Removing and Installing

Power Steering Gear, Removing And Installing

WARNING: Airbags and related equipment (e.g. steering wheel) must only be disassembled, assembled and repaired by trained Audi Service Department personnel. Disconnecting the battery alone will NOT prevent the accidental deployment of the airbag(s). Before working on any airbag, instrument panel or steering column component, always disconnect the airbag power supply harness connector(s), and refer to all airbag system Warnings and Cautions. After the airbag power supply has been disconnected, make sure that the front wheels face straight-ahead when the steering wheel is removed (this is to ensure that the airbag spiral spring will not be damaged). Make sure that no person is in the vehicle when connecting the battery Ground strap.

CAUTION! Before disconnecting the battery, determine the correct coding for the anti-theft radio.

Note: Brake booster must be removed when removing and installing steering gear.


Removing

Disconnect battery Ground strap.






Remove strut tower crossmember (arrows).
Pry cover off intake air silencer using screwdriver.






Remove both intake air silencer mounting bolts.
Disconnect intake air duct at mass air flow sensor.
Disconnect crankcase ventilation hose at large diameter end and disconnect from cylinder head covers.
Push intake air silencer to the rear and lift upward.
Disconnect vacuum hose from throttle body, and remove intake air silencer.
Remove strainer from brake fluid reservoir, and remove brake fluid.






Disconnect both brake lines between brake master cylinder and ABS hydraulic unit.
Disconnect harness connector for brake fluid level sensor at brake fluid reservoir.
Remove brake master cylinder from brake booster.
Remove bolt for fastening crankcase breather from cylinder head cover.
Disconnect cruise control vacuum line.
Disconnect cruise control diaphragm with bracket from throttle body.
Disconnect connectors for knock sensor, heated oxygen sensor and oxygen sensor heater from bracket.
Plug holes for brake lines on brake master cylinder and ABS hydraulic unit with bleeder screws.
Disconnect check valve with vacuum line from brake booster.
Disconnect supply line for clutch slave cylinder from brake fluid reservoir.






Block off supply and return lines with hose clamps 3094.
Disconnect harness connector for engine coolant temperature sensor in rear coolant line.
Remove lower instrument panel knee bar on driver's side.






Remove safety clip from pin on brake pedal.
Remove bolt from clevis.
Disconnect spring from clevis.






Remove mounting bolts for flanged tube with bracket at steering pinion and steering column.
Press steering column off coupling.
Remove flanged tube with bracket from steering pinion, then push steering column slightly to one side.
Disconnect brake booster from pedal bracket.
Carefully remove brake booster.






Disconnect pressure hose banjo fitting from steering gear.
Move steering by turning wheels from stop to stop, so that hydraulic oil can be removed from pressure hose connection.
Seal hose in steering gear housing with plug.
Remove self-locking nuts from tie rod carrier mounting bolts.
Remove mounting bolts for steering damper to bracket on wheelhousing side.






Remove both tie rod carrier mounting bolts.
Disconnect tie rod carrier from steering rack.
Remove steering damper with bracket.






Disconnect return hose banjo fitting from steering gear.
Seal hole with plug.
For vehicles with Servotronic, disconnect harness connector for Servotronic valve.






Remove steering gear mounting bolts on left wheelhousing.
Remove bracket for steering damper on wheelhousing side. While doing so, disconnect brake line from retaining clip.
Unclip fasteners for bulkhead seal (working from engine compartment).
Remove bulkhead seal from floor footwell.






Disconnect steering gear mounting nuts from bulkhead using angled box wrench.
Pull steering gear slightly toward front of vehicle, so that it comes free from bulkhead.






Guide steering gear upward by turning slightly as necessary, then remove.


Installing

Installation is the reverse of removal; note the following points:

Install steering gear and attach to bulkhead by hand.
Tighten steering gear to left wheelhousing with steering damper bracket (2 technicians required).
Tighten steering gear to bulkhead with angled box wrench.
Carefully place bulkhead seal into position.
Attach brake line in holding clip on bracket for steering damper, wheelhousing side.
Connect return hose on rotary valve housing and on pressure hose on steering gear housing in such a way that hose does not contact anything.
Connect harness connector for Servotronic valve.
Attach brake booster to bulkhead and secure, then install bulkhead seal onto bulkhead.
Install harness connector for engine coolant temperature sensor at rear coolant line.
Install threaded pin.
Mount cruise control diaphragm with bracket on throttle body.
Connect cruise control vacuum line.
Clip in connectors.
Connect coil spring to pedal clevis.
Install pin in clevis and/or install pedal, and secure with new clip.
Connect harness connector for brake fluid level sensor on brake fluid reservoir.
Connect hose line for clutch master cylinder on brake fluid reservoir.
Remove hose clamps 3094 from supply and return hoses.
Connect vacuum hose on throttle body.
Connect both crankcase breather hoses to cylinder head cover.

Install strut tower crossmember.
Tightening torque: 20 Nm (15 ft lb)

Turn steering wheel several times from lock-to-lock (engine not running) to bleed air from steering gear.

Note: If noises occur during the test drive, this procedure must be repeated.

Bleed brake system and check for leaks.
Bleed clutch slave cylinder.
Connect battery Ground strap.
Check hydraulic oil level and top off if necessary
Check return hose on rotary valve housing for leaks.
Check pressure hose on steering gear housing for leaks.
Adjust toe.