Service

Workshop Manual
Audi 100 1991 ➤
Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive
Edition 11.2008

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
40 - Front suspension
42 - Rear suspension
43 - Self-levelling suspension
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
44 - Wheels, tyres, vehicle geometry permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
48 - Steering

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 Audi AG, Ingolstadt 00052505220

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Repairing thread in longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Proper disposal of oil and gas-filled components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Releasing gas from shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Draining steering damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Draining power-assisted steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Checking shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Shock absorber leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Shock absorber noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Checking shock absorber following removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.4 Checking shock absorbers on shock tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Exploded view of front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Exploded view of subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Removing and installing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Front suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Exploded view of front suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 Exploded view of shock absorber, coil spring and wheel bearing housing . . . . . . . . . . . . 21
2.4 Removing and installing wheel bearing with suspension strut removed . . . . . . . . . . . . . . 27
2.5 Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.6 Removing and installing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3 Front drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.2 Exploded view of drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.3 Removing and installing drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.4 Exploded view of drive shaft with constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.5 Quantities and type of grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.6 Plastic boot (Hytrel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.7 Exploded view of drive shaft with triple roller joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.8 Quantities and type of grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1 Rear suspension - Front-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Protected by copyright.Exploded
1.2 view
Copying for private of rear suspension
or commercial purposes, in part or.in. whole,
. . . .is. not
..................................... 44
1.3 authorised
permitted unless Exploded view
by AUDI AG. AUDIofAGrear
doesaxle beamor accept
not guarantee . . . .any. . liability
...................................... 45
with respect to the correctness of information in this document. Copyright by AUDI AG.
1.4 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2 Rear suspension strut - Front-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.1 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.2 Exploded view of suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.3 Dismantling and assembling suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3 Rear wheel bearings - Front-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Contents i
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

3.2 Exploded view of wheel bearings - Vehicles with drum brakes . . . . . . . . . . . . . . . . . . . . . . 61

3.3 Exploded view of wheel bearings - Vehicles with disc brakes . . . . . . . . . . . . . . . . . . . . . . 65
4 Rear suspension - Four-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2 Exploded view of rear subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.3 Exploded view of rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.4 Exploded view of trapezium link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.5 Removing and installing trapezium link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.6 Exploded view of support for trapezium link with bonded rubber bush . . . . . . . . . . . . . . . . 85
4.7 Replacing bonded rubber bush for trapezium link support . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.8 Removing and installing transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.9 Exploded view of connecting link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.10 Exploded view of anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.11 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5 Rear suspension strut - Four-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.1 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.2 Exploded view of suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.3 Dismantling and assembling suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.4 Exploded view of suspension strut with self-levelling suspension . . . . . . . . . . . . . . . . . . . . 102
5.5 Dismantling and assembling suspension strut with self-levelling suspension . . . . . . . . . . 104
6 Rear wheel bearing - Four-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.1 Exploded view of wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
7 Rear drive shaft - Four-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.2 Exploded view of drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.3 Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7.4 Quantities and type of grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

43 - Self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

1 Self-levelling suspension - Front-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.2 Exploded view of self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.3 Checking operation of control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.4 Checking control valve for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.5 Checking pressure container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.6 Adjusting self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2 Self-levelling suspension - Four-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
2.2 Exploded view of self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
2.3 Checking operation of control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.4 Checking control valve for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.5 Checking pressure container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2.6 Adjusting self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1 Wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.2 Exploded view of steel disc wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.3 Exploded view of light alloy wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1.4 unlessBalancing
permitted wheels
authorised by AUDI on AG
AG. AUDI vehicle . . . . . .or. accept
does not guarantee . . . .any
. .liability
................................... 147
2 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

2.2 Test prerequisites for wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2.3 Wheel alignment specifications - Front-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . 149

ii Contents
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

2.4 Wheel alignment specifications - Four-wheel drive vehicles except Audi S6 Plus . . . . . . . . 149
2.5 Wheel alignment specifications - Audi S6 Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.6 Adjusting front axle camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.7 Adjusting front axle toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.8 Checking rear axle camber - Front-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2.9 Adjusting rear axle camber - Four-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2.10 Adjusting rear axle toe - Four-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1 Power-assisted steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.2 Exploded view of power-assisted steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.3 Exploded view of track rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.4 Removing and installing power-assisted steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 Power-assisted
permitted unless authorised steering
by AUDI AG.-AUDI
Audi AGS4/S6 . . . . .or. accept
does not guarantee . . . .any
. .liability
............................ 165
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.2 Exploded view of power-assisted steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

2.3 Exploded view of track rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2.4 Removing and installing power-assisted steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3 Power-assisted steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.2 Exploded view of power-assisted steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.3 Adjusting steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4 Servotronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4.2 Exploded view of Servotronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4.3 Checking power supply for Servotronic - Vehicles up to Model Year 1993 . . . . . . . . . . . . 182
4.4 Checking power supply for Servotronic - Vehicles as of Model Year 1994 . . . . . . . . . . . . 183
4.5 Checking Servotronic solenoid valve N119 - Vehicles up to Model Year 1993 . . . . . . . . . . 183
4.6 Checking Servotronic solenoid valve N119 - Vehicles as of Model Year 1994 . . . . . . . . . . 184
4.7 Checking vehicle speed signal - Vehicles as of Model Year 1994 . . . . . . . . . . . . . . . . . . . . 185
4.8 Checking wiring between Servotronic control unit J236 and connector point “1” - Vehicles up
to Model Year 1993 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
4.9 Checking wiring between Servotronic solenoid valve N119 and connector point “1” - Vehicles
up to Model Year 1993 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.10 Checking valve wiring for short to voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
4.11 Checking valve wiring for short to earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
5 Steering wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5.1 Safety precautions when working on airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5.2 Exploded view of steering wheel with airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5.3 Removing and installing steering wheel with airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.4 Exploded view of steering wheel without airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
5.5 Removing and installing steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
5.6 Removing and installing steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
5.7 Exploded view of steering column switch for adjustable steering column . . . . . . . . . . . . . . 195
5.8 Removing and installing steering column switch for adjustable steering column . . . . . . . . 196
6 Steering column with column tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
6.1 Exploded view of steering column with column tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
6.2 Removing and installing column tube with steering column . . . . . . . . . . . . . . . . . . . . . . . . 199
7 Adjustable steering column with column tube up to Model Year 1994 . . . . . . . . . . . . . . . . 202
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7.2 Exploded view of adjustable steering column with column tube . . . . . . . . . . . . . . . . . . . . 202
7.3 Removing and installing column tube with adjustable steering column . . . . . . . . . . . . . . . . 205
7.4 Replacing steering column adjustment cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
7.5 Adjusting steering column adjustment cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Contents iii
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

8 Adjustable steering column - Vehicles as of Model Year 1995 . . . . . . . . . . . . . . . . . . . . . . 211

8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
8.2 Exploded view of adjustable steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
8.3 Replacing steering column adjustment cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
8.4 Adjusting steering column adjustment cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
9 Hydraulic pipes, reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
9.2 Exploded view of hydraulic fluid circuit for power-assisted steering . . . . . . . . . . . . . . . . . . 215
9.3 Exploded view of reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
10 Vane pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
10.2 Exploded view of vane pump - Vehicles with 4-cyl. engine . . . . . . . . . . . . . . . . . . . . . . . . 218
10.3 Exploded view of vane pump - Vehicles with 5-cyl. engine . . . . . . . . . . . . . . . . . . . . . . . . 221
10.4 Exploded view of vane pump - Vehicles with 6-cyl. 2V engine . . . . . . . . . . . . . . . . . . . . . . 222
10.5 Removing and installing vane pump - Vehicles with 6-cyl. 2V engine . . . . . . . . . . . . . . . . 224
10.6 Exploded view of vane pump - Vehicles with 6-cyl. 5V engine . . . . . . . . . . . . . . . . . . . . . . 226
10.7 Removing and installing vane pump - Vehicles with 6-cyl. 5V engine . . . . . . . . . . . . . . . . 227
11 Vane pump delivery pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
11.1 Checking delivery pressure of vane pump - Vehicles with 4-cyl. engine . . . . . . . . . . . . . . 231
11.2 Checking delivery pressure of vane pump - Vehicles with 5-cyl. engine . . . . . . . . . . . . . . 233
11.3 Checking delivery pressure of vane pump - Vehicles with 6-cyl. 2V engine . . . . . . . . . . . . 235
11.4 Checking delivery pressure of vane pump - Vehicles with 6-cyl. 5V engine . . . . . . . . . . . . 237
11.5 Checking delivery pressure of vane pump - Audi S4/S6 and Audi S6 Plus with 8-cyl.
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
12 Tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
12.2 Exploded view - Vehicles with 4-cyl. engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
12.3 Exploded view - Vehicles with 5-cyl. engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
12.4 Exploded view - Audi S4/S6 with 5-cyl. turbo engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
12.5 Exploded view - Vehicles with 6-cyl. engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
12.6 Removing and installing tandem pump - Vehicles with 6-cyl. engines . . . . . . . . . . . . . . . . 251
12.7 Exploded view - Audi S4/S6 and Audi S6 Plus with 8-cyl. engine . . . . . . . . . . . . . . . . . . . . 253
13 Plunger pump delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
13.1 Checking delivery of plunger pump - Vehicles with 4-cyl. engine . . . . . . . . . . . . . . . . . . . . 255
13.2 Checking delivery of plunger pump - Vehicles with 5-cyl. engine . . . . . . . . . . . . . . . . . . . . 256
13.3 Checking delivery of plunger pump - Vehicles with 6-cyl. 2V and 5V engine . . . . . . . . . . . . 257
13.4 Checking delivery of plunger pump - Audi S4/S6 and Audi S6 Plus with 8-cyl. engine . . . . 259
14 Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
14.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
14.2 Removing and installing tandem pump - Audi S4/S6 with 5-cyl. turbo engine . . . . . . . . . . 262
14.3 Removing and installing tandem pump - Audi S4/S6 with 8-cyl. engine . . . . . . . . . . . . . . 266
14.4 Checking and adjusting poly V-belt alignment - Audi S4/S6 with 5-cyl. and 8-cyl. engine
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
14.5 Removing and installing tandem pump - Audi S6 Plus with 8-cyl. engine . . . . . . . . . . . . . . 271
14.6 Checking and adjusting poly V-belt alignment - Audi S6 Plus with 8-cyl. engine . . . . . . . . 274
15 Checking fluid level, bleeding steering system, checking for leaks . . . . . . . . . . . . . . . . . . 276
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
15.1 Checking power steering fluid level . . unless
permitted . . . .authorised
. . . . . by
. .AUDI
. . .AG.
. . AUDI
. . . AG
. . does
. . .not
. .guarantee
. . . . . or. .accept
. . . any
. . liability
. . 276
15.2 Bleeding steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
with respect to the correctness of information in this document. Copyright by AUDI AG.

15.3 Checking steering system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

iv Contents
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

00 – Technical data
1 Technical data
⇒ “1.1 Running gear”, page 1
⇒ “1.2 Steering”, page 1

1.1 Running gear Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Determine the running gear version from the vehicle data sticker.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

The vehicle data sticker can be found in the spare wheel recess
at the rear and in the service schedule.

♦ 1BA = Standard running gear

♦ 1BE = Sports running gear
♦ 1BG = Standard running gear with self-levelling suspension at
rear
Front and four-wheel drive
Standard running gear (1BA) Sports running gear (1BE)
Self-levelling suspension (1BG)
Front-wheel drive Four-wheel drive Front-wheel drive Four-wheel drive
Wheelbase 1) in mm 2687 2692 2687 2692
Front track 1) in mm 1520 1520 1526 1526
S-models: 1563
Rear track 1) in mm 1524 1524 1524 1528
• 1) at kerb weight

1.2 Steering
Front and four-wheel drive
Steering box Power-assisted steering box
Maximum steering angle 40°
Turning circle diameter approx. 11.4 m

1. Technical data 1
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

2 General
⇒ “2.1 General information”, page 2
⇒ “2.2 Contact corrosion”, page 2
⇒ “2.3 Repairing thread in longitudinal member”, page 3

2.1 General information

♦ Welding and straightening operations are not permitted on
loadbearing or suspension components.
♦ Always replace self-locking bolts and nuts.
♦ Always replace corroded bolts/nuts.
♦ The tightening torques stated apply to non-lubricated bolts and
nuts.
♦ The contact surfaces must be cleaned when fitting waxed
components. Contact surfaces must be free from wax and
grease. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Drive shafts with respect to the correctness of information in this document. Copyright by AUDI AG.

Do not attempt to move a vehicle without the drive shaft fitted as

this would result in wheel bearing damage. If a vehicle has to be
moved, always heed the following:
– Fit an outer joint instead of the drive shaft.
– Tighten the outer joint to 50 Nm.
Coil springs
♦ Always take care to avoid the following in conjunction with coil
springs: Hammer blows, weld spatter, subsequent application
of coloured marks
♦ Never perform welding or grinding (separating) operations in
the area of the coil spring or suspension struts. Cover the coil
spring or suspension struts if appropriate.
Bonded rubber bushes
♦ Bonded rubber bushes can only be turned to a limited extent.
The bolted joints at the suspension links are therefore not to
be tightened until the vehicle is in the kerb weight or reference
position.
♦ If wheel alignment is subsequently to be performed, the bolts
and nuts unfastened for adjustment work are only tightened to
torque. These bolts and nuts are then to be finish-tightened by
the specified extra turn on completion of wheel alignment/ad‐
justment.

WARNING

All bolts and nuts must be properly tightened on vehicles being

driven on public roads.

2.2 Contact corrosion

Contact corrosion can occur if use is made of unsuitable con‐
necting elements (bolts, nuts, washers ...).
For this reason, only connecting elements with a special surface
coating are fitted.
In addition, rubber or plastic parts and adhesives are made of
non-conductive material.

2 Rep. Gr.00 - Technical data

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

In cases of doubt about suitability, always use new parts ⇒ Elec‐

tronic parts catalogue .
Important:
♦ We recommend the use of genuine replacement parts only, as
these have been checked and are compatible with aluminium.
♦ We advise using Audi accessories.
♦ Damage caused by contact corrosion is not covered by war‐
ranty.

2.3 Repairing thread in longitudinal member

Given certain conditions it is possible to repair the thread in the
weld nuts in the longitudinal member.
♦ Each thread is only to be repaired once.
♦ If a second repair is needed, the weld nut must be replaced.

WARNING

Always wear safety goggles when drilling.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Have the thread repair checked by the foreman or immediate

superior.
♦ The threaded insert must be of the same length as the thread
in the body.
♦ Eliminate any damage to the underseal; refer to ⇒ General
information; Body repairs, General body repairs.

2. General 3
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

3 Proper disposal of oil and gas-filled

components
⇒ “3.1 Releasing gas from shock absorbers”, page 4
⇒ “3.2 Draining steering damper”, page 5
⇒ “3.3 Draining power-assisted steering box”, page 5

3.1 Releasing gas from shock absorbers

A - Drilling open
– Clamp the gas-filled shock absorber vertically in a vice with
the piston rod facing downwards.

WARNING
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Wear safety goggles whilst drilling.

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Drill a Ø 3 mm hole -arrow A- through the outer tube of the

damper.

Note

Gas escapes whilst doing so.

– Keep drilling until the inner tube is fully penetrated (approx. 25

mm deep).
– Drill a second Ø 6 mm hole -arrow B- through the outer and
inner tube of the damper.
– Hold the damper over a drip tray and execute a full piston rod
stroke several times until no further oil emerges.

B - Opening with chain pipe cutter -VAS 6254-

WARNING

Wear safety goggles whilst drilling and sawing.

– Drill a Ø 3 mm hole -arrow- through the outer tube of the

damper/saw through the tube wall.

Note

Gas escapes whilst drilling/sawing.

– Apply the chain pipe cutter -VAS 6254- as shown and cut
through the outer tube.
– Pull the piston rod upwards. At the same time hold the inner
tube securely with pliers and press it downwards, so that it
remains in the outer tube on slowly pulling up the piston rod.
– Detach the piston rod from the inner tube.
– Drain the shock absorber tube.

4 Rep. Gr.00 - Technical data

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

3.2 Draining steering damper

– Clamp the steering damper horizontally in a vice.

WARNING

Wear safety goggles whilst sawing.

– Make a saw cut in the steering damper at the locations

marked.
♦ -Arrow A- = 30 mm from end of tube
♦ -Arrow B- = 10 mm from end of tube
– Hold the damper over a drip tray and execute a full piston rod
stroke several times until no further oil emerges.

3.3 Draining power-assisted steering box

• The ambient temperature should be at least 20 °C when drain‐
ing the steering box.
– Turn the steering pinion as far as it will go in
-arrow direction-.
– Clamp the steering box horizontally in a vice.

– Place a drip tray beneath the steering box.

– Saw off the steering box at the location marked by -arrow A-.
– Hold the sawn off steering box over the drip tray and drain off
the hydraulic fluid. If necessary, turn the steering pinion onto
the opposite stop.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Proper disposal of oil and gas-filled components 5

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

4 Checking shock absorbers

⇒ “4.1 Shock absorber leakage”, page 6
⇒ “4.2 Shock absorber noise”, page 6
⇒ “4.3 Checking shock absorber following removal”, page 6
⇒ “4.4 Checking shock absorbers on shock tester”, page 7

4.1 Shock absorber leakage

Complaints are often received about leaking shock absorbers
which are then replaced. Inspections on a test bench and in the
vehicle have shown that - in the majority of cases - such replace‐
ment is not justified.
Slight discharge of oil ("sweating") at the piston rod seal is not a
reason for shock absorber replacement. Shock absorbers with a
slight discharge of oil are OK under the following conditions:
♦ Emergence of oil (hatched area in illustration) visible, but dull,
matt and possibly dust dry.
♦ Emergence of oil does not extend beyond upper shock ab‐
sorber seal (piston rod oil seal) and lower spring plate
-arrow-.

Note

A slight discharge of oil is beneficial, as it lubricates the piston rod

seal and thus extends the service life. This applies to both front
and rear shock absorbers.

