine, Mechanical Components
Dismantling and assembling engine
Checking alignment of ribbed belt

Top up power steering fluid and bleed steering system:
Check hydraulic fluid level =>Page
48-144
Bleed steering system => Page
48-146
Check steering system for leaks =>Page
48-149

Tightening torques

Component · Nm
Vane pump to bracket · 22
Belt pulley to vane pump · 22
Bracket for crankcase breather pressure control valve to body · / 10
Pressure pipe for hydraulic cooler to vane pump · / 50
Heat shield on bracket for vane pump · 10
Hydraulic pressure pipe for steering gear to vane pump · / 47
Hose clamps · 2