Power Steering Pump, Removing And Installing, 6-Cylinder Diesel Engine, Vehicles Without Dynamic Steering: Installing

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Installation is the reverse of removal, with special attention to the following:

NOTE:

Replace seals and sealing rings.

Before installing the new power steering pump on the intake side, fill the Hydraulic Oil and install it by hand until oil drains out on the high pressure side.

Secure all hose connections with new hose clamps.

Tightening specifications. Refer to OVERVIEW - POWER STEERING PUMP, VEHICLES WITH 6-CYLINDER DIESEL ENGINE, VEHICLES WITHOUT DYNAMIC STEERING .

Tightening specifications. .

-- Note the installed dimension of the clamp. The dimension -a- must be 4 mm.

Fig 1: Identifying Power Steering Pump Intake Hose Installation Dimension

GWWA48-10371

Courtesy of AUDI OF AMERICA, LLC

-- Before installing the power steering pump, connect the intake hose -1- and align the marking -5- on the power steering pump with the "P" marking -3-.

Fig 2: Identifying Intake Hose

GWWA48-10394

Courtesy of AUDI OF AMERICA, LLC

-- Secure the evacuation hose -1- with the new clamp -2-.

-- Secure the wiring harness on the supports using a new cable tie -4-.

NOTE:

The clamp -2- cannot be tightened using the Hose Clip Pliers VAG1275A when the power steering pump is installed due to restricted space.

-- Turn the hub by hand until oil runs out of the pressure side.

-- Insert the power steering pump -2-.

Fig 3: Identifying Power Steering Pump Bolts And Sleeve

GWWA48-10383

Courtesy of AUDI OF AMERICA, LLC

The sleeve -3- is driven back slightly.

-- First install the bolts -1- loosely.

-- Then install the rear bolt -4- loosely.

-- Install and tighten the bolts -1- and -4-.

-- Insert the pressure line -2- in the power steering pump and install the bolts -1- loosely.

Fig 4: Identifying Power Steering Pump Pressure Line

GWWA48-10396

Courtesy of AUDI OF AMERICA, LLC

-- Push the pressure line -2- all the way into the power steering pump. Then tighten the bolts -1-.

Fig 5: Identifying Power Steering Pump Pressure Line

GWWA48-10396

Courtesy of AUDI OF AMERICA, LLC

-- If the pressure line -C- is also attached to the A/C compressor by a bracket, then tighten the front upper A/C compressor bolt.

Fig 6: Marking Direction Of Operation Of Ribbed Belt

GWWA87-10577

Courtesy of AUDI OF AMERICA, LLC

-- Clean oiled places in engine compartment.

-- Align the marking -arrow- made on the belt pulley to the marking made on the hub.

Fig 7: Identifying Belt Pulley To Hub Marking

GWWA48-10240

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the belt pulley bolts -arrows-. .

Fig 8: Identifying Pulley Bolts

GWWA10-0340

Courtesy of AUDI OF AMERICA, LLC

-- Install the ribbed belt and then check ribbed belt alignment. .

Fig 9: Identifying Ribbed Belt Components

GWWA13-0866

Courtesy of AUDI OF AMERICA, LLC

NOTE:

When installing ribbed belt, ensure it is correctly seated in ribbed belt pulley.

Generator
Idler pulley
Idler pulley
Coolant pump
Power Steering Pump
A/C Compressor
Ribbed belt tensioner
Crankshaft

-- Fill with coolant and bleed. .

-- Install the intake manifold upper section. .

-- Check power steering fluid level. Refer to POWER STEERING FLUID LEVEL, CHECKING .

-- Bleed the steering. Refer to STEERING, BLEEDING AFTER REPLACING .

-- Check the steering for leaks. Refer to STEERING, CHECKING FOR LEAKS .

-- Install the noise insulation. Refer to OVERVIEW - NOISE INSULATION .