4.2 Shock absorber noise

Complaints are often received about rattling shock absorbers
which are then replaced. Inspections on a test bench and in the
vehicle have shown that in roughly 70 % of cases the shock ab‐
sorbers are not defective and such replacement is not justified.
Proceed as follows in the event of complaints which are interpre‐
ted as rattling or clicking noise:
– Perform a test drive with the customer - if at all possible on a
dry uneven road surface - to establish where, when and how
the noise becomes apparent.

Note

The shock absorber is hardly ever the cause of the noise.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4.3 Checking shock absorber following re‐
moval
Defective shock absorbers become apparent whilst driving on
account of loud rattling noises - as a result of wheel jumping -
particularly on uneven surfaces. A further visible sign is severe oil
loss.

6 Rep. Gr.00 - Technical data

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Note

Shock absorbers are maintenance-free; the shock absorber oil

cannot be replenished.

Following removal, a shock absorber can be checked by hand as

follows:
– Squeeze the shock absorber by hand.
• The piston rod should move smoothly over the entire stroke
with uniform resistance and without jolts.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Release the piston rod.unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
with respect to the correctness of information in this document. Copyright by AUDI AG.
• Gas-filled dampers: Given adequate shock absorber gas pres‐
sure, the piston rod returns automatically to its initial position.

Note

♦ If this is not the case, it is not absolutely essential to replace

the shock absorber. Provided there has been no major loss of
oil, the mode of operation corresponds to that of a conven‐
tional shock absorber.
♦ The damping effect is fully maintained even without gas pres‐
sure provided there has been no major loss of oil. The noise
level may however increase.

4.4 Checking shock absorbers on shock

tester
The shock tester (shock absorber tester) permits in situ checking
of shock absorbers. The damping effect can be assessed on the
basis of the pointer deflection or the printout.
Special tools and workshop equipment required
♦ Boge shock tester or
♦ Sachs shock tester -V.A.G 1975-
♦ Running gear tester -VAS 1990S-
Test requirements
• Temperature +10 ... +40 °C
• Driver in vehicle
• Correct inflation pressure
• Vehicle positioned centrally and straight on contact patches
• Front wheels in straight ahead position
• Handbrake not applied, foot brake not pressed
Limit values
The shock absorber condition can only be assessed as follows:
♦ Adequate damping effect or
♦ Inadequate damping effect

4. Checking shock absorbers 7

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Note

♦ Intermediate readings for reduced damping action are not

possible.
♦ Service life forecasts are not permissible.
♦ Measured values obtained with the action of the spring travel
end stops are biased.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

8 Rep. Gr.00 - Technical data

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

40 – Front suspension
1 Front suspension
⇒ “1.1 Exploded view of front suspension”, page 9
⇒ “1.2 Exploded view of subframe”, page 13
⇒ “1.3 Removing and installing subframe”, page 15

1.1 Exploded view of front suspension

1 - Bolt
2 - Self-locking nut, 40 Nm
❑ Always replace after re‐
moving Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Washer permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4 - Bonded rubber bush
❑ Always replace after re‐
moving
❑ Installation position:
Ribbed side facing up‐
wards
❑ Extracting ⇒ page 12
❑ Fitting ⇒ page 12
5 - Bolt
❑ Always replace after re‐
moving
❑ 110 Nm + further 90°
turn
6 - Bonded rubber bush
7 - Bolt
❑ Always replace after re‐
moving
8 - Subframe
❑ Removing and installing
⇒ page 15
❑ Wheel alignment is only
necessary if the bonded
rubber bushes for the
subframe at the rear
have been unfastened
or removed
⇒ Item 11 (page 14)
9 - Self-locking nut, 65 Nm
❑ Always replace after removing
10 - Sleeve
❑ Fit flush in subframe
❑ Extracting ⇒ page 13 and ⇒ page 13
11 - Inner bush for wishbone
❑ Pressing out and pressing in ⇒ page 11
❑ Installation position ⇒ page 12
❑ Bush/wishbone projection ⇒ page 12

1. Front suspension 9
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

❑ A modified bush was fitted as of vehicle ident no. NN 107 874 or PN 000 433
❑ Only the modified bush is available as replacement part, the installation specifications as per
⇒ page 12 thus no longer apply
12 - Washer
13 - Self-locking nut
❑ Always replace after removing
❑ 120 Nm + further 90° turn
14 - Outer bush for wishbone
15 - Wishbone
❑ Different on left and right;
Protected for assignment
by copyright. referorto
Copying for private ⇒ Electronic
commercial parts
purposes, in part or catalogue
in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ On removal and installation,
with respect toremove the ofsleeve
the correctness ⇒ inItem
information 10 (page
this document. 9) and
Copyright unscrew
by AUDI AG. the anti-roll bar clamps
⇒ Item 17 (page 10)

Note

On vehicles with 6-cyl. engine, re‐

move the entire subframe
⇒ page 15 .

16 - Rubber bush
❑ Pay attention to anti-roll bar diameter; for assignment refer to ⇒ Electronic parts catalogue
17 - Anti-roll bar clamp
18 - Self-locking nut, 100 Nm
❑ Always replace after removing
19 - Anti-roll bar
❑ Removing and installing
– Vehicle standing on its wheels.

– Unscrew the anti-roll bar clamps ⇒ Item 17 (page 10) .

– Unscrew the nuts ⇒ Item 13 (page 10) .

– The anti-roll bar is pulled out/inserted on extending and compressing the suspension.

Note

On vehicles with 6-cyl. engine, re‐

move the entire subframe
⇒ page 15 .
❑ Different diameters; for assignment refer to ⇒ Electronic parts catalogue
20 - Washer
❑ Always replace after removing
❑ Fit with ribbed side facing upwards
21 - Bolt
❑ Always replace after removing
❑ 110 Nm + further 90° turn

10 Rep. Gr.40 - Front suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Special tools and workshop

equipment required
♦ Thrust plate -VW 402-
♦ Press tool -VW 412-
♦ Pressing-on sleeve -VW
455-
♦ Pipe -32 - 119-
♦ Thrust pad -3051-
♦ Thrust pad -3124-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Pressing out/pressing in inner bush for wishbone

Note

♦ On pressing in, the side of the wishbone eye with the greater
chamfer faces the wishbone bush.
♦ Align the bush ⇒ page 12 and press in.

1. Front suspension 11
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Installation position of inner bush in wishbone

Note

The marking -B- on the wishbone bush may deviate from the cen‐
tre line -C- by ± 5°.

The previously applicable installation specifications can be ignor‐

ed when fitting a modified bush as of vehicle ident. no. NN 107
874 or PN 000 433.

Wishbone bush/wishbone projection

• -a- = 4.5 mm ± 0.8 mm.

Extracting bonded rubber bush from subframe

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
a - Threaded spindle M10, approx. 200 mm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
b - Nut M10
c - Packing plate with 12 mm inside diameter
– Keep tightening the nut -arrow B- until the bush is extracted
from the subframe.

Note

The pipe -32 - 119- must not rest on the collar of the bush.

Fitting bonded rubber bush in subframe

– Moisten the bush with assembly lubricant; for assembly lubri‐
cant refer to ⇒ Electronic parts catalogue .
– Fit the bonded rubber bush by turning the nut -arrow B-.

12 Rep. Gr.40 - Front suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Inserting extractor in sleeve

– Screw out the subframe bolt.
– Insert the extractor e.g. -Kukko 21/2- .
– Tighten the nut until the two jaws of the puller are spread apart
in the sleeve.
– Insert a suitable screwdriver in the extractor to provide sup‐
port.

Extracting sleeve

Note

The vehicle must be standing on its wheels for extracting the

sleeve.

– Screw a puller, e.g. -Kukko 22/1- onto the thread of the ex‐
tractor until the two jaws are resting on the subframe.
– Screw the nut onto the spindle of the puller until the sleeve is
extracted.

1.2 Exploded view of subframe

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Front suspension 13
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Subframe
❑ Removing and installing
⇒ page 15
❑ Wheel alignment is only
necessary if the bonded
rubber bushes for the
subframe at the rear
have been unfastened
or removed
⇒ Item 11 (page 14)
2 - Washer
❑ Always replace after re‐
moving
❑ Fit with ribbed side fac‐
ing upwards
3 - Bolt
❑ Always replace after re‐
moving
❑ 110 Nm + further 90°
turn
❑ If internal thread is dam‐
aged or bolts have bro‐
ken off, refer to
⇒ page 3
4 - Washer
❑ Always replace after re‐
moving
❑ Lug of washer engages
in recess at subframe
5 - Bolt
❑ Always replace after re‐
moving
❑ 110 Nm + further 90°
turn
6 - Self-locking nut, 40 Nm
❑ Always replace after removing
7 - Bonded rubber bush
8 - Longitudinal member
9 - Self-locking nut, 65 Nm
❑ Always replace after removing
10 - Bolt
❑ Always replace after removing
❑ Installation position: Bolt head facing rear axle
11 - Bonded rubber bush
❑ Different versions ⇒ Electronic parts catalogue
❑ Front axle
Protected wheelCopying
by copyright. alignment must
for private be performed
or commercial after
purposes, in part or inremoval
whole, is notand installation
❑ Before tightening the bolts ⇒ Item 12 (page 15) , centrally
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept align the subframe:
any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Loosely screw in both bonded rubber bushes with the bolts ⇒ Item 12 (page 15) .

– Loosely screw in the subframe with the bolts ⇒ Item 3 (page 14) and ⇒ Item 5 (page 14) .

– Centrally align the subframe with respect to the bolts ⇒ Item 12 (page 15) by moving it sideways in the
elongated holes of the bonded rubber bushes.

– Tighten all the bolts to torque.

14 Rep. Gr.40 - Front suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Perform wheel alignment.

12 - Bolt
❑ Always replace after removing
❑ 40 Nm + further 90° turn

1.3 Removing and installing subframe

Special tools and workshop

equipment required
♦ Support bar -10 - 222 A-
♦ Frame -10 - 222 A /1-
♦ Gearbox support -3147-
♦ Torque wrench -V.A.G
1332-
♦ Engine and gearbox lifter -
V.A.G 1383 A-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Removing
Vehicles with 4-cyl. engine:
– Fit the support bar -10 - 222 A- with the frame -10 - 222 A /1- .

1. Front suspension 15
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Vehicles with 5-cyl. engine:

– Detach the distributor cap.
– Remove the engine/gearbox connecting bolt at the top left.
– Fit the support bar -10 - 222 A- with the frame -10 - 222 A /1-
and the gearbox support -3147- .

Vehicles with 6-cyl. engine:

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Fit the support barpermitted
-10 - 222unlessA- with the
authorised frame
by AUDI -10 AG
AG. AUDI - 222
doesA
not/1- .
guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Vehicles with 8-cyl. engine:

– Completely remove the anti-roll bar, air pipes and air cleaner
housing ⇒ page 159 .
– Fit the support bar -10 - 222 A- with the frame -10 - 222 A /1-
and the gearbox support -3147- .

Note

The illustration shows the support bar with the engine removed
for greater clarity.

All vehicles (continued):

– Slightly pre-tension the engine/gearbox assembly by way of
the spindles.
– Remove the wheels.
– Remove the noise insulation.

– Screw out the joint pin bolts.

16 Rep. Gr.40 - Front suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Unscrew the gearbox mounting nut -arrow-.

Vehicles with 4 and 5-cyl. engine:

– Unscrew the wires from the subframe.
Vehicles with 5-cyl. engine:
– Unscrew the protective conduit for the alternator wire at the
subframe.
All vehicles (continued):
– Position the engine and gearbox lifter -V.A.G 1383 A- under
the subframe.
– Screw out the subframe bolts.
– Lower the subframe with the engine and gearbox lifter -V.A.G
1383 A- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Front suspension 17
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Installing
– Align the pins of the ball joints with respect to the wheel bearing
housings on both sides such that the two joint pins can be
inserted in the wheel bearing housing -arrow-.

Note

Take care not to damage the bellows of the wishbones on insert‐

ing the joint pins.

– Insert new joint pin clamping bolts on both sides.

• Bolt head faces rear axle.
– Fit new subframe bolts and packing plates at the rear.

Note

The locating lug of the subframe bushes at the rear must engage
in the recess of the subframe.

– Raise the subframe further until both nuts for securing the
gearbox mountings can be inserted.

Note

The locating lug of the gearbox carrier bushes at the rear must
engage in the recess of the subframe.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Fit new subframe bolts and packing plates at the front.

Note

The ribs of the packing plates face the subframe.

– Lower the gearbox lifter.

– Tighten the subframe, gearbox carrier bushes and ball joint
clamping bolts to torque.
– Screw the wires to the subframe.
– Fit the noise insulation.
– Fit the wheels: Steel disc wheel ⇒ page 144 , light alloy wheel
⇒ page 146 .
– Remove the support bar -10 - 222 A- .

18 Rep. Gr.40 - Front suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

2 Front suspension strut

⇒ “2.1 Exploded view of front suspension strut”, page 19
⇒ “2.2 Removing and installing suspension strut”, page 20
⇒ “2.3 Exploded view of shock absorber, coil spring and wheel
bearing housing”, page 21
⇒ “2.4 Removing and installing wheel bearing with suspension
strut removed ”, page 27
⇒ “2.5 Removing and installing coil spring”, page 29
⇒ “2.6 Removing and installing shock absorber”, page 31

2.1 Exploded view of front suspension strut

1 - Trim cap
❑ Arrow faces wheel
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Self-locking nut, 30 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
3 - Washer
4 - Suspension strut dome
5 - Track rod
6 - Self-locking nut, 50 Nm
❑ Always replace after re‐
moving
7 - Drive shaft
❑ Need not be removed to
take out the suspension
strut
8 - Self-locking nut, 65 Nm
❑ Always replace after re‐
moving
9 - Suspension strut
❑ Removing and installing
⇒ page 20
❑ Exploded view
⇒ page 21
10 - Bolt
❑ Always replace after re‐
moving
11 - Bolt
❑ Always replace after re‐
moving
❑ 190 Nm + further 180°
turn
❑ The vehicle must be
standing on its wheels when slackening off and tightening - risk of accident
❑ Switched from hexagon head to hexagon socket. Combined fitting is permissible
12 - Wishbone

2. Front suspension strut 19

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

2.2 Removing and installing suspension

strut
♦ Suction grip -3208-

Removing
– Detach the wheel trim. Use the suction grip -3208- to remove
the trim cap on vehicles with light alloy wheels.
– Screw out the drive shaft bolt (only slacken off with vehicle
standing on its wheels - risk of accident).
– Remove the wheel.
– Vehicles with ABS: Pull out the speed sensor.
– Remove the noise insulation.
– Remove the bearing shell -arrows-.
– Vehicles with 6-cyl. engine: Remove the entire subframe
⇒ page 15 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Screw both bolts -top arrows- out of the brake caliper and take
out.
– Detach the brake caliper housing and set down such that the
weight of the brake caliper does not strain or damage the brake
hose.
– Detach the brake disc.
– Remove the clamping bolt -bottom arrow-.

20 Rep. Gr.40 - Front suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Press out the joint pin.

Note

Take care not to damage the boot of the guide joint when pressing
out the joint pin.

– Use a tubular section (approx. 1.5 m long) if the joint pin is very
firm.
• The slots in the wheel bearing housing are never to be en‐
larged using a chisel or similar.
– Unscrew the nut from the track rod joint.

– Press the track rod off the steering arm.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Detach the cap. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unscrew the suspension strut at the top -arrows-. Hold at the

bottom whilst doing so and then detach from the drive shaft.
Installing
Install in reverse order.

2.3 Exploded view of shock absorber, coil spring and wheel bearing housing

2. Front suspension strut 21

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - End cap
2 - Buffer stop
❑ For assignment, refer to
⇒ Electronic parts cata‐
logue
3 - Cap 240 Nm
❑ Screwing on and un‐
screwing ⇒ page 31
4 - Piston rod
❑ Support with Allen key by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
when unfastening/tight‐
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
ening nut with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ Item 10 (page 23)
5 - Shock absorber
❑ For assignment, refer to
⇒ Electronic parts cata‐
logue
❑ Vehicles with sports
running gear are fitted
with gas-filled dampers
❑ Checking ⇒ page 6
❑ Heed PR no. (factory
code) on vehicle data
sticker prior to replace‐
ment ⇒ page 1
❑ Disposal ⇒ page 4
6 - Wheel bearing housing
❑ A modified wheel bear‐
ing housing with an ap‐
prox. 10 mm lower
steering arm was fitted
as of vehicle ident no.
PN 001 984
❑ Do not widen the slots in
the wheel bearing housing to press out the joint pin
❑ The Audi S4 is provided with a three-point brake caliper mount (internal caliper disc brake)
❑ The Audi S4/S6 4.2 is provided with a two-point brake caliper mount (dual-piston brake caliper).
7 - Wheel bearing
❑ Can also be replaced using -V.A.G 1459 B- and -V.A.G 1459 B/2- with the suspension strut fitted
❑ Stepped inside diameter
❑ Installation position: Large inside diameter of wheel bearing facing wheel hub
With suspension strut removed:
❑ Pressing out ⇒ page 28
❑ Pressing in ⇒ page 28
8 - Wheel hub
❑ Can also be replaced using -V.A.G 1459 B- and -V.A.G 1459 B/2- with the suspension strut fitted
❑ Different versions ⇒ Electronic parts catalogue
❑ Stepped
With suspension strut removed:
❑ Pressing out ⇒ page 27
❑ Detaching bearing inner race ⇒ page 27
❑ Pressing in ⇒ page 28

22 Rep. Gr.40 - Front suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

9 - Self-locking nut, 55 Nm
❑ Always replace after removing
10 - Self-locking nut, 60 Nm
❑ Always replace after removing
❑ Tightening ⇒ page 31
11 - Stop
❑ Different versions ⇒ Electronic parts catalogue
12 - Suspension Protected
strut mount
by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Mark installation
permittedposition
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
13 - Support plate
14 - Axial deep groove ball bearing
15 - Spring plate
16 - Protective collar
17 - Protective sleeve
❑ Fit lower end on screw cap ⇒ Item 3 (page 22) , upper end on spring plate ⇒ Item 15 (page 23)
18 - Packing ring
❑ Insert in spring plate ⇒ Item 15 (page 23)
❑ Different thicknesses
❑ Can be identified by the studs on the underside
19 - Coil spring
❑ Surface of spring winding must not be damaged
❑ Pay attention to coloured mark, faces downwards; for assignment refer to ⇒ Electronic parts catalogue
❑ Heed PR no. (factory code) on vehicle data sticker prior to replacement ⇒ page 1
❑ Removing ⇒ page 29
❑ Installing ⇒ page 30

2. Front suspension strut 23

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Special tools and workshop

equipment required
♦ Fitting tool for crankshaft
seal -VW 204 B-
♦ Adapter -VW 295 A-
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-
♦ Press tool -VW 407-
♦ Press tool -VW 408 A-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

24 Rep. Gr.40 - Front suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ Press tool -VW 412-

♦ Pressing-on sleeve -VW
455-
♦ Thrust plate -30 - 11-
♦ Pipe wrench for damper
cartridge -2069 A-
♦ Thrust plate -3005-
♦ 22 mm socket attachment
-3078-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Front suspension strut 25

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ Thrust piece -3124-

♦ Sleeve -3144-
♦ Torque wrench -V.A.G
1332-
♦ Torque wrench -V.A.G
1576-
♦ Suspension strut tensioner
-V.A.G 1752-

♦ Hydraulic removal and installation tool -V.A.G 1459B- with

supplementary set -V.A.G 1459B/2-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

26 Rep. Gr.40 - Front suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ Shock absorber set -T10001-

2.4 Removing and installing wheel bearing

with suspension strut removed
Removing
– Remove the suspension strut ⇒ page 20 .
– Press the wheel hub out of the wheel bearing housing.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Detach the bearing inner race from the wheel hub.

