AUDI A4 1999 B5 / 1.G Suspension Power Steering Pump Remove And Install User Guide

48-53

Installing power steering pump (power
steering pump FP-4) m.y. 1997

- Install pressure line and tighten banjo bolt -2-.

Always replace seals
Tightening torque: 50 Nm (37 ft lb)
- Install suction hose -1-.
Mark -P- (upper arrow) must align with seam on pump (lower arrow)
- Remove 3094 hose clamps.
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- Install pressure line and tighten banjo bolt -2-.

Always replace seals
Tightening torque: 50 Nm (37 ft lb)
- Install suction hose -1-.

- Tighten socket-head bolts for coolant pump pulley.
Tightening torque: 25 Nm (18 ft lb)
- Install fan at viscous coupling.
Tightening torque: 10 Nm (7 ft lb)
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CAUTION!
Note:
Illustration is shown without the lock carrier installed for greater clarity.
Repair Manual, Body Exterior, Repair Group 63
- Install ribbed belt.
Mark the running direction before removing. Reinstalling a used
belt in reversed running direction could damage the belt. Make sure that the belt is correctly seated in the pulleys.
- Top off hydraulic fluid page 48
-22
.
- Install bumper:- Start engine and make sure ribbed belt runs properly.
- Check hydraulic fluid level page 48
-22
.
- Bleed steering system page 48
-24
.
- Check steering system for leaks page 48
-25
.
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Power steering pump (6-cyl. engine),
removing and installing

Notes:

Always replace seals.
Do not reuse hydraulic fluid.
The power steering system uses hydraulic fluid,
Part No. G 002 000.
System hydraulic fluid capacity: approx. 1 liter
(1 qt).
1 -
Pressure line with hose
2 -
Bolt
8 Nm (71 in. lb)
3 -
Plate with mounting hole At intake manifoldFor mounting line - 1 -
4 -
Power steering pump Fill with hydraulic fluid before installing
Notes, page 48
-27

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5 -
Belt pulley
6 -
Socket-head bolts
25 Nm (18 ft lb)Counterhold using VAG1590 (if applicable)
while loosening and tightening
7 -
Bolts 25 Nm (18 ft lb)
8 -
Socket-head bolts 25 Nm (18 ft lb)
9 -
Power steering pump bracket
10 -
Ignition coils with bracket
11 -
Socket-head bolt 25 Nm (18 ft lb)
12 -
Banjo bolt 40 Nm (30 ft lb)
13 -
Seals 16 x 22 Always replace
14 -
Seal 18 x 24 Always replace6 cyl. 2V gasoline engine only
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Removing 15 -
Line union
50 Nm (37 ft lb)Vehicles with V6 2V gasoline engineVehicles with power steering pump: FP-3
16 -
Clamp Always replaceUse VAG1275 to tighten
17 -
Bolts 25 Nm (18 ft lb)
18 -
Slotted bushing
19 -
Socket-head bolt 25 Nm (18 ft lb)
20 -
Bracket
21 -
Suction line with hose
22 -
Bolt 8 Nm (71 in. lb)
- Unclip and remove engine cover Fig.
1 .
-
Unbolt and remove cover for ribbed belt
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Fig. 2
.
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Installing
Note:
The ignition wires must be correctly reinstalled in
the correct firing order Fig. 4
. - Loosen and remove ribbed belt Fig. 3
.
- Counterhold belt pulley - 5 - using VAG1590 (if
applicable) and remove.
- Disconnect ignition wires from ignition coils - 10 -
.
- Pinch off suction hose using 3094 hose clamp.
- Remove pressure and suction lines.
- Unbolt bracket - 9 - and remove together with
pump - 4 -.
- Remove bolts mounting pump to bracket and
remove pump.
- Install in reverse order of removal.
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Fig. 1 Unclipping and removing top engine cover

Fig. 2 Unbolting ribbed belt cover
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CAUTION!
Mark the running direction before removing. Reinstalling a used belt
in reversed running direction could damage the belt. Fig. 3 Loosening and removing ribbed belt
- Using 17 mm hex wrench, turn clockwise (arrow) to loosen ribbed belt.
- Align holes -A- and -B-.
- Insert 3204 drift to lock tensioner in position.
- Remove ribbed belt from belt pulley.

The ignition wires are numbered from 1 to 6: Fig. 4 Assignment of ignition wires to ignition coils
A - Ignition coil for cylinders 5 and 3
B - Ignition coil for cylinders 4 and 2
C - Ignition coil for cylinders 6 and 1
- Connect ignition wires 5 and 3 to ignition coil -A-.
- Connect ignition wires 4 and 2 to ignition coil -B-.
- Connect ignition wires 6 and 1 to ignition coil -C-.
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