Note

Always use a puller with tensioner e.g. -Kukko 204-2- .

2. Front suspension strut 27

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Press the wheel bearing out of the wheel bearing housing.

Installing
Install in reverse order, paying attention to the following:
– Press the wheel bearing into the wheel bearing housing.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Large inside
permitted diameter
unless authorised of wheel
by AUDI bearing
AG. AUDI faces
AG does wheelorhub.
not guarantee accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
• The wheel bearing housing is not to be greased before press‐
ing in the wheel bearing.
• The chamfered side of the sleeve -3144- faces the fitting tool
for crankshaft seal -VW 204 B- .

– Press the wheel hub into the wheel bearing.

– When pressing in, only allow the pressing-on sleeve -VW 455-
to rest on the bearing inner race.

28 Rep. Gr.40 - Front suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

2.5 Removing and installing coil spring

Note

Note the different versions of the components for the “Standard,

sports and heavy-duty models”.

Removing
– permitted
Remove unlessthe suspension strut
AUDI⇒
AGpage 20 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
authorised by AUDI AG. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Clamp the suspension strut holder -V.A.G 1752/2- in the vice.
– Insert the suspension strut in the suspension strut holder -
V.A.G 1752/2- .

– Pre-tension the coil spring with the spring tensioner -V.A.G

1752/1- until the upper spring plate is free.

– Make sure the coil spring is positioned correctly in the spring

holder -V.A.G 1752/7- -arrow-.

2. Front suspension strut 29

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Unscrew the nut from the piston rod whilst providing support
with an Allen key.
– Detach the individual components of the suspension strut and
coil spring with the spring tensioner -V.A.G 1752/1- .

Note

Instead of the 22 mm socket attachment -3078- , use can be made

of the shock absorber set -T10001- .

Installing
– Tension the new spring, paying attention to the coloured mark‐
ing -arrow-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Pull the piston rod as far as it will go out of the shock absorber.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Position the coil spring with the spring tensioner -V.A.G
1752/1- on the spring seat.
– Fit the spring plate with packing plate on the coil spring.
– The end of the spring must make contact with the stop of the
spring seat.

– Tighten the nut of the shock absorber piston rod to 60 Nm.

Note

Instead of the 22 mm socket attachment -3078- , use can be made

of the shock absorber set -T10001- .

– Slacken off the coil spring.

– Detach the spring tensioner.
– Insert the protective sleeve in the spring plate.

30 Rep. Gr.40 - Front suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

2.6 Removing and installing shock absorber

Removing

Note

Replace the shock absorber with the suspension strut fitted (ve‐
hicle standing on its wheels).

– Detach the cap.

– Unscrew the nut for the upper damper mount.
– Mark the installation position of the suspension strut mount
(camber adjustment).
– Remove the suspension strut mount.
– Turn the steering wheel such that the piston rod can be cen‐
trally aligned with the support plate (jam wooden block be‐
tween spring and wheel housing).
– Detach the washer and buffer stop from the piston rod.

– Detach the protective sleeve from the cap.

– Unscrew the cap using a pipe wrench for damper cartridge
-2069 A- or -2069- .
– Take out the shock absorber.
Installing
– Fit the shock absorber.
– Tighten the cap to 240 Nm using a pipe wrench for damper
cartridge -2069 A- or -2069- .
– Fit the protective sleeve on the cap.

– Tighten the nut of the shock absorber piston rod to 60 Nm.

Note

Instead of the 22 mm socket attachment -3078- , use can be made

of the shock absorber set -T10001- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Front suspension strut 31

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

3 Front drive shaft

⇒ “3.1 General ”, page 32
⇒ “3.2 Exploded view of drive shaft”, page 32
⇒ “3.3 Removing and installing drive shafts”, page 36
⇒ “3.4 Exploded view of drive shaft with constant velocity joint”,
page 36
⇒ “3.5 Quantities and type of grease”, page 39
⇒ “3.6 Plastic boot (Hytrel) ”, page 40
⇒ “3.7 Exploded view of drive shaft with triple roller joint”,
page 40
⇒ “3.8 Quantities and type of grease”, page 43

3.1 General

Note

Heed the general information ⇒ page 2 .

3.2 Exploded view of drive shaft

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

32 Rep. Gr.40 - Front suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Gearbox
2 - Seal
❑ Vehicles with constant
velocity shaft only
❑ Replace
3 - Drive shaft with constant
velocity joint
❑ For vehicles with man‐
ual gearbox
❑ Removing and installing
⇒ page 36
❑ Exploded view
⇒ page 36
4 - Packing plate
5 - Bolt
❑ M8: 40 Nm
❑ M10: 77 Nm
6 - Bolt, 77 Nm
7 - Drive shaft with triple roller
joint
❑ Removing and installing
⇒ page 36
❑ Exploded view
⇒ page 40
8 - Suspension strut
9 - Bolt
❑ Always replace after re‐
moving
❑ 190 Nm + further 180°
turn
❑ The vehicle must be
standing on its wheels when slackening off and tightening - risk of accident
❑ Switched from hexagon head to hexagon socket. Combined fitting is permissible

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Front drive shaft 33

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Special tools and workshop

equipment required
♦ Circlip pliers -VW 161 A-
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-
♦ Press tool -VW 408 A-
♦ Support sleeve -VW 522-
♦ Tensioner -40 - 204 A-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

34 Rep. Gr.40 - Front suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ Pressure screw -3207-

♦ Suction grip -3208-
♦ Torque wrench -V.A.G
1331-
♦ Torque wrench -V.A.G
1332-
♦ Wedges -V.A.G 1474/5-
from parting tool for bonded
windows -V.A.G 1474B-
♦ Tensioning tool -V.A.G
1682-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Front drive shaft 35

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

3.3 Removing and installing drive shafts

Removing
– Detach the wheel trim. Use the suction grip -3208- to remove
the trim cap on vehicles with light alloy wheels.
– Screw out the drive shaft/wheel hub bolt (only slacken off with
vehicle standing on its wheels - risk of accident).
– Remove the wheel.
– Vehicles with ABS: Pull the speed sensor slightly out of the
wheel bearing housing.
– Unscrew the drive shaft from the flange shaft/gearbox.
– Turn the steering wheel accordingly and take out the drive
shaft.
Installing
– Replace the seal on drive shafts with an inner constant velocity
joint.
– Insert the drive shaft in the wheel bearing housing and bolt to
the flange shaft.
– Vehicles with ABS: Press home the speed sensor in the wheel
bearing housing.
– Fit the wheel: Steel disc wheel ⇒ page 144 , light alloy wheel
⇒ page 146 .
– Tighten the drive shaft bolt. The vehicle must be standing on
its wheels - risk of accident.

3.4 Exploded view of drive shaft with constant velocity joint

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

36 Rep. Gr.40 - Front suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Circlip
❑ Replace
❑ Remove and install us‐
ing circlip pliers -VW
161 A-
2 - Seal
❑ Replace
❑ Detach the backing and
bond into the joint
3 - Inner constant velocity joint
❑ Different outside diame‐
ters; for assignment re‐
fer to ⇒ Electronic parts
catalogue
❑ Replace as a complete
unit
❑ Pressing off
⇒ page 38
❑ Pressing on
⇒ page 38
4 - Inner constant velocity joint
boot
❑ With vent hole
❑ Check for cracks and
abrasion
❑ Drive off with mandrel
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Before attaching to con‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
stant velocity joint, apply with respect to the correctness of information in this document. Copyright by AUDI AG.
sealant to sealing sur‐
face; for sealant refer to
⇒ Electronic parts cata‐
logue
5 - Drive shaft
❑ Different lengths on left and right and different joint versions; for assignment refer to ⇒ Electronic parts
catalogue
6 - Clamp
❑ Replace
7 - Boot
❑ Check for cracks and abrasion
❑ Before tensioning the clamp, briefly lift the boot to permit pressure equalisation ⇒ page 39
❑ Plastic version (Hytrel) ⇒ page 40
8 - Clamp
❑ Replace
❑ Tensioning ⇒ page 39
9 - Dished washer
❑ Large ∅ (concave side) makes contact with thrust washer
❑ Installation position ⇒ page 38
10 - Thrust washer
❑ Installation position ⇒ page 38
11 - Circlip
❑ Replace
❑ Insert in shaft groove

3. Front drive shaft 37

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

12 - Outer constant velocity joint

❑ Different outside diameters; for assignment refer to ⇒ Electronic parts catalogue
❑ Replace as a complete unit
❑ Removing ⇒ page 38
❑ Installing: Drive onto the shaft with a plastic-headed hammer until the circlip engages

Pressing off outer constant velocity joint

– Clamp the drive shaft in a vice with soft jaws.
– Detach the large clamp and fold back the boot.
– Screw the special tool into the joint pin until the constant ve‐
locity joint can be detached.

Pressing off inner constant velocity joint

Note

♦ Use a mandrel to drive off the boot beforehand.

♦ Support the ball hub.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Pressing on inner constant velocity joint

Note

The chamfer at the inside diameter of the ball hub (splines) must
face the contact collar of the drive shaft.

– Press home the joint.

– Fit the circlip.

Installation position of spacer and dished washer (at wheel)

1- Dished washer
2- Spacer (plastic)

38 Rep. Gr.40 - Front suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Venting boot

Note

Only applies to rubber boots.

The boot is often squashed when fitting it on the joint body. This
produces a vacuum in the boot, which causes a fold to form whilst
driving -arrow-. After fitting, the boot must therefore be vented
briefly at the small diameter to provide pressure equalisation.

Tensioning clamp

Note

Only applies to rubber boots.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3.5 Quantities and type of grease

Joint Grease fill of constant velocity joints;
Grease ⇒ Electronic parts catalogue
Total quantity Joint Bellows
g g g
Outer joint ∅ mm 89 90 40 50
98 120 80 40
Inner joint ∅ mm 100 80 30 50
108 120 35 85

Note

Re-grease the joint if necessary on replacing the boot.

3. Front drive shaft 39

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

3.6 Plastic boot (Hytrel)

♦ A plastic boot is used for the 89 mm outer joint (wheel end) on
the Audi A6 front axle.
♦ It can be identified from the harder material (compared to rub‐
ber).
♦ Stainless steel clamps are needed for securing the boot on
account of the greater pre-tension required.
♦ It is not possible to fit older drive shafts with plastic boots on
account of the fitting grooves -arrows- required on the drive
shaft.
Tensioning stainless steel clamp
♦ Due to the hard boot material (compared to rubber) and the
stainless steel clamp thus required, the clamp can only be
tensioned with the tensioning tool -V.A.G 1682- .
♦ Use a torque wrench with 5...50 Nm adjustment range (e.g. -
V.A.G 1331- ).
♦ Make sure the thread of the spindle of the tensioning tool -
V.A.G 1682- is not seized. Lubricate with MoS2 grease if
necessary.
♦ Stiffness, e.g. dirt on the thread, prevents attainment of the
required clamp tensioning force at the specified torque.

– Apply the tensioning tool -V.A.G 1682- as shown. Ensure that

the jaws of the tool make contact with the corners -arrows B-
of the clamp.
– Tension the clamp to 20 Nm by turning the spindle -arrow A-
with a torque wrench (take care to keep the tool straight).

3.7 Exploded view of drive shaft with triple roller joint

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

40 Rep. Gr.40 - Front suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Drive shaft with triple roller

joint
❑ Replacement parts are
supplied with boot and
grease fill
2 - Clamp
❑ Replace
❑ Tensioning
⇒ page 43
3 - Inner boot
❑ Check for cracks and
abrasion
❑ Replace the inner boot
(only possible on shafts
up to ∅ 32 mm)
❑ To replace, press off the
outer constant velocity
joint
❑ Fold the boot over the
bead of the profile shaft
⇒ page 42
4 - Clamp
❑ Replace
❑ Tensioning
⇒ page 43
5 - Outer constant velocity joint
boot Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Check for cracks and with respect to the correctness of information in this document. Copyright by AUDI AG.
abrasion
❑ Before tensioning the
clamp, briefly lift the
boot to permit pressure
equalisation
⇒ page 42
❑ Plastic version (Hytrel) ⇒ page 40
6 - Clamp
❑ Replace
❑ Tensioning ⇒ page 43
7 - Dished washer
❑ Installation position ⇒ page 42
8 - Spacer (plastic)
❑ Installation position ⇒ page 42
9 - Circlip
❑ Replace
❑ Insert prior to assembly in annular groove of shaft (not visible with joint fitted)
10 - Outer constant velocity joint
❑ Different outside diameters; for assignment refer to ⇒ Electronic parts catalogue
❑ Replace as a complete unit
❑ Pressing off ⇒ page 42
❑ Installing: Drive onto the shaft with a plastic-headed hammer until the circlip engages

3. Front drive shaft 41

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Pressing off outer constant velocity joint

– Clamp the drive shaft in a vice with soft jaws.
– Detach the large clamp and fold back the boot.
– Screw the special tool into the joint pin until the constant ve‐
locity joint can be detached.

Installation position of spacer and dished washer (at wheel)

1- Dished washer
2- Spacer (plastic)

Folding boot over bead of profile shaft

– When fitting on the profile shaft, grease the bead on the profile
shaft slightly and carefully fold the boot over with a wedge -
V.A.G 1474/5- .

Venting boot

Note

Only applies to rubber boots.

The boot is often squashed when fitting it on the joint body. This
produces a vacuum in the boot, which causes a fold to form whilst
driving -arrow-. After fitting, the boot must therefore be vented
briefly at the small diameter to provide pressure equalisation.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

42 Rep. Gr.40 - Front suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Tensioning clamp

Note

Only applies to rubber boots.

3.8 Quantities and type of grease

Joint Grease fill of outer constant velocity joints;
Grease ⇒ Electronic parts catalogue
Total quantity Joint Bellows
g g g
Outer joint ∅ mm 89 90 40 50
98 120 80 40

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Note

Re-grease the joint if necessary on replacing the boot.

3. Front drive shaft 43

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

42 – Rear suspension
1 Rear suspension - Front-wheel drive
vehicles
⇒ “1.1 General ”, page 44
⇒ “1.2 Exploded view of rear suspension”, page 44
⇒ “1.3 Exploded view of rear axle beam”, page 45
⇒ “1.4 Removing and installing rear axle”, page 47

1.1 General

Note

Heed the general information ⇒ page 2 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1.2 Exploded view of rear suspension

1 - Bolt, 110 Nm
❑ The vehicle must be
standing on its wheels
when tightening
2 - Handbrake cable
3 - Suspension strut
4 - Brake drum
5 - Spring for brake pressure
regulator
❑ The brake pressure reg‐
ulator was discontinued
on introduction of ABS
“Bosch 5.0” as of Model
Year 1995
6 - Bolt
7 - Washer
8 - Panhard rod
9 - Washer
10 - Self-locking nut, 100 Nm
❑ Always replace after re‐
moving
11 - Rear axle beam
❑ Removing and installing
⇒ page 47
❑ As of Model Year 1997
brake pressure regula‐
tors were fitted at the
rear axle beam to re‐
duce the brake pressure
⇒ page 45
12 - Self-locking nut, 95 Nm
❑ Always replace after removing

44 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

❑ The vehicle must be standing on its wheels when tightening

13 - Bushing
❑ Only on vehicles with 4-cyl. engine
14 - Bolt

Rear wheel brake pressure regulators as of Model Year 1997

As of Model Year 1997 brake pressure regulators -a- were fitted
at the rear wheels to reduce the brake pressure.
Replacement parts are only available as a set ⇒ Electronic parts
catalogue .

1.3 Exploded view of rear axle beam

1 - Self-locking nut, 100 Nm

❑ Always replace after re‐
moving
❑ The vehicle must be
standing on its wheels
when tightening
2 - Bolt

Note

-Items 2, 4, 5, 6, 7- were discontin‐

ued on introduction of ABS “Bosch
5.0” as of Model Year 1995.

3 - Bonded rubber bush

❑ Replacing ⇒ page 47
and ⇒ page 47
❑ Installation position
⇒ page 47
4 - Self-locking nut, 20 Nm
❑ Always replace after re‐
moving
5 - Spacer sleeve
6 - Mount
7 - Spring for brake pressure regulator
8 - Bolt
9 - Bolt
10 - Washer
11 - Rubber bush
❑ Replacing ⇒ page 47
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Rear suspension - Front-wheel drive vehicles 45

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

12 - Panhard rod
13 - Bushing
❑ Only on vehicles with 4-cyl. engine
14 - Anti-roll bar
15 - Self-locking nut, 80 Nm
❑ Always replace after removing
❑ The vehicle must be standing on its wheels when tightening
16 - Bolt
17 - Axle beam
❑ Different version for drum and disc brakes
❑ Axle beams for vehicles with disc brakes are provided with a bushing for mounting the speed sensors.
❑ The two bushings are to be driven out for use on vehicles without ABS
18 - Self-locking nut, 100 Nm
❑ Always replace after removing
❑ The vehicle must be standing on its wheels when tightening

Special tools and workshop

equipment required
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-
♦ Press tool -VW 407- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Press tool -VW 412- with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Guide piece -VW 436 A-

♦ Collar -3260-

46 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ Pipe -3259-

Pressing out bonded

rubber bush

Installation position
– Press in bush such that it is flush.
• Line -A- must be at an angle of 90° with respect to line -B-.

Note

Line -B- may deviate by ± 4° from the kidney-shaped recesses in

the bush.

ProtectedFitting bonded
by copyright. Copyingrubber
for private bush
or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Pressing out and pressing in bonded rubber bush

1.4 Removing and installing rear axle

Special tools and workshop equipment required

1. Rear suspension - Front-wheel drive vehicles 47

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ Engine and gearbox lifter -V.A.G 1383 A-

♦ Brake pedal depressor -V.A.G 1869/2-

Removing
• Vehicle standing on its wheels over a lifting platform
– Detach the wheel trim.
– Raise the vehicle.
– Draw off the brake fluid.
– Remove the wheels.
– Vehicles with 5 and 6-cyl. engine: Remove the guard under
the tank.
– Vehicles with load-sensitive brake pressure regulator: Unfas‐
ten the brake pressure regulator nut -arrow-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

48 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Remove the brake drum ⇒ Rep. Gr. 46 .

– Disengage the handbrake cable -arrow-.
– Take the rubber grommet out of the trailing link.

– Take the wire loop out of the trailing link -arrow-.

– Pull the handbrake cable out of the brake carrier and trailing
link.

– Vehicles with disc brakes: Disengage the handbrake cable

-arrow-.
– Insert the brake pedal depressor -V.A.G 1869/2- .
– Press the brake pedal down by at least 60 mm with the brake
pedal depressor.

Note

Use of the brake pedal depressor stops the brake fluid reservoir
running empty.

– Unscrew the brake pipes -left arrow- at both sides of the rear
axle.
– Unscrew the trailing link bolts but do not as yet completely un‐
fasten the left bolt.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Rear suspension - Front-wheel drive vehicles 49

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Remove the Panhard rod bolt -arrow-.

– Position the engine and gearbox lifter -V.A.G 1383 A- under

the rear axle.
– Use the tensioning straps provided to secure the rear axle
beam.

– Unscrew the suspension strut bolt -arrow- on both sides of the

rear axle.
– Screw out the left trailing link bolt.
– Lower the rear axle.
Installing
Install in reverse order, paying attention to the following:
– Insert the wire loop for the handbrake cables in the trailing
links.
– Install the brake drums ⇒ byRep.
AUDI Gr. 46 AG
. does not guarantee or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised AG. AUDI

– Adjust the brake pressure regulator ⇒ Rep. Gr. 47 .

with respect to the correctness of information in this document. Copyright by AUDI AG.

– Bleed the brake system ⇒ Rep. Gr. 47 .

50 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

2 Rear suspension strut - Front-wheel

drive vehicles
⇒ “2.1 Removing and installing suspension strut”, page 51
⇒ “2.2 Exploded view of suspension strut”, page 55
⇒ “2.3 Dismantling and assembling suspension strut ”,
page 57

2.1 Removing and installing suspension strut

Special tools and workshop

equipment required
♦ 14 mm socket wrench
-3150-
♦ Torque wrench -V.A.G
1331- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Torque wrench -V.A.G with respect to the correctness of information in this document. Copyright by AUDI AG.
1332-
♦ Self-levelling suspension
system tester -V.A.G 1354-
♦ Engine and gearbox lifter -
V.A.G 1383 A-

2. Rear suspension strut - Front-wheel drive vehicles 51

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ 17 mm Crow ring spanner (e.g. from Stahlwille) or

♦ 17 mm open twelve-point socket attachment (e.g. from Hazet)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

52 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Suspension strut
Removing

– Remove the wheel.

Vehicles with self-levelling

suspension:

– Detach the dust cap

from the bleed screw of
the connector.

– Attach the bleed hose of

the self-levelling sus‐
pension system tester -
V.A.G 1354- to the
bleed screw
⇒ page 54 .

– Open the bleed screw

and collect the hydraulic
fluid.

– Close the bleedProtected

screw,by copyright. Copying for private or commercial purposes, in part or in whole, is not
detach the bleed hoseunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
and attach the dust cap.
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unscrew the hydraulic

pipe ⇒ page 54 .

All vehicles (continued):

– Screw out the bolt for

the suspension strut at
the bottom.

– Unscrew the nuts

⇒ Item 2 (page 53) .

– Take out the suspen‐

sion strut.

Installing

– Insert the suspension strut.

– Insert the bolt for the suspension strut at the bottom.

– Raise the rear axle with the engine and gearbox lifter -V.A.G 1383 A- until all the nuts
⇒ Item 2 (page 53) can be inserted ⇒ page 54 .

– Tighten the nuts ⇒ Item 2 (page 53) to torque.

Vehicles with self-levelling suspension:

– Screw on the hydraulic pipe ⇒ page 54 .

All vehicles (continued):

– Lower the rear axle.

– Fit the wheel: Steel disc wheel ⇒ page 144 , light alloy wheel ⇒ page 146 .

– Set down the vehicle on its wheels and tighten the bolt for the suspension strut at the bottom to torque.

2 - Self-locking nut, 25 Nm
❑ Always replace after removing

2. Rear suspension strut - Front-wheel drive vehicles 53

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

3 - Self-locking nut, 95 Nm
❑ Always replace after removing

Attaching bleed hose of self-levelling suspension system tester -

V.A.G 1354-

Unscrewing and screwing on hydraulic pipe

♦ For standard hydraulic pipe: 14 mm socket wrench -3150- .
♦ For heavy-duty hydraulic pipe: 17 mm Crow ring spanner (e.g.
from Stahlwille) or 17 mm open twelve-point socket attach‐
ment (e.g. from Hazet).
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Note
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Conversion to the heavy-duty pressure pipe also involves re‐

placing the connection piece ⇒ Item 5 (page 56) .
♦ The suspension strut has to be removed ⇒ page 51 and dis‐
mantled ⇒ page 57 for this purpose.

Tightening torque for union nuts: 40 Nm.

Supporting rear axle

54 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

2.2 Exploded view of suspension strut

Standard and sports running gear

1 - Self-locking nut, 30 Nm
❑ Always replace after re‐
moving
2 - Rubber bush
❑ Apply talc before fitting
3 - Upper spring plate
4 - Damping ring
❑ Apply talc before fitting
❑ Different thicknesses;
for assignment refer to
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ Electronic
with respect parts
to the correctness cata‐ in this document. Copyright by AUDI AG.
of information
logue
5 - Buffer stop
❑ Insert in protective
sleeve
⇒ Item 6 (page 55)
and fit jointly in damping
ring ⇒ Item 4 (page 55)
6 - Protective sleeve
7 - Coil spring
❑ Surface of spring wind‐
ing must not be dam‐
aged
❑ Pay attention to colour
code; for assignment re‐
fer to ⇒ Electronic parts
catalogue
❑ Heed PR no. (factory
code) on vehicle data
sticker prior to replace‐
ment ⇒ page 1
8 - Protective cap
9 - Lower spring plate
❑ With stop for coil spring
10 - Shock absorber
❑ Can be replaced separately
❑ For assignment, refer to ⇒ Electronic parts catalogue
❑ Vehicles with sports running gear are fitted with gas-filled dampers
❑ Checking ⇒ page 6
❑ Heed PR no. (factory code) on vehicle data sticker prior to replacement ⇒ page 1
❑ Disposal ⇒ page 4

Standard running gear with self-levelling suspension at rear

2. Rear suspension strut - Front-wheel drive vehicles 55

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Self-locking nut, 30 Nm
❑ Always replace after re‐
moving
2 - Rubber bush
❑ Apply talc before fitting
3 - Upper spring plate
4 - Damping ring
❑ Apply talc before fitting
❑ Different thicknesses;
for assignment refer to
⇒ Electronic parts cata‐
logue
5 - Connection piece with
spacer
❑ M14x1.5
❑ On replacing the pres‐
sure pipes, the connec‐
tion piece must also be
renewed as only heavy-
duty M16x1.5 pressure
pipes are now available
❑ Installation position of
pressure pipes: Saloon
⇒ page 57 , Avant
⇒ page 57
❑ Attach to piston rod
❑ Take care not to twist
connection piece when
tightening self-locking
nut
6 - O-ring
❑ Coat with silicone
grease; for silicone
grease refer to ⇒ Elec‐
tronic parts catalogue
❑ Insert in annular grooves of piston rod
7 - Washer
8 - Buffer stop
9 - Coil spring
❑ Surface of spring winding must not be damaged
❑ Pay attention to colour code; for assignment refer to ⇒ Electronic parts catalogue
❑ Heed PR no. (factory code) on vehicle data sticker prior to replacement ⇒ page 1
❑ Installation position ⇒ page 60
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
10 - Protective cap with respect to the correctness of information in this document. Copyright by AUDI AG.

11 - Lower spring plate

❑ With stop for coil spring
❑ Installation position ⇒ page 59
12 - Shock absorber
❑ For assignment, refer to ⇒ Electronic parts catalogue
❑ Checking ⇒ page 6
❑ Heed PR no. (factory code) on vehicle data sticker prior to replacement ⇒ page 1
❑ Disposal ⇒ page 4

56 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Installation position of pressure pipes for self-levelling suspension

- Saloon
a - Installation angle of pressure pipe on left side of vehicle ap‐
prox. 30°
b - Installation angle of pressure pipe on right side of vehicle ap‐
prox. 20°
L - Left side of vehicle
R - Right side of vehicle
F - Direction of travel

Installation position of pressure pipes for self-levelling suspension

- Avant
a - Installation angle of pressure pipe on left side of vehicle ap‐
prox. 80°
b - Installation angle of pressure pipe on right side of vehicle ap‐
prox. 65°
L - Left side of vehicle
R - Right side of vehicle
F - Direction of travel

2.3 Dismantling and assembling suspen‐

sion strut
Special tools and workshop equipment required
♦ Shock absorber wrench -3017 A-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Suspension strut tensioner -V.A.G 1752-

2. Rear suspension strut - Front-wheel drive vehicles 57

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ Shock absorber set -T10001-

Dismantling Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Note

Note the different versions of the components for standard and

sports running gear ⇒ Electronic parts catalogue .

– Clamp the suspension strut holder -V.A.G 1752/2- in the vice.

– Insert the suspension strut in the suspension strut holder -
V.A.G 1752/2- .
– Insert the studs in the holes in the upper spring plate, screw
to the spring plate and fix in this position by way of the clamp‐
ing levers.

– Pay attention to the exact position of the pointer for angle ad‐
justment.
• The pointer position must be observed on assembly.

58 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Pre-tension the coil spring with the spring tensioner -V.A.G

1752/1- until the upper spring plate is free.
– Make sure the coil spring is positioned correctly in the spring
holder -V.A.G 1752/3A- .
– Unscrew the nut from the piston rod using the shock absorber
set -T10001- or a shock absorber wrench -3017 A- .
– Detach the rubber bush.

– Release the clamping lever -bottom arrow-, push up the height

adjuster and swivel aside.
– Detach the corresponding components.

Assembly
– Pull the piston rod as far as it will go out of the shock absorber.
– Position the lower spring plate on the shock absorber.
• Installation position: Turn the stop of the spring plate -arrow-
through 90° with respect to the axis of the shock absorber eye.
– Position the coil spring with the spring tensioner -V.A.G
1752/1- on the shock absorber.
• The coloured mark on the coil spring must face the lower
spring plate.
– Fit all components with the exception of the upper spring plate
and rubber bush.
– Set the height adjuster together with the spring plate to 45°,
position over the suspension strut, lower and secure.
– Fit the rubber bush and screw on the nut.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Rear suspension strut - Front-wheel drive vehicles 59

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Make sure the ends of the springs are in contact with the stops
of the spring support and the spring seat.
• The end of the spring winding must make contact with the stop
-arrow-.

– Tighten the nut to 30 Nm using the shock absorber set -

T10001- or a shock absorber wrench -3017 A- .
– Carefully slacken off the coil spring, paying attention to correct
positioning of the coil spring and the upper and lower spring
plates.
– As soon as the spring tensioner -V.A.G 1752/1- is free, stop
slackening off and detach the spring tensioner.
– Take the suspension strut out of the suspension strut holder -
V.A.G 1752/2- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

60 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

3 Rear wheel bearings - Front-wheel

drive vehicles
⇒ “3.1 General ”, page 61
⇒ “3.2 Exploded view of wheel bearings - Vehicles with drum
brakes”, page 61
⇒ “3.3 Exploded view of wheel bearings - Vehicles with disc
brakes”, page 65

3.1 General

Note

Heed the general information ⇒ page 2 .

♦ Careful sealing, cleanliness and proper adjustment are crucial

to a long wheel bearing service life. Attention is therefore to
be paid to the following:
♦ Fit the seal and grease cap as shown.
♦ Only re-install clean bearings; never wash out bearings.
♦ Ensure careful wheel bearing clearance adjustment.

3.2 Exploded view of wheel bearings - Vehicles with drum brakes

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Rear wheel bearings - Front-wheel drive vehicles 61

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Stub axle
❑ Straightening work is
not permissible.
2 - Brake carrier
❑ Bolt with stub axle to
rear axle
3 - Seal
❑ Fill with multi-purpose
grease between sealing
lips; for multi-purpose
grease refer to ⇒ Elec‐
tronic parts catalogue
4 - Bolt, 30 Nm
5 - Inner wheel bearing
❑ Drive out outer race with
copper mandrel
❑ Pressing in
⇒ page 65
6 - Brake drum
❑ Before removing, reset
brake shoes through
wheel bolt tapped hole
⇒ page 64
❑ When detaching brake
drum, secure outer
wheel bearing to stop it
dropping out
❑ Before installing, fill hub
with multi-purpose
grease; for multi-pur‐
pose grease refer to ⇒ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Electronic parts cata‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
logue with respect to the correctness of information in this document. Copyright by AUDI AG.

7 - Outer wheel bearing

❑ Drive out outer race with copper mandrel
❑ Pressing in ⇒ page 65
8 - Nut
❑ Adjusting wheel bearing clearance ⇒ page 64
9 - Grease cap
❑ Pressing off ⇒ page 63 and ⇒ page 64
❑ Driving in ⇒ page 64
10 - Split pin
❑ Replace

62 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Special tools and workshop

equipment required
♦ Mandrel -VW 295-
♦ Thrust pad -VW 447 H-
♦ Thrust pad -VW 512-
♦ Hub cap puller -VW 637/2-
♦ Fitting sleeve -40 - 21-
♦ Torque wrench -V.A.G
1331-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Pressing off grease cap

Tap gently on the claw to release the grease cap from its seat.

3. Rear wheel bearings - Front-wheel drive vehicles 63

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Pressing off grease cap

Driving in grease cap

Note

♦ Always replace damaged grease caps.

♦ Damaged grease caps permit the ingress of moisture. It is
therefore essential to use the tool shown.

Adjusting wheel bearing clearance

Note

It must be possible to move the thrust washer with a screwdriver

by pressing with a finger and without exerting leverage -arrow-.

– Secure with a locking ring and a new split pin.

Resetting brake
– To do so, press the adjuster upwards with a screwdriver
through a hole in the brake drum.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

64 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Pressing in outer race for outer wheel bearing

Pressing in outer race for inner bearing

3.3 Exploded view of wheel bearings - Vehicles with disc brakes

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Rear wheel bearings - Front-wheel drive vehicles 65

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Stub axle
❑ Straightening work is
not permissible.
2 - Splash plate
3 - Seal
❑ Fill with multi-purpose
grease between sealing
lips; for multi-purpose
grease refer to ⇒ Elec‐
tronic parts catalogue
4 - Inner wheel bearing
❑ Drive out outer race with
copper mandrel
❑ Pressing in
⇒ page 70
5 - Rotor for speed sensor
❑ Vehicles with ABS only
❑ Pressing in
⇒ page 70
6 - Stub axle for vehicles with
ABS
❑ Straightening work is
not permissible.
7 - Bolt, 30 Nm
8 - Wheel hub
❑ Before installing, fill hub
with multi-purpose
grease; for multi-pur‐
pose grease refer to ⇒
Electronic parts cata‐
logue
9 - Outer wheel bearing
❑ Drive out outer race with copper mandrel
❑ Pressing in ⇒ page 69
10 - Nut
❑ Adjusting wheel bearing clearance ⇒ page 69
11 - Split pin
❑ Replace
12 - Grease cap
❑ Pressing off ⇒ page 68 and ⇒ page 69
❑ Driving in ⇒ page 64

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

66 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Special tools and workshop

equipment required
♦ Mandrel -VW 295-
♦ Thrust plate -VW 401-
♦ Press tool -VW 407-
♦ Thrust pad -VW 512-
♦ Hub cap puller -VW 637/2-
♦ Fitting mandrel -30 - 505-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Rear wheel bearings - Front-wheel drive vehicles 67

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ Pressing-in tool -30 - 506 B-

♦ Pipe -32 - 119-
♦ Fitting sleeve -40 - 21-
♦ Thrust pad -2050-
♦ Torque wrench -V.A.G
1331-

Pressing off grease cap

– Tap gently on the claw to release the grease cap from its seat.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

68 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Pressing off grease cap

Driving in grease cap

Note

♦ Always replace damaged grease caps.

♦ Damaged grease caps permit the ingress of moisture. It is
therefore essential to use the tool shown.

Adjusting wheel bearing clearance

Note

It must be possible to move the thrust washer with a screwdriver

by pressing with a finger and without exerting leverage -arrow-.

– Secure with a locking ring and a new split pin.

Pressing in outer race for outer wheel bearing

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Rear wheel bearings - Front-wheel drive vehicles 69

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Pressing in outer race for inner wheel bearing

Pressing in rotor

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

70 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

4 Rear suspension - Four-wheel drive

vehicles
⇒ “4.1 General ”, page 71
⇒ “4.2 Exploded view of rear subframe”, page 71
⇒ “4.3 Exploded view of rear suspension”, page 75
⇒ “4.4 Exploded view of trapezium link”, page 80
⇒ “4.5 Removing and installing trapezium link”, page 84
⇒ “4.6 Exploded view of support for trapezium link with bonded
rubber bush”, page 85
⇒ “4.7 Replacing bonded rubber bush for trapezium link support”,
page 87
⇒ “4.8 Removing and installing transverse link”, page 89
⇒ “4.9 Exploded view of connecting link”, page 90
⇒ “4.10 Exploded view of anti-roll bar”, page 91 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ “4.11 Removing and installing anti-roll bar”, page 91with respect to the correctness of information in this document. Copyright by AUDI AG.

4.1 General

Note

Heed the general information ⇒ page 2 .

4.2 Exploded view of rear subframe

4. Rear suspension - Four-wheel drive vehicles 71

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Bracket
❑ Different versions; for
assignment refer to ⇒
Electronic parts cata‐
logue
2 - Seal
❑ Replace
3 - Rear subframe
❑ Different versions; for
assignment refer to ⇒
Electronic parts cata‐
logue
❑ Continuous offset edge
faces in direction of trav‐
el
4 - Bonded rubber bush
❑ Pressing out and press‐
ing in ⇒ page 74
5 - Self-locking nut 60 Nm
❑ Always replace after re‐
moving
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6 - Propshaft permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Mark installation posi‐
tion for re-installation
7 - Bolt, 55 Nm
❑ Always replace after re‐
moving
8 - Cross piece
❑ Different versions; for
assignment refer to ⇒
Electronic parts cata‐
logue

Note

♦ When securing, make sure the

four holes in the cross piece are
aligned as centrally as possible.
♦ Perform rear axle wheel align‐
ment after repair work.

9 - Self-locking nut, 60 Nm
❑ Always replace after removing
10 - Wire holder
❑ Bolt to link
11 - Wire for speed sensor
12 - Trapezium link
❑ Removing and installing ⇒ page 84
❑ Exploded view ⇒ page 80
13 - Nut, 10 Nm
14 - Bolt, 45 Nm
15 - Self-locking nut, 45 Nm
❑ Always replace after removing

72 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

16 - Bracket
17 - Bonded rubber bush
❑ Moisten with assembly lubricant and press in by hand; for assembly lubricant refer to ⇒ Electronic parts
catalogue
18 - Transverse link
❑ Different versions; for assignment refer to ⇒ Electronic parts catalogue
❑ Removing and installing ⇒ page 89
❑ Check camber following replacement
19 - Speed sensor
❑ Press home in wheel bearing housing
20 - Wheel bearing housing
21 - Holder for speed sensor wire
22 - Self-locking nut, 40 Nm
❑ Always replace after removing
23 - Washer
24 - Self-locking nut, 45 Nm
❑ Always replace after removing
25 - Self-locking nut, 85 Nm
❑ Always replace after removing
❑ The vehicle must be standing on its wheels when tightening

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Rear suspension - Four-wheel drive vehicles 73

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Special tools and workshop

equipment required
♦ Thrust plate -VW 401-
♦ Press tool -VW 412-
♦ Tubular section -VW 415 A-
♦ Tubular section -VW 416 B-
♦ Torque wrench -V.A.G
1331-

Pressing out and pressing in bonded rubber bush at rear sub‐

frame
• Installation position: The kidney-shaped recesses of the bush
must be positioned vertically in the subframe.

Note

Viewed in the direction of travel, the bush must be pressed in until

the outer race is flush at the rear with the welded-in bushing.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

74 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

4.3 Exploded view of rear suspension

Vehicles with no anti-roll bar

1 - Seal
❑ Replace
❑ Not on vehicles with 4-
cyl. engine
2 - Bolt
❑ M8: 40 Nm
❑ M10: 77 Nm
3 - Drive shaft
❑ Removing and installing
⇒ page 116
❑ Exploded view
⇒ page 116
4 - Suspension strut
❑ Removing and installing
⇒ page 92
5 - Self-locking nut, 25 Nm
❑ Always replace after re‐
moving
6 - Cross piece
❑ Different versions; for
assignment refer to ⇒
Electronic parts cata‐
logue

Note

♦ When securing, make sure the

four holes in the cross piece are
aligned as centrally as possible.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Perform rear axle wheel align‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

ment after repair work. with respect to the correctness of information in this document. Copyright by AUDI AG.

7 - Self-locking nut, 40 Nm
❑ Always replace after removing
8 - Ball head
❑ Different versions; for assignment refer to ⇒ Electronic parts catalogue
❑ Note angular position at joint
❑ Pay attention to uniform screwing-in depth
9 - Nut, 60 Nm
10 - Transverse link
❑ Removing and installing ⇒ page 89
❑ Different versions; for assignment refer to ⇒ Electronic parts catalogue
❑ Note angular position at joint
11 - Bolt
12 - Ball joint
❑ Pay attention to uniform screwing-in depth
13 - Self-locking nut, 200 Nm
❑ Always replace after removing

4. Rear suspension - Four-wheel drive vehicles 75

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

14 - Bolt
❑ Always replace after removing
❑ 190 Nm + further 180° turn
❑ The vehicle must be standing on its wheels when slackening off and tightening - risk of accident
❑ Switched from hexagon head to hexagon socket. Combined fitting is permissible
15 - Nut, 110 Nm
❑ Always replace after removing
16 - Self-locking bolt
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Always replace
permitted after removing
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 170 Nm + further 135° turn
❑ Use a M14x1.5 tap to remove residual adhesive from the thread in the wheel bearing housing
❑ The vehicle must be standing on its wheels when tightening
17 - Mounting bracket
❑ Cross faces upwards when fitted
❑ Check toe and camber following removal and installation
18 - Washer
19 - Trapezium link
❑ Removing and installing ⇒ page 84
❑ Servicing ⇒ page 80
❑ Check toe and camber following removal and installation
20 - Bolt
21 - Self-locking nut, 90 Nm
❑ Always replace after removing
❑ The vehicle must be standing on its wheels when tightening
22 - Wheel bearing housing
❑ Removing and installing ⇒ page 114
23 - Bonded rubber bush
❑ Pressing out ⇒ page 79
❑ Pressing in ⇒ page 79
24 - Washer
25 - Self-locking bolt
❑ Always replace after removing
❑ 170 Nm + further 135° turn
❑ Use a M14x1.5 tap to remove residual adhesive from the thread in the wheel bearing housing
❑ The vehicle must be standing on its wheels when tightening
26 - Bolt
27 - Speed sensor
❑ Pull out to remove
❑ On installation, grease all round with brake cylinder paste and press home by hand
28 - Clamping sleeve
❑ Grease all round with brake cylinder paste before inserting in wheel bearing housing
❑ Press home in wheel bearing housing
29 - Holder for speed sensor wire

Vehicles with anti-roll bar

76 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Seal
❑ Replace
❑ Not on vehicles with 4-
cyl. engine
2 - Bolt
❑ M8: 40 Nm
❑ M10: 77 Nm
3 - Drive shaft
❑ Removing and installing
⇒ page 116
❑ Exploded view
⇒ page 119
4 - Suspension strut
❑ Removing and installing
⇒ page 92
5 - Self-locking nut, 25 Nm
❑ Always replace after re‐
moving
6 - Clip Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

7 - Mount
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

8 - Cross piece
❑ Pay attention to different
versions

Note

♦ When securing, make sure the

four holes in the cross piece are
aligned as centrally as possible.
♦ Perform rear axle wheel align‐
ment after repair work.

9 - Self-locking nut, 40 Nm
❑ Always replace after removing
10 - Ball head
❑ Pay attention to different versions
❑ Note angular position at joint
❑ Pay attention to uniform screwing-in depth
11 - Nut, 60 Nm
12 - Anti-roll bar
❑ Removing and installing ⇒ page 91
13 - Bolt, 25 Nm
14 - Transverse link
❑ Removing and installing ⇒ page 89
❑ Pay attention to different versions
❑ Note angular position at joint
15 - Bolt
16 - Ball joint
❑ Pay attention to uniform screwing-in depth

4. Rear suspension - Four-wheel drive vehicles 77

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

17 - Self-locking nut, 200 Nm

❑ Always replace after removing
18 - Bolt
❑ Always replace after removing
❑ 190 Nm + further 180° turn
❑ The vehicle must be standing on its wheels when slackening off and tightening - risk of accident
❑ Switched from hexagon head to hexagon socket. Combined fitting is permissible
19 - Nut, 110 Nm
❑ Always replace after removing
20 - Self-locking bolt
❑ Always replace after removing
❑ 170 Nm + further 135° turn
❑ Use a M14x1.5 tap to remove residual adhesive from the thread in the wheel bearing housing
❑ The vehicle must be standing on its wheels when tightening
21 - Mounting bracket
❑ Cross faces upwards when fitted
❑ Check toe and camber following removal and installation
22 - Washer
23 - Trapezium link
❑ Removing and installing ⇒ page 84
❑ Servicing ⇒ page 80
❑ Check toe and camber following removal and installation
24 - Bolt
25 - Connecting link
❑ Connects anti-roll bar to wheel bearing housing
❑ Removing and installing ⇒ page 90
26 - Self-locking nut, 90 Nm
❑ Always replace after removing
❑ The vehicle must be standing on its wheels when tightening
27 - Wheel bearing housing
❑ Removing and installing ⇒ page 114
28 - Holder
29 - Bonded rubber bush
❑ Pressing out ⇒ page 79
❑ Pressing in ⇒ page 79
30 - Washer
31 - Self-locking bolt
❑ Always replace after removing
❑ 170 Nm + further 135° turn
❑ Use a M14x1.5 tap to remove residual adhesive from the thread in the wheel bearing housing
❑ The vehicle must be standing on its wheels when tightening
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
32 - Bolt, 20 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.
33 - Bolt
34 - Speed sensor
❑ Pull out to remove
❑ On installation, grease all round with brake cylinder paste and press home by hand

78 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

35 - Clamping sleeve
❑ On installation, grease all round with brake cylinder paste and press home in wheel bearing housing
36 - Holder for speed sensor wire
37 - Self-locking nut, 25 Nm
❑ Always replace after removing

Pressing bonded rubber bush out of wheel bearing housing

Pressing bonded rubber bush into wheel bearing housing

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Rear suspension - Four-wheel drive vehicles 79

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

4.4 Exploded view of trapezium link

1 - Self-locking bolt
❑ Always replace after re‐
moving
❑ 170 Nm + further 180°
turn
❑ Use a M14x1.5 tap to re‐
move residual adhesive
from the thread in the
wheel bearing housing
❑ The vehicle must be
standing on its wheels
when tightening
2 - Washer
❑ Thickness 3 mm
❑ Modified design as of
Model Year 1992
⇒ page 85
3 - Stud, body
4 - Trapezium link
❑ Pay attention to different
versions
❑ Removing and installing
⇒ page 84
❑ Check toe and camber
following removal and
installation
5 - Bonded rubber bush
❑ New rubber blend (25 %
harder) as of Model
Year 1997
❑ Combination with old
bushes not permissible
❑ Pressing out and press‐
ing in ⇒ page 82
❑ Pay attention to installation position ⇒ page 83

Note

As there is no obvious distinction

between old and new bushes, bush‐
es are only to be replaced in pairs.

6 - Nut, 110 Nm
❑ Always replace after removing
7 - Mounting bracket
❑ Cross faces upwards when fitted
❑ Check toe and camber following removal and installation
8 - Ribbed nut, 135 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Always replace
permittedafter
unless removing
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
9 - Support for trapezium link
❑ Replacement part supplied with bonded rubber bush for Model Year 1991
❑ Modified design as of Model Year 1992 ⇒ page 85

80 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

10 - Washer
❑ Thickness 6 mm
❑ Modified design as of Model Year 1992 ⇒ page 85
11 - Bolt
12 - Bonded rubber bush
❑ Pressing out ⇒ page 83
❑ Pressing in ⇒ page 83 and ⇒ page 84

Special tools and workshop

equipment required
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Thrustwith
plate -VW
respect 401-
to the correctness of information in this document. Copyright by AUDI AG.

♦ Press tool -VW 412-

♦ Tubular section -VW 415 A-
♦ Tubular section -VW 418 A-
♦ Thrust pad -VW 432-
♦ Guide sleeve -3039-

4. Rear suspension - Four-wheel drive vehicles 81

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ Tubular section -3146-

♦ Pressing tool -3157-
♦ Torque wrench -V.A.G
1332-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Pressing out and pressing in bonded rubber bush

Note

Press in the bonded rubber bush such that the projection viewed
in the direction of travel is 3 mm ⇒ page 83 .

82 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Installation position of bonded rubber bush

• Dimension -a- = 3 ± 1 mm

Pressing out bonded rubber bush

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Pressing bonded rubber bush roughly 20 mm into mounting

bracket

Note

Before pressing the bonded rubber bush into the mounting brack‐
et, make sure the collar of the bonded rubber bush is facing in the
direction of travel.

4. Rear suspension - Four-wheel drive vehicles 83

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Pressing bonded rubber bush into mounting bracket

4.5 Removing and installing trapezium link

Removing
– Remove the wheel.
– Vehicles with ABS: Detach the speed sensor wire -arrows-.

– If fitted, disengage the brake pressure regulator spring

-arrow-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

84 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Slacken off the trapezium link bolt at the wheel bearing hous‐
ing -arrow-.

– Slacken off the mounting bracket bolt at the trapezium link

-arrow-.
– Slacken off the trapezium link bolt at the cross piece.

– Slacken off the support bolt at the trapezium link

-centre right arrow-.
– Unscrew the support from the floor panel.
– Screw out all the bolts previously slackened off and detach the
trapezium link.
Installing
Install in reverse order.

4.6 Exploded view of support for trapezium link with bonded rubber bush

Note

The bonded rubber bushes cannot be replaced on Model Year 1991 vehicles.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Rear suspension - Four-wheel drive vehicles 85

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Stud, body
2 - Self-locking bolt
❑ Always replace after re‐
moving
❑ 170 Nm + further 180°
turn
❑ Use a M14x1.5 tap to re‐
move residual adhesive
from the thread in the
wheel bearing housing
❑ The vehicle must be
standing on its wheels
when tightening
3 - Washer

Note

♦ As of Model Year 1992 only

dished washers have been fitted.
♦ When installing new supports in
Model Year 1991 vehicles, al‐
ways fit dished washers ⇒ Elec‐
tronic parts catalogue .

4 - Front bonded rubber bush

❑ Replacing ⇒ page 87
5 - Ribbed nut, 135 Nm
❑ Always replace after re‐
moving Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
6 - Support for trapezium link with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Pay attention to different
versions
❑ Replacement part also
available with bush
7 - Rear bonded rubber bush
❑ Provided with 8 studs on end face for identification
❑ Replacing ⇒ page 87
8 - Washer

Note

♦ As of Model Year 1992 only

dished washers have been fitted.
♦ When installing new supports in
Model Year 1991 vehicles, al‐
ways fit dished washers ⇒ Elec‐
tronic parts catalogue .

9 - Trapezium link

86 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

4.7 Replacing bonded rubber bush for trapezium link support

Special tools and workshop

equipment required
♦ Thrust plate -VW 401-
♦ Press tool -VW 407-
♦ Tubular section -3146-
♦ Assembly tool -3291-
♦ Assembly tool -3294-
♦ Torque wrench -V.A.G
1332-

Sequence of operations
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– permitted
Insert an internal puller e.g. -Kukko 21/2- in the bonded rubber
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
bush and tighten the nut -arrow a-.

4. Rear suspension - Four-wheel drive vehicles 87

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Insert an approx. 80 mm long M14 bolt in the hole in the bush

and press out one half of the bush.

– Press out the second half of the bush.

– Press home the rear bush.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

88 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Press in the front bush approx. 5 mm.

– Press home the bush.

Note

Terminate the pressing-in operation immediately when the bush

makes flush all-round contact with the support.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4.8 Removing and installing transverse link

Special tools and workshop equipment required
♦ Pressing-out tool for supporting joints -VW 267 A-

Removing

Note

The illustrations show a rear axle with no anti-roll bar.

– Remove the wheel.

– Unscrew the transverse link from the wheel bearing housing
and the cross piece -arrows-.

4. Rear suspension - Four-wheel drive vehicles 89

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Raise the link, insert the pressing-out tool and press out the
joint.
Installing
Install in reverse order.

4.9 Exploded view of connecting link

1 - Anti-roll bar
2 - Connecting link
❑ Connects anti-roll bar to
wheel bearing housing
3 - Holder for speed sensor
4 - Self-locking nut, 45 Nm
❑ Always replace after re‐
moving

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

90 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

4.10 Exploded view of anti-roll bar

1 - Rear cross piece

❑ Pay attention to different
versions
2 - Anti-roll bar
❑ Removing and installing
⇒ page 91
3 - Mount
4 - Clip Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
5 - Bolt, 25 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.

4.11 Removing and installing anti-roll bar

Removing
– Unscrew the anti-roll bar from the connecting links.
– Vehicles with self-levelling suspension: Unscrew the control
valve linkage from the lever.
– Unscrew the clip on either side from the rear cross piece.
– Take out the mount and anti-roll bar.
Installing
Install in reverse order.

4. Rear suspension - Four-wheel drive vehicles 91

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

5 Rear suspension strut - Four-wheel

drive vehicles
⇒ “5.1 Removing and installing suspension strut”, page 92
⇒ “5.2 Exploded view of suspension strut”, page 95
⇒ “5.3 Dismantling and assembling suspension strut ”,
page 97
⇒ “5.4 Exploded view of suspension strut with self-levelling sus‐
pension”, page 102
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “5.5 Dismantling and assembling
permitted suspension
unless authorised by AUDI AG.strut
AUDIwith
AG doesself-
not guarantee or accept any liability
levelling suspension”, page 104 to the correctness of information in this document. Copyright by AUDI AG.
with respect

5.1 Removing and installing suspension strut

Special tools and workshop

equipment required
♦ Torque wrench -V.A.G
1331-
♦ Torque wrench -V.A.G
1332-
♦ Self-levelling suspension
system tester -V.A.G 1354-
♦ Engine and gearbox lifter -
V.A.G 1383 A-

Removing
• Vehicle standing on its wheels over a lifting platform
– Detach the wheel trim.
– Raise the vehicle.

92 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Remove the wheels.

Vehicles with self-levelling suspension:
– Detach the dust cap from the bleed screw of the connector.
– Attach the bleed hose of the self-levelling suspension system
tester -V.A.G 1354- to the bleed screw.
– Open the bleed screw and collect the hydraulic fluid.

Note

The hydraulic fluid drained off is not to be re-used.

– Close the bleed screw, detach the bleed hose and attach the
dust cap.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Unscrew the hydraulic pipe.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

All vehicles (continued):

– Unscrew the suspension strut connection -arrow-.

– Unscrew the nuts -arrows- and take out the suspension strut.

5. Rear suspension strut - Four-wheel drive vehicles 93

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Installing
– Fit the suspension strut connection -arrow-.

– Raise the rear axle with the engine and gearbox lifter -V.A.G
1383 A- until the suspension strut securing nuts can be inser‐
ted.
– Protected
Tighten the nuts
by copyright. to 25forNm.
Copying private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Vehicles with self-levelling suspension:

– Screw on the hydraulic pipe.
• There must be approx. 15 mm clearance between the marking
lug and the hydraulic pipe -arrow-.

Installation position of pressure pipes for self-levelling suspen‐

sion:
a - Installation angle of pressure pipe on left side of vehicle ap‐
prox. 110°
b - Installation angle of pressure pipe on right side of vehicle ap‐
prox. 110°
L - Left side of vehicle
R - Right side of vehicle
F - Direction of travel
All vehicles (continued)
– Lower the rear axle.
– Fit the wheels: Steel disc wheel ⇒ page 144 , light alloy wheel
⇒ page 146 .
– Set down the vehicle on its wheels and tighten the bolt for the
suspension strut at the bottom to 90 Nm.

94 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

5.2 Exploded view of suspension strut

Standard running gear

1 - Self-locking nut, 30 Nm
❑ Always replace after re‐
moving
2 - Rubber bush
❑ Apply talc before fitting
3 - Upper spring plate
4 - Damping ring
❑ Apply talc before fitting
❑ Different thicknesses;
for assignment refer to
⇒ Electronic parts cata‐
logue
❑ Installation position
⇒ page 97
5 - Spacer
6 - Washer
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
7 - Buffer stop
with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Insert in protective
sleeve
8 - Protective sleeve
9 - Coil spring
❑ Surface of spring wind‐
ing must not be dam‐
aged
❑ Pay attention to colour
code; for assignment re‐
fer to ⇒ Electronic parts
catalogue
❑ Heed PR no. (factory
code) on vehicle data
sticker prior to replace‐
ment ⇒ page 1
❑ Installation position ⇒ page 101
10 - Protective cap
❑ Attach to shock absorber
11 - Lower spring plate
❑ With stop for coil spring
❑ Installation position ⇒ page 97
12 - Shock absorber
❑ For assignment, refer to ⇒ Electronic parts catalogue
❑ Checking ⇒ page 6
❑ Heed PR no. (factory code) on vehicle data sticker prior to replacement ⇒ page 1
❑ Disposal ⇒ page 4

Sports and standard running gear for Audi S4/S6

5. Rear suspension strut - Four-wheel drive vehicles 95

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Self-locking nut, 50 Nm
❑ Always replace after re‐
moving
2 - Dished washer
3 - Stop ring
4 - Adapter
❑ Pay attention to different
versions
❑ Marking lug (rounded on
left, square on right)
faces outwards
5 - Bearing ring
❑ On assembly, insert po‐
sitioning stud in adapter
recess
6 - Upper spring plate
7 - Ring
8 - Damping ring
9 - Buffer stop
❑ Pay attention to different
versions
10 - Protective sleeve
11 - Coil spring
❑ Can be replaced sepa‐
rately
❑ Surface of spring wind‐
ing must not be dam‐
aged
❑ Pay attention to colour
code; for assignment re‐
fer to ⇒ Electronic parts
catalogue
❑ Heed PR no. (factory code) on vehicle data sticker prior to replacement ⇒ page 1
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ permitted
Installation positionby ⇒
unless authorised AUDIpage 101AG does not guarantee or accept any liability
AG. AUDI
with respect to the correctness of information in this document. Copyright by AUDI AG.
12 - Protective cap
13 - Lower spring plate
❑ Installation position ⇒ page 97
14 - Shock absorber
❑ For assignment, refer to ⇒ Electronic parts catalogue
❑ Checking ⇒ page 6
❑ Heed PR no. (factory code) on vehicle data sticker prior to replacement ⇒ page 1
❑ Disposal ⇒ page 4

96 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Installation position of damping ring

• Both lugs of the damping ring must be in contact with the spring
plate.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installation position of lower spring plate
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
• Stop of coil spring faces centre of damper eye.

5.3 Dismantling and assembling suspension strut

5. Rear suspension strut - Four-wheel drive vehicles 97

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Special tools and workshop

equipment required
♦ Driving-on sleeve -VW 244
B-
♦ Shock absorber wrench
-3017 A-
♦ 19 mm socket attachment
-3077-
♦ Suspension strut tensioner
-V.A.G 1752-

♦ Shock absorber set -T10001-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

98 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Dismantling
– Clamp the suspension strut holder -V.A.G 1752/2- in the vice.
– Insert the suspension strut in the suspension strut holder -
V.A.G 1752/2- .
– Insert the studs in the holes in the upper spring plate, screw
to the spring plate and fix in this position by way of the clamp‐
ing levers.

– Pay attention to the exact position of the pointer for angle ad‐
justment.
• The pointer position must be observed on assembly.
– Position the coil spring with the spring tensioner -V.A.G
1752/1- on the spring seat.

– Make sure the coil spring is positioned correctly in the spring

holder -V.A.G 1752/4- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5. Rear suspension strut - Four-wheel drive vehicles 99

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Pre-tension the coil spring with the spring tensioner -V.A.G

1752/1- until the upper spring plate is free.
– Use the shock absorber wrench -3017 A- to unscrew the nut
from the piston rod.
– On versions with M12 piston rod thread, use the shock ab‐
sorber set -T10001- or a 19 mm socket attachment -3077- and
provide support with an Allen key.
– Detach the rubber bush.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Release the clamping lever -bottom arrow-, push up the height

adjuster and swivel aside.
– Detach the corresponding components.

Assembly
– Pull the piston rod as far as it will go out of the shock absorber.
– Position the lower spring plate on the shock absorber, paying
attention to the position of the spring winding stop -arrow a-
with respect to the damper eye -arrow b-.
• Installation position: The stop of the spring plate faces to the
front at the right suspension strut and to the rear at the left
suspension strut.
– Press home the protective cap on the shock absorber.

100 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Position the coil spring with the spring tensioner -V.A.G

1752/1- on the shock absorber.
• The coloured mark on the coil spring must face the lower
spring plate.
– Make sure the ends of the springs are in contact with the stops
of the spring support and the spring seat -arrow-.

– Position the damping ring on the coil spring.

• The stop of the damping ring must make contact with the end
of the spring winding.
– Fit the buffer stop.
– Fit the components corresponding to the running gear version.
– Screw on the nut.

– Set up the locking tool.

– Tighten all the clamping levers of the locking tool.
– Set the height adjuster together with the spring plate to 45°,
position over the suspension strut, lower and secure.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Tighten the nut to 30 Nm using the shock absorber wrench

-3017 A- .
– Carefully slacken off the coil spring, paying attention to correct
positioning of the coil spring and the upper and lower spring
plates.
– As soon as the spring tensioner -V.A.G 1752/1- is free, stop
slackening off and detach the spring tensioner.
– Take the suspension strut out of the suspension strut holder -
V.A.G 1752/2- .

5. Rear suspension strut - Four-wheel drive vehicles 101

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

5.4 Exploded view of suspension strut with self-levelling suspension

Note

For installation position of pressure pipes, refer to ⇒ page 103 .

1 - Self-locking nut, 50 Nm
❑ Always replace after re‐
moving
2 - Dished washer
3 - Stop ring
4 - Adapter
❑ Different versions; for
assignment refer to ⇒
Electronic parts cata‐
logue
❑ Marking lug (rounded on
left, square on right)
faces outwards
5 - Bearing with positioning
stud
❑ On assembly, insert po‐
sitioning stud in adapter
recess
❑ Installation position
⇒ page 104 and
⇒ page 104
6 - Upper spring plate
❑ Installation position
⇒ page 104
7 - Buffer stop
❑ Pay attention to different
versions
8 - Damping ring
❑ Installation position
⇒ page 103
9 - Coil spring
❑ Can be replaced sepa‐
rately
❑ Surface of spring winding must not be damaged
❑ Pay attention to colour code; for assignment refer to ⇒ Electronic parts catalogue
❑ Heed PR no. (factory code) on vehicle data sticker prior to replacement ⇒ page 1
❑ Installation position ⇒ page 108
10 - Protective cap
❑ Prising off shock absorber ⇒ page 103
❑ Always replace after removing
❑ Installation position ⇒ page 103
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
11 - Bellows permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Installation position ⇒ page 103
12 - Lower spring plate
❑ Installation position ⇒ page 104

102 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

13 - O-ring
❑ Coat with silicone grease; for silicone grease refer to ⇒ Electronic parts catalogue
❑ Insert in annular grooves of piston rod
14 - O-ring
❑ Coat with silicone grease; for silicone grease refer to ⇒ Electronic parts catalogue
❑ Insert in annular grooves of piston rod
15 - Shock absorber
❑ For assignment, refer to ⇒ Electronic parts catalogue
❑ Checking ⇒ page 6
❑ Heed PR no. (factory code) on vehicle data sticker prior to replacement ⇒ page 1
❑ Disposal ⇒ page 4

Installation position of pressure pipes for self-levelling suspension

a - Installation angle of pressure pipe on left side of vehicle ap‐
prox. 110°
b - Installation angle of pressure pipe on right side of vehicle ap‐
prox. 110°
L - Left side of vehicle
R - Right side of vehicle
F - Direction of travel

Prising protective cap off shock absorber

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installation position of damping
permitted unless authorised byring, protective
AUDI AG. cap
AUDI AG does notand bellows
guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
8 - Damping ring
10 - Protective cap
11 - Bellows

5. Rear suspension strut - Four-wheel drive vehicles 103

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Installation position of lower spring plate

• Stop of coil spring faces centre of damper eye.

Note

The illustration shows the right suspension strut; at the left sus‐
pension strut the stop faces to the rear.

a - Coil spring
b - Lower spring plate
c - Damper

Installation position of bearing ring with respect to upper spring

plate
• The recess -arrow B- points towards the connection of the hy‐
draulic pipe at the spring plate.
• Left suspension strut: The positioning stud Copying
Protected by copyright. -arrowforA- points
private or commercial purposes, in part or in whole, is not
towards “L” at the upper spring plate.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
• Right suspension strut: The positioning stud -arrow A- points
towards “R” at the upper spring plate.

Installation position of bearing with positioning stud

– Attach the bearing such that the positioning stud engages in
the recess of the suspension strut adapter -arrow-.

5.5 Dismantling and assembling suspension strut with self-levelling suspension

104 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Special tools and workshop

equipment required
♦ Driving-on sleeve -VW 244
B-
♦ Shock absorber wrench
-3017 A-
♦ 19 mm socket attachment
-3077-
♦ Suspension strut tensioner
-V.A.G 1752-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Shock absorber set -T10001-

5. Rear suspension strut - Four-wheel drive vehicles 105

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Dismantling
– Clamp the suspension strut holder -V.A.G 1752/2- in the vice.
– Insert the suspension strut in the suspension strut holder -
V.A.G 1752/2- .
– Insert the studs in the holes in the upper spring plate, screw
to the spring plate and fix in this position by way of the clamp‐
ing levers.

– Pay attention to the exact position of the pointer for angle ad‐by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
justment. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
• The pointer position must be observed on assembly.
– Position the coil spring with the spring tensioner -V.A.G
1752/1- on the spring seat.

– Make sure the coil spring is positioned correctly in the spring

holder -V.A.G 1752/4- .

106 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Pre-tension the coil spring with the spring tensioner -V.A.G

1752/1- until the upper spring plate is free.
– Use the shock absorber wrench -3017 A- to unscrew the nut
from the piston rod.
– On versions with M12 piston rod thread, use the shock ab‐
sorber set -T10001- or a 19 mm socket attachment -3077- and
provide support with an Allen key.
– Detach the rubber bush.

– Release the clamping lever -bottom arrow-, push up the height

adjuster and swivel aside.
– Detach the corresponding components.

Assembly
– Pull the piston rod as far as it will go out of the shock absorber.
– Position the lower spring plate on the shock absorber, paying
attention to the position of the spring winding stop -arrow a-
with respect to the damper eye -arrow b-.
• Installation position: The stop of the spring plate faces to the
rear at the right suspension strut and to the front at the left
suspension strut.
– Pre-assemble the protective cap in the bellows ⇒ page 102 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5. Rear suspension strut - Four-wheel drive vehicles 107

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Position the coil spring with the spring tensioner -V.A.G

1752/1- on the shock absorber.

Note

The coloured mark on the coil spring must face the lower spring
plate.

– Make sure the ends of the springs are in contact with the stops
of the spring support and the spring seat -arrow-.

– Position the damping ring on the coil spring.

– The stop of the damping ring must make contact with the end
of the spring winding.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Use the driving-on sleeve -VW 244 B- to drive home the pro‐
tective cap with bellows on the damper.
– Fit the buffer stop.

– Fold the bellows over the damping ring.

• The bellows must not be twisted when fitted.
– Fit the components corresponding to the running gear version.
– Screw on the nut.

108 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Set up the locking tool.

– Tighten all the clamping levers of the locking tool.
– Set the height adjuster together with the spring plate to 45°,
position over the suspension strut, lower and secure.

– Tighten the nut to 30 Nm using the shock absorber wrench

-3017 A- .
– Carefully slacken off the coil spring, paying attention to correct
positioning of the coil spring and the upper and lower spring
plates.
– As soon as the spring tensioner -V.A.G 1752/1- is free, stop
slackening off and detach the spring tensioner.
– Take the suspension strut out of the suspension strut holder -
V.A.G 1752/2- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5. Rear suspension strut - Four-wheel drive vehicles 109

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

6 Rear wheel bearing - Four-wheel

drive vehicles
⇒ “6.1 Exploded view of wheel bearing”, page 110
⇒ “6.2 Removing and installing wheel bearing housing”,
page 114

6.1 Exploded view of wheel bearing

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1 - Circlip with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Ensure correct position‐
ing
❑ Joint faces downwards
2 - Wheel bearing housing
❑ Removing and installing
⇒ page 114
3 - Wheel bearing
❑ Can also be replaced
using -V.A.G 1459B-
and -V.A.G 1459B/2-
with the wheel bearing
housing fitted
❑ Stepped inside diame‐
ter
❑ Installation position:
Large inside diameter of
wheel bearing facing
wheel hub
❑ Pressing out
⇒ page 113
❑ Pressing in
⇒ page 114
❑ Detaching bearing inner
race ⇒ page 113
4 - Splash plate
5 - Bolt, 10 Nm
6 - Wheel hub
❑ Can also be replaced
using -V.A.G 1459B-
and -V.A.G 1459B/2-
with the wheel bearing
housing fitted
❑ Different versions ⇒ Electronic parts catalogue
❑ Pressing out ⇒ page 112
❑ Pressing in ⇒ page 113

110 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Special tools and workshop

equipment required
♦ Adapter -VW 295 A-
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-
♦ Press tool -VW 408 A-
♦ Press tool -VW 412-
♦ Pressing-on sleeve -VW
455-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

6. Rear wheel bearing - Four-wheel drive vehicles 111

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ Thrust plate -30 - 11-

♦ Thrust pad -2050-

♦ Suction grip -3208-

♦ Hydraulic removal
and installation tool -
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
V.A.G 1459B- with with respect to the correctness of information in this document. Copyright by AUDI AG.
supplementary set -
V.A.G 1459B/2-

Pressing out wheel hub

112 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Pressing wheel bearing out of wheel bearing housing

Note

Start by removing the circlip.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Pressing wheel hub into wheel bearing

Detaching bearing inner race from wheel hub

Always use a puller with tensioner e.g. -Kukko 204-2- .

6. Rear wheel bearing - Four-wheel drive vehicles 113

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Pressing wheel bearing into wheel bearing housing

Note

Insert circlip.

6.2 Removing and installing wheel bearing

housing
Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Detach the permitted
wheel trim. Use the suction grip -3208- to remove
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
the trim cap on vehicles with light alloy disc wheels.
– Screw out the drive shaft bolt (only slacken off with vehicle
standing on its wheels - risk of accident).
– Remove the wheels.

– Unscrew the brake caliper and secure with a piece of wire such
that the weight of the brake caliper does not strain or damage
the brake hose.
– Detach the brake disc.

114 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Remove the wheel bearing housing/trapezium link connection

-lower arrow-.
– Pull the ABS speed sensor out of the wheel bearing housing.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Unscrew the wheel bearing housing from the mounting brack‐
with respect to the correctness of information in this document. Copyright by AUDI AG.

et.

– Remove the suspension strut connection -arrow-.

– Unscrew the connecting link holder on vehicles with an anti-
roll bar at the rear.

– Unscrew the transverse link from the wheel bearing housing.

– Detach the wheel bearing housing from the drive shaft.
Installing
– Secure the drive shaft to the wheel hub with a new bolt, tighten
to 190 Nm and give a further 180° turn.

WARNING

Risk of accident.
♦ The vehicle must be standing on its wheels when slack‐
ening off and tightening.

6. Rear wheel bearing - Four-wheel drive vehicles 115

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

7 Rear drive shaft - Four-wheel drive

vehicles
⇒ “7.1 General ”, page 116
⇒ “7.2 Exploded view of drive shaft”, page 116
⇒ “7.3 Removing and installing drive shaft ”, page 119
⇒ “7.4 Quantities and type of grease”, page 120

7.1 General

Note

Heed the general information ⇒ page 2 .

7.2 Exploded view of drive shaft

1 - Circlip
❑ Use commercially avail‐
able circlip pliers for re‐
moving and installing
2 - Seal
❑ Replace
❑ Detach the backing and
bond into the joint
❑ Not on vehicles with 4-
cyl. engine
3 - Inner constant velocity joint
❑ Different outside diame‐
ters ⇒ Electronic parts
catalogue
❑ Replace as a complete
unit
❑ Pressing off
⇒ page 118
❑ Pressing on
⇒ page 118
4 - Inner constant velocity joint
boot
❑ With vent hole for joint
diameters 100 and 108
mm
❑ Check for cracks and
abrasion
❑ Drive off with mandrel
❑ Before attaching to con‐
stant velocity joint, apply
sealant to sealing sur‐
face; for sealant refer to
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ Electronic parts cata‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
logue
5 - Profile shaft
❑ Same length on left and right

116 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

6 - Boot
❑ Check for cracks and abrasion
7 - Clamp
❑ Replace
❑ Tensioning ⇒ page 119
8 - Circlip
❑ Always replace after removing
❑ Insert in shaft groove
9 - Outer constant velocity joint
❑ Different outside diameters ⇒ Electronic parts catalogue
❑ Replace as a complete unit
❑ Pressing off ⇒ page 119
❑ Installing: Drive onto the shaft with a plastic-headed hammer until the circlip engages

Special tools and workshop

equipment required
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-
♦ Press tool -VW 411-
♦ Support sleeve -VW 522-
♦ Tensioner -40 - 204 A-
♦ Pressure screw -3207-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

7. Rear drive shaft - Four-wheel drive vehicles 117

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ Suction grip -3208-

♦ Hose clamp pliers -

V.A.G 1275-

Pressing off inner con‐

stant velocity joint

Note

♦ Use a mandrel to
drive off the boot be‐
forehand.
♦ Support the ball hub.

Pressing on inner constant velocity joint

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note with respect to the correctness of information in this document. Copyright by AUDI AG.

The chamfer at the inside diameter of the ball hub (splines) must
face the contact collar of the drive shaft.

– Press home the joint.

– Insert the circlip.

118 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Pressing off outer constant velocity joint

– Clamp the drive shaft in a vice with soft jaws.
– Detach the large clamp and fold back the boot.
– Spread the circlip -arrow- and at the same time screw in the
M16 threaded end of the pressure screw -3207- until the con‐
stant velocity joint is pressed off the profile shaft.

Tensioning clamp

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

7.3 Removing and installing drive shaft

Removing
– Detach the wheel trim. Use the suction grip -3208- to remove
the trim cap on vehicles with light alloy disc wheels.
– Screw out the drive shaft bolt (only slacken off with vehicle
standing on its wheels - risk of accident).
– Raise the vehicle.
– Remove the wheels.

– Unscrew the brake caliper and secure with a piece of wire such
that the weight of the brake caliper does not strain or damage
the brake hose.
– Detach the brake disc.

Note

♦ Remove the heat shield for the inner joint when taking out the
left drive shaft.
♦ Remove the cover plate for the fuel tank when taking out the
right drive shaft.

7. Rear drive shaft - Four-wheel drive vehicles 119

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Screw the wheel bolts into the wheel hub and secure the wheel
hub with a tyre lever to prevent it turning.
– Unscrew the drive shaft from the drive flange.
– Pull the ABS speed sensor slightly out of the axle support.

– Remove the suspension strut connection -arrow-.

– Unscrew the transverse link from the wheel bearing housing.

– Swivel aside the wheel bearing housing downwards.
– If necessary, use a plastic-headed hammer to knock the drive
shaft out of the wheel hub.
– Take out the drive shaft.
Installing
– Secure the drive shaft to the wheel hub with a new
Protected bolt, tighten
by copyright. Copying for private or commercial purposes, in part or in whole, is not
to 190 Nm and give a further 180° turn. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

WARNING

Risk of accident.
♦ The vehicle must be standing on its wheels when slack‐
ening off and tightening.

7.4 Quantities and type of grease

Joint Grease fill of constant velocity joints;
Grease ⇒ Electronic parts catalogue
Total quantity Joint Bellows
g g g
Outer joint ∅ mm 89 90 40 50
98 120 80 40
Inner joint ∅ mm 100 80 30 50
108 120 35 85

120 Rep. Gr.42 - Rear suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Note

Re-grease the joint if necessary on replacing the boot.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

7. Rear drive shaft - Four-wheel drive vehicles 121

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

43 – Self-levelling suspension
1 Self-levelling suspension - Front-
wheel drive vehicles
⇒ “1.1 General ”, page 122
⇒ “1.2 Exploded view of self-levelling suspension”, page 122
⇒ “1.3 Checking operation of control valve ”, page 129
⇒ “1.4 Checking control valve for leaks ”, page 129
⇒ “1.5 Checking pressure container ”, page 130
⇒ “1.6 Adjusting self-levelling suspension”, page 132

1.1 General
♦ The self-levelling suspension is set by way of an adjustable-
length connecting link between the self-levelling control valve
and a lever attached to the anti-roll bar of the rear axle
⇒ page 142 .
♦ Provide support for the corresponding components when tight‐
ening pipe unions. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ When the fluid circuit has been opened, always: with respect to the correctness of information in this document. Copyright by AUDI AG.

– Check all unions for leaks, start the engine and perform a vis‐
ual inspection.
– Check the hydraulic fluid level with the vehicle unladen and
top up if necessary ⇒ page 276 .
♦ The system is vented automatically whilst driving.

1.2 Exploded view of self-levelling suspension

Reservoir, suction hose, return pipe, connector

Note

Items -1 ... 9- apply to all vehicles.

122 Rep. Gr.43 - Self-levelling suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Clamp
2 - Return hose
❑ Between rotary slide
valve housing and con‐
nector
3 - Connector
4 - Return pipe
❑ Between self-levelling
control valve and con‐
nector
5 - Return pipe
❑ Between connector and
reservoir
6 - Reservoir
❑ Fresh fill with hydraulic
fluid, capacity 2.5 l; for
hydraulic fluid refer to ⇒
Electronic parts cata‐
logue
❑ Checking hydraulic fluid
level with vehicle unla‐
den ⇒ page 276
7 - Coolant hose
8 - Suction hose
❑ Between reservoir and
tandem pump
9 - Return pipe
❑ Between connector and
reservoir

Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Items -10 ... 17- only apply to vehi‐
with respect to the correctness of information in this document. Copyright by AUDI AG.

cles with 6-cyl. engine.

10 - Holder
11 - Nut, 10 Nm
12 - Retaining plate
13 - Pipe
❑ Between expansion hose and control valve
14 - Expansion hose
❑ Between pump and clip at longitudinal member
15 - Clip
16 - Buffer
17 - Combi bolt, 35 Nm

Note

Items -18 ... 26- only apply to vehi‐

cles with 4 and 5-cyl. engines.

1. Self-levelling suspension - Front-wheel drive vehicles 123

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

18 - Nut, 10 Nm
19 - Buffer
20 - Retaining plate
21 - Pipe
❑ Between expansion hose and control valve
22 - Clip
23 - Expansion hose
❑ Between pump and clip at longitudinal member
24 - Self-tapping screw, 8 Nm
25 - Holder
26 - Clip

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Right pressure container, pressure pipe, self-levelling control
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

valve
with respect to the correctness of information in this document. Copyright by AUDI AG.

27 - Direction of travel
28 - Nut, 20 Nm
29 - Right suspension strut
❑ Exploded view
⇒ page 19
30 - Pressure pipe
❑ Between right suspen‐
sion strut and right pres‐
sure container
❑ Replacement part of
heavy-duty design ⇒
Electronic parts cata‐
logue
❑ On replacing the pres‐
sure pipes, the connec‐
tion piece
⇒ Item 5 (page 56) must
also be renewed as only
heavy-duty M16x1.5
pressure pipes are now
available
❑ Installation position of
pressure pipes: Saloon
⇒ page 128 , Avant
⇒ page 128
❑ Tightening torque for
union nuts: 40 Nm
❑ Unscrewing
⇒ page 128
31 - Bolt, 20 Nm
32 - Pipe
❑ Between pressure con‐
tainer and self-levelling

124 Rep. Gr.43 - Self-levelling suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

control valve
33 - Rear axle
34 - Self-locking nut, 5 Nm
35 - Bolt, 20 Nm
36 - Combi bolt, 10 Nm
37 - Holder
38 - Self-levelling control valve
❑ Pipe connections ⇒ page 127
❑ Checking operation ⇒ page 129
❑ Checking for leaks ⇒ page 129
39 - Washer
40 - Connecting link
❑ Self-levelling control valve - rear axle
41 - Washer
42 - Right pressure container
❑ As-new charge pressure at 20 °C: 24 ... 25 bar
❑ Minimum charge pressure at 20 °C: 15 bar
❑ Checking pressure container ⇒ page 130
❑ Disposal ⇒ page 4
❑ Different installation position ⇒ page 128

Left pressure container, brake pressure regulator, pressure pipe,

connector

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Self-levelling suspension - Front-wheel drive vehicles 125

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

43 - Direction of travel
44 - Pipe
❑ Connector - self-level‐
ling control valve
45 - Connector
❑ On introduction of ABS
“Bosch 5.0” as of Model
Year 1995, the pipe
⇒ Item 47 (page 126)
was replaced by an ad‐
ditional vent valve
⇒ Item 48 (page 126)
46 - Brake pressure regulator
❑ Cannot be adjusted
❑ Discontinued on intro‐
duction of ABS “Bosch
5.0” as of Model Year
1995
47 - Pipe
❑ Between connector and
brake pressure regula‐
tor
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Discontinued on intro‐
with respect to the correctness of information in this document. Copyright by AUDI AG.
duction of ABS “Bosch
5.0” as of Model Year
1995
48 - Vent valve, 15 Nm
❑ Unfasten to dissipate
pressure
49 - Washer
50 - Bolt, 20 Nm
51 - Bolt, 10 Nm
52 - Pipe
❑ Connector - left pressure container
53 - Left pressure container
❑ As-new charge pressure at 20 °C: 24 ... 25 bar
❑ Minimum charge pressure at 20 °C: 15 bar
❑ Checking pressure container ⇒ page 130
❑ Disposal ⇒ page 4
54 - Nut, 20 Nm
55 - Pressure pipe
❑ Between left suspension strut and left pressure container
❑ Replacement part of heavy-duty design ⇒ Electronic parts catalogue
❑ On replacing the pressure pipes, the connection piece ⇒ Item 5 (page 56) must also be renewed as only
heavy-duty M16x1.5 pressure pipes are now available
❑ Installation position of pressure pipes: Saloon ⇒ page 128 , Avant ⇒ page 128
❑ Tightening torque for union nuts: 40 Nm
❑ Unscrewing ⇒ page 128
56 - Right suspension strut
❑ Exploded view ⇒ page 19

126 Rep. Gr.43 - Self-levelling suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Special tools and work‐

shop equipment re‐
quired
♦ 14 mm socket wrench
-3150-

♦ 17 mm Crow ring
spanner (e.g. from
Stahlwille) or

♦ 17 mm open twelve-
point socket attach‐
ment (e.g. from Ha‐
zet)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Self-levelling control
valve pipe connections
1- Pipe: Control valve
- right pressure
container
2- Self-levelling con‐
trol valve
3- Pressure pipe:
Tandem pump -
self-levelling con‐
trol valve
4- Return pipe: Self-
levelling control
valve - manifold in
engine compart‐
ment

1. Self-levelling suspension - Front-wheel drive vehicles 127

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

5- Pipe: Self-levelling
control valve - con‐
nector

Installation position of right pressure container on Avant

Note

The -arrow- points in the direction of travel.

Unscrewing and screwing on hydraulic pipe

♦ For standard hydraulic pipe: 14 mm socket wrench -3150- .
♦ For heavy-duty hydraulic pipe: 17 mm Crow ring spanner (e.g.
from Stahlwille) or 17 mm open twelve-point socket attach‐
ment (e.g. from Hazet).

Note

♦ Conversion to the heavy-duty pressure pipe also involves re‐

placing the connection piece ⇒ Item 5 (page 56)Protected
. by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ The suspension strut has to be removed ⇒ page 51 and dis‐
with respect to the correctness of information in this document. Copyright by AUDI AG.

mantled ⇒ page 57 for this purpose.

Tightening torque for union nuts: 40 Nm.

Installation position of pressure pipes for self-levelling suspension

- Saloon
a - Installation angle of pressure pipe on left side of vehicle ap‐
prox. 30°
b - Installation angle of pressure pipe on right side of vehicle ap‐
prox. 20°
L - Left side of vehicle
R - Right side of vehicle
F - Direction of travel

Installation position of pressure pipes for self-levelling suspension

- Avant
a - Installation angle of pressure pipe on left side of vehicle ap‐
prox. 80°
b - Installation angle of pressure pipe on right side of vehicle ap‐
prox. 65°
L - Left side of vehicle
R - Right side of vehicle
F - Direction of travel

128 Rep. Gr.43 - Self-levelling suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1.3 Checking operation of control valve

Sequence of operations
– Leave the engine idling. The vehicle must be standing on its
wheels.
Checking raising function
– Load the luggage compartment with approx. 100 kg (2 peo‐
ple).
• The rear of the vehicle must be raised (time required: up to
approx. 2 minutes).
Checking lowering function
– Remove the load from the luggage compartment.
• The vehicle must be lowered again after extension of the sus‐
pension.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

1.4 Checking control valve for leaks

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Special tools and workshop equipment required

♦ Self-levelling suspension system tester -V.A.G 1354-

♦ Flanging device for brake pipes -VAS 6056-

Sequence of operations
– Detach the dust cap from the bleed screw.
– Attach the bleed hose of the self-levelling suspension system
tester -V.A.G 1354- to the bleed screw.
– Open the bleed screw and collect the hydraulic fluid emerging
with a suitable vessel.
– Close the bleed screw at the connector.
– Detach the bleed hose from the bleed screw of the connector
and attach to the bleed screw of the pressure tester.

1. Self-levelling suspension - Front-wheel drive vehicles 129

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Unscrew the pressure pipe at the brake pressure regulator

-arrow-.
Vehicles with no brake pressure regulator:

Note

The load-sensitive brake pressure regulator was discontinued on

introduction of ABS “Bosch 5.0” as of Model Year 1995. A further
bleed screw is thus fitted in place of the pressure pipe.

– Connection of the self-levelling suspension system tester -

V.A.G 1354- requires a further brake pipe as adapter between
the connector and the pressure tester.
– This pipe should be produced using the flanging tool from the
flanging device for brake pipes -VAS 6056- .

All vehicles (continued):

– Connect the self-levelling suspension system tester -V.A.G
1354- to the pressure pipe.
– Load the luggage compartment with approx. 100 kg.
– Start the engine and let it idle.
– Observe the reading on the pressure gauge and switch off the
ignition at approx. 50 bar. Note down the gauge pressure.
– Leave the vehicle for roughly 3 hours.
– Check the reading on the pressure gauge: Max. pressure drop
5 bar.
– If the drop in pressure is more than 5 bar, the control valve is
leaking and should be replaced.
– Remove the self-levelling suspension system tester -V.A.G
1354- .
– Check the hydraulic fluid level in the reservoir and replenish
the fluid if necessary.

1.5 Checking pressure container

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Special tools and workshop equipment required
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Self-levelling suspension system tester -V.A.G 1354-

130 Rep. Gr.43 - Self-levelling suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Sequence of operations
– Detach the dust cap from the bleed screw.
– Attach the bleed hose of the self-levelling suspension system
tester -V.A.G 1354- to the bleed screw.
– Open the bleed screw and collect the hydraulic fluid emerging
with a suitable vessel.
– Close the bleed screw at the connector.
– Detach the bleed hose from the bleed screw of the connector
and attach to the bleed screw of the pressure tester.

Checking left pressure container:

– Unscrew the pipe at the right pressure container and connect
up the self-levelling suspension system tester -V.A.G 1354- .

– Adjust the linkage in the direction of travel.

– Move the linkage upwards as far as it will go.

– Leave the engine idling.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Observe the reading on the pressurepermitted
gauge andauthorised
unless switchbyoff theAG. AUDI AG does not guarantee or accept any liability
AUDI

ignition at approx. 30 bar.

with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Self-levelling suspension - Front-wheel drive vehicles 131

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Carefully open the bleed screw of the self-levelling suspension

system tester -V.A.G 1354- until the pressure gauge pointer
slowly drops.
– Use a suitable vessel to collect the hydraulic fluid emerging.

Note

♦ The pressure at which the pointer stops dropping slowly and

drops abruptly to 0 bar is the charge pressure of the pressure
container.
♦ Specification: 15 ... 25 bar

Checking right pressure container:

– Unscrew the pipe at the left pressure container and connect
up the self-levelling suspension system tester -V.A.G 1354- .
– Further testing is the same as for the left pressure container.
– Conclude by attaching the dust cap to the bleed screw at the
connector and checking the hydraulic fluid level with the vehi‐
cle unladen; top up if necessary ⇒ page 276 .

Note

If the charge pressure is close to the minimum pressure (15 bar),

e.g. left pressure container 15 bar and right pressure container
16.5 bar, it is advisable to replace both pressure containers.

1.6 Adjusting self-levelling suspension

Special tools and workshop equipment required
♦ ∅ 4 mm bit

Note

♦ Adjustment is best performed on a lifting platform with ramp or

over a pit.
♦ Two wooden adjusting blocks of size 50 x 50 x 324 mm are
required.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

132 Rep. Gr.43 - Self-levelling suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Sequence of operations
– Fit the adjusting blocks on the left and right at the measure‐
ment points shown (dimension “b”).
– Just load the luggage compartment to the extent required for
the adjusting blocks to make contact with the measurement
points (approx. 100 kg).

– Unfasten the nut -arrow-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Fix the lever in position at the self-levelling control valve hous‐

ing with a ∅ 4 mm bit.
– Tighten the nut.
– Remove the bit.

1. Self-levelling suspension - Front-wheel drive vehicles 133

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

2 Self-levelling suspension - Four-

wheel drive vehicles
⇒ “2.1 General ”, page 134
⇒ “2.2 Exploded view of self-levelling suspension”, page 134
⇒ “2.3 Checking operation of control valve ”, page 139
⇒ “2.4 Checking control valve for leaks ”, page 139
⇒ “2.5 Checking pressure container ”, page 140
⇒ “2.6 Adjusting self-levelling suspension”, page 142

2.1 General
♦ The self-levelling suspension is set by way of an adjustable-
length connecting link between the self-levelling control valve
and a lever attached to the anti-roll bar of the rear axle
⇒ page 142 .
♦ Provide support for the corresponding components when tight‐
ening pipe unions.
♦ When the fluid circuit has been opened, always:
– Check all unions for leaks, start the engine and perform a vis‐
ual inspection.
– Check the hydraulic fluid level with the vehicle unladen and
top up if necessary ⇒ page 276 .
♦ The system is vented automatically whilst driving.

2.2 Exploded view of self-levelling suspension

Reservoir, suction hose, return pipe, connector

Note

Items -1 ... 9- apply to all vehicles.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

134 Rep. Gr.43 - Self-levelling suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Clamp
2 - Return hose
❑ Between rotary slide
valve housing and con‐
nector
3 - Connector
4 - Return pipe
❑ Between self-levelling
control valve and con‐
nector
5 - Return pipe
❑ Between connector and
reservoir
6 - Reservoir
❑ Fresh fill with hydraulic
fluid, capacity 2.5 l; for
hydraulic fluid refer to ⇒
Electronic parts cata‐
logue
❑ Checking hydraulic fluid
level with vehicle unla‐
den ⇒ page 276
7 - Coolant hose
8 - Suction hose
❑ Between reservoir and
vane pump
9 - Return pipe
❑ Between connector and
reservoir

Note

Items -10 ... 17- only apply to vehi‐

cles with 6-cyl. engine.

10 - Holder
11 - Nut, 10 Nm
12 - Retaining plate
13 - Pipe
❑ byBetween
Protected expansion
copyright. Copying for privatehose and control
or commercial valve
purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
14
with- respect
Expansion hose of information in this document. Copyright by AUDI AG.
to the correctness
❑ Between pump and clip at longitudinal member
15 - Clip
16 - Buffer
17 - Combi bolt, 35 Nm

Note

Items -18 ... 26- only apply to vehi‐

cles with 4 and 5-cyl. engines.

2. Self-levelling suspension - Four-wheel drive vehicles 135

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

18 - Nut, 10 Nm
19 - Buffer
20 - Retaining plate
21 - Pipe
❑ Between expansion hose and control valve
22 - Clip
23 - Expansion hose
❑ Between pump and clip at longitudinal member
24 - Self-tapping screw, 8 Nm
25 - Holder
26 - Clip

Right pressure container, pressure pipe, self-levelling control

valve

27 - Right suspension strut

❑ Exploded view
⇒ page 19
28 - Washer
29 - Nut, 20 Nm
30 - Bolt, 20 Nm
31 - Holder
32 - Self-locking nut, 10 Nm
33 - Lever
34 - Anti-roll bar
35 - Bearing ring (rubber)
36 - Clip
37 - Bolt
38 - Self-locking nut, 10 Nm
❑ Tighten alternately to
the specified torque
39 - Spacer
40 - Shackle
41 - Self-locking nut, 5 Nm
42 - Connecting link
❑ Self-levelling control
valve - lever
43 - Washer
44 - Nut
45 - Self-levelling control valve
❑ Pipe connections Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

136 Rep. Gr.43 - Self-levelling suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

⇒ page 139
❑ Checking operation ⇒ page 139
❑ Checking for leaks ⇒ page 139
46 - Bolt, 10 Nm
47 - Cross piece
48 - Right pressure container
❑ As-new charge pressure at 20 °C: 24 ... 25 bar
❑ Minimum charge pressure at 20 °C: 15 bar
❑ Checking pressure container ⇒ page 140
❑ Disposal ⇒ page 4
49 - Pipe
❑ Between right pressure container and control valve
50 - Holder Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

51 - Pressure pipe
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Between right suspension strut and right pressure container
❑ Installation position of pressure pipes on all four-wheel drive vehicles ⇒ page 139 .
52 - Direction of travel

Left pressure container, brake pressure regulator, pressure pipe,

connector

2. Self-levelling suspension - Four-wheel drive vehicles 137

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

53 - Direction of travel
54 - Pressure pipe
❑ Between left suspen‐
sion strut and left pres‐
sure container
❑ Installation position of
pressure pipes on all
four-wheel drive vehi‐
cles ⇒ page 139 .
55 - Holder
56 - Bolt, 20 Nm
57 - Washer
58 - Left pressure container
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

❑ As-new charge pres‐

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
sure at 20 °C: 24 ... 25
bar
❑ Minimum charge pres‐
sure at 20 °C: 15 bar
❑ Checking pressure con‐
tainer ⇒ page 140
❑ Disposal ⇒ page 4
59 - Nut, 20 Nm
60 - Holder
61 - Brake pressure regulator
❑ Discontinued on intro‐
duction of ABS “Bosch
5.0” as of Model Year
1995
62 - Pipe
❑ Between connector and
left pressure container
63 - Pipe
❑ Between connector and brake pressure regulator
❑ Control pressure for brake pressure regulator
64 - Connector
65 - Washer
66 - Nut, 10 Nm
67 - Vent valve, 15 Nm
❑ Unfasten to dissipate pressure
68 - Pipe
❑ Connector - self-levelling control valve
69 - Left suspension strut
❑ Exploded view ⇒ page 19

138 Rep. Gr.43 - Self-levelling suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Control valve pipe connections

1- Control valve
2- Pipe: Control valve - right pressure container
3- Pressure pipe: Tandem pump - control valve
4- Return pipe: Control valve - manifold in engine compartment
5- Pipe: Control valve - connector

Installation position of pressure pipes for self-levelling suspension

on all four-wheel drive vehicles
a - Installation angle of pressure pipe on left side of vehicle ap‐
prox. 110°
b - Installation angle of pressure pipe on right side of vehicle ap‐
prox. 110°
L - Left side of vehicle
R - Right side of vehicle Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
F - Direction of travel with respect to the correctness of information in this document. Copyright by AUDI AG.

2.3 Checking operation of control valve

Sequence of operations
– Leave the engine idling. The vehicle must be standing on its
wheels.
Checking raising function:
– Load the luggage compartment with approx. 100 kg (2 peo‐
ple).
• The rear of the vehicle must be raised (time required: up to
approx. 2 minutes).
Checking lowering function:
– Remove the load from the luggage compartment.
• The vehicle must be lowered again after extension of the sus‐
pension.

2.4 Checking control valve for leaks

Special tools and workshop equipment required
♦ Self-levelling suspension system tester -V.A.G 1354-

2. Self-levelling suspension - Four-wheel drive vehicles 139

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Sequence of operations
– Detach the dust cap from the bleed screw.
– Attach the bleed hose of the self-levelling suspension system
tester -V.A.G 1354- to the bleed screw.
– Open the bleed screw and collect the hydraulic fluid emerging
with a suitable vessel.
– Close the bleed screw at the connector.
– Detach the bleed hose from the bleed screw of the connector
and attach to the bleed screw of the pressure tester.

– Unscrew the pressure pipe at the left or right pressure con‐

tainer.

– Connect the self-levelling suspension system tester -V.A.G

1354- to the pressure pipe.
– Load the luggage compartment with approx. 100 kg.
– Start the engine and let it idle.
– Observe the reading on the pressure gauge and switch off the
ignition at approx. 50 bar. Note down the gauge pressure.
– Leave the vehicle for roughly 3 hours.
– Check the reading on the pressure gauge: Max. pressure drop
5 bar.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– If the drop in pressure
permittedis more
unless than by
authorised 5 AUDI
bar,AG. theAUDI
control
AG doesvalve is or accept any liability
not guarantee
leaking and shouldwith
berespect
replaced.
to the correctness of information in this document. Copyright by AUDI AG.

– Remove the self-levelling suspension system tester -V.A.G

1354- .
– Check the hydraulic fluid level in the reservoir and replenish
the fluid if necessary.

2.5 Checking pressure container

Special tools and workshop equipment required

140 Rep. Gr.43 - Self-levelling suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ Self-levelling suspension system tester -V.A.G 1354-

Sequence of operations
– Detach the dust cap from the bleed screw.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Attach the bleed hose of the self-levelling suspension system
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
tester -V.A.G 1354- to the bleed screw. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Open the bleed screw and collect the hydraulic fluid emerging
with a suitable vessel.
– Close the bleed screw at the connector.
– Detach the bleed hose from the bleed screw of the connector
and attach to the bleed screw of the pressure tester.

Checking right pressure container:

– Unscrew the pipe at the left pressure container and connect
up the self-levelling suspension system tester -V.A.G 1354- .

– Unscrew the linkage of the control valve at the rear axle

-arrow-.

2. Self-levelling suspension - Four-wheel drive vehicles 141

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Move the linkage in the direction of travel until it is horizontal.

– Leave the engine idling.
– Observe the reading on the pressure gauge and switch off the
ignition at approx. 30 bar.

– Carefully open the bleed screw of the self-levelling suspension

system tester -V.A.G 1354- until the pressure gauge pointer
slowly drops.
– Use a suitable vessel to collect the hydraulic fluid emerging.

Note

♦ The pressure at which the pointer stops dropping slowly and

drops abruptly to 0 bar is the charge pressure of the pressure
container.
♦ Specification: 15 ... 25 bar

Checking left pressure container:

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Unscrew the pipe permitted
at the unless
right authorised
pressure container
by AUDI AG. AUDIandAG doesconnect
not guarantee or accept any liability
up the self-levellingwith
suspension system tester -V.A.G 1354- .
respect to the correctness of information in this document. Copyright by AUDI AG.

– Further testing is the same as for the right pressure container.

– Conclude by attaching the dust cap to the bleed screw at the
connector and checking the hydraulic fluid level with the vehi‐
cle unladen; top up if necessary ⇒ page 276 .

Note

If the charge pressure is close to the minimum pressure (15 bar),

e.g. left pressure container 15 bar and right pressure container
16.5 bar, it is advisable to replace both spring cylinders.

2.6 Adjusting self-levelling suspension

Special tools and workshop equipment required
♦ ∅ 4 mm bit

Note

♦ Adjustment is best performed on a lifting platform with ramp or

over a pit.
♦ Two wooden adjusting blocks of size 50 x 50 x 342 mm are
required.

142 Rep. Gr.43 - Self-levelling suspension

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Sequence of operations
– Fit the adjusting blocks on the left and right at the measure‐
ment points shown (dimension “b”).
– Just load the luggage compartment to the extent required for
the adjusting blocks to make contact with the measurement
points (approx. 100 kg).

– Unfasten the nut -arrow- at the self-levelling control valve lev‐

er.

– Fix the lever in position at the self-levelling control valve hous‐

ing with a ∅ 4 mm bit.
– Tighten the nut at the self-levelling control valve lever.
– Remove the bit.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Self-levelling suspension - Four-wheel drive vehicles 143

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

44 – Wheels, tyres, vehicle geometry

1 Wheels and tyres
⇒ “1.1 General ”, page 144
⇒ “1.2 Exploded view of steel disc wheel”, page 144
⇒ “1.3 Exploded view of light alloy wheel ”, page 146
⇒ “1.4 Balancing wheels on vehicle”, page 147

1.1 General
To ensure vehicle safety, tyres are not to be replaced individually
but rather at least on an axle basis.
The tyres with the deeper tread should always be fitted on the
front wheels.
It is advisable to use tyres of the same make, design and tread
type on all wheels.
Always replace the rubber valve when renewing a disc wheel or
the tyre.
A wheel/tyre combination for the right side of the vehicle must be
fitted as spare wheel in the case of tyres with directional tread
pattern.

1.2 Exploded view of steel disc wheel

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

144 Rep. Gr.44 - Wheels, tyres, vehicle geometry

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Tyre
2 - Valve
❑ Always replace
❑ For assignment, refer to
⇒ Electronic parts cata‐
logue
3 - Rim
4 - Wheel bolt/lockable wheel
bolt, 120 Nm
❑ Anti-theft wheel bolt
⇒ page 147
❑ M14x1.5x27.5 mm
5 - Lock cylinder
❑ Attach to the corre‐
sponding wheel bolt and
lock
6 - Trim cap
❑ Attach to lock cylinder
7 - Wheel trim cap
❑ Place large opening
(marked on back with
tyre valve symbol) over
valve and then press on‐
to disc wheel to ensure
proper fit
8 - Retaining spring for balanc‐
ing weights
9 - Balancing weights
❑ Max. 60 g per rim flange
permissible

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Wheels and tyres 145

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1.3 Exploded view of light alloy wheel

1 - Tyre
2 - Rim
3 - Valve
❑ Always replace
❑ For assignment, refer to
⇒ Electronic parts cata‐
logue
4 - Wheel bolt/lockable wheel
bolt, 120 Nm
❑ M14×1.5x27.5 mm
❑ Anti-theft wheel bolt
⇒ page 147
5 - Lock cylinder
❑ Attach to the corre‐
sponding wheel bolt and
lock
6 - Trim cap
❑ Attach to lock cylinder
7 - Retaining spring for balanc‐
ing weight
8 - Balancing weight
❑ Max. 60 g per rim flange
permissible
9 - Wheel trim cap
❑ Detaching ⇒ page 146

Detaching wheel trim cap

– Clean the trim cap with a moist sponge.
– Attach the suction grip -3208- to the trim cap and press on.
– Detach the trim cap. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Release the suction grip from the trim cap by moving with
it side‐
respect to the correctness of information in this document. Copyright by AUDI AG.
ways.

146 Rep. Gr.44 - Wheels, tyres, vehicle geometry

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Anti-theft wheel bolt

1- Anti-theft wheel bolt
2- Trim cap
3- Adapter for wheel bolt

1.4 Balancing wheels on vehicle

Establish whether the vehicle is fitted with a traction control sys‐
tem (ASR).
On such vehicles the traction control system must be deactivated
before performing balancing work.

Note

♦ Wheel imbalance causes front end judder and steering wheel

vibration.
♦ During the balancing procedure, position the vehicle on the
sensor platforms (both axles for four-wheel drive, front axle for
front-wheel drive).
♦ Heed the operating instructions of the balancing equipment
manufacturer.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Wheels and tyres 147

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

2 Wheel alignment
⇒ “2.1 General ”, page 148
⇒ “2.2 Test prerequisites for wheel alignment”, page 148
⇒ “2.3 Wheel alignment specifications - Front-wheel drive vehi‐
cles”, page 149
⇒ “2.4 Wheel alignment specifications - Four-wheel drive vehicles
except Audi S6 Plus”, page 149
⇒ “2.5 Wheel alignment specifications - Audi S6 Plus”,
page 150
⇒ “2.6 Adjusting front axle camber”, page 150
⇒ “2.7 Adjusting front axle toe”, page 151
⇒ “2.8 Checking rear axle camber - Front-wheel drive vehicles”,
page 152
⇒ “2.9 Adjusting rear Protected
axle camber - Four-wheel
by copyright. drive
Copying for private vehicles”,
or commercial purposes, in part or in whole, is not
page 152 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ “2.10 Adjusting rear axle toe - Four-wheel drive vehicles”, page
152

2.1 General
♦ Wheel alignment is only to be performed using wheel align‐
ment equipment approved by AUDI.
♦ Alignment always includes both the front and rear axles.
♦ Proper vehicle performance cannot otherwise be ensured.

Note

♦ Wheel alignment should not be checked before the vehicle has

completed 1000 ... 2000 km to allow the coil springs to fully
settle.
♦ When performing adjustment work, always attempt to adhere
as closely as possible to the relevant specifications.

2.2 Test prerequisites for wheel alignment

Determine the running gear version from the vehicle data sticker.

Note

The vehicle data sticker can be found in the spare wheel recess
at the rear and in the service schedule.

♦ 1BA = Standard running gear

♦ 1BE = Sports running gear
♦ 1BG = Standard running gear with self-levelling suspension at
rear
• Proper attachment and adjustment of sensors; heed operating
instructions of equipment manufacturer
• Tread depth difference of no more than 2 mm on one axle
• Specified tyre inflation pressure

148 Rep. Gr.44 - Wheels, tyres, vehicle geometry

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

• When performing wheel alignment, make sure that no sliding

base or turntable is on the end stop.
• Vehicle kerb weight 1).
• Vehicle properly aligned, bounced several times and allowed
to settle
• Suspension, steering and steering linkage checked for imper‐
missible play and damage
1)Kerb weight means: Weight of vehicle ready for operation (fuel
tank full, spare wheel, vehicle tool kit, vehicle jack)

2.3 Wheel alignment specifications - Front-

wheel drive vehicles
Applicable to all engines
Front axle Standard running gear Sports running gear
(1BA) (1BE)
Self-levelling suspen‐
sion (1BG)
Toe per wheel (no pressure) +7′ ± 5′ +7′ ± 5′
Overall toe (no pressure) +15′ ± 10′ +15′ ± 10′
Camber –40′ +35′ / –25′ –50′ +25′ / –35′
Camber (vehicles with 6-cyl. engine) –50′ +35′ / –25′ –50′ +35′ / –25′
Max. perm. difference between the two sides max. 30′ max. 30′
Toe-out on turns at 20 degrees –1° 40′ ± 30′ –1° 40′ ± 30′
Caster (not adjustable) –1° 10′ ± 40′ –1° 10′ ± 40′
Max. perm. difference between the two sides max. 1° max. 1°

Rear axle Standard running gear (1BA)

Self-levelling suspension (1BG)
Sports running gear (1BE)
Camber –50′ ± 30′
Max. perm. difference between the two sides max. 30′
Overall toe +5′ + 25′
Max. perm. misalignment with respect to longitudinal max. 20′
axis of vehicle

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2.4 Wheel
permitted unless authorised alignment
by AUDI AG. AUDI AG doesspecifications
not guarantee or accept-any
Four-wheel
liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
drive vehicles except Audi S6
Plus
Front axle Standard running gear Sports running gear
(1BA) (1BE)
Self-levelling suspen‐
sion (1BG)
Toe per wheel (no pressure) +7′ ± 5′ +7′ ± 5′
Overall toe (no pressure) +15′ ± 10′ +15′ ± 10′
Camber –40′ +35′ / –25′ –50′ +35′ / –25′
Camber (vehicles with 98 kW 5-cyl. engine and 103 kW –50′ +25′ / –35′
4-cyl./16V engine)
Camber (vehicles as of 169 kW Audi S4, S6, S4 4.2 and –50′ +20′ / –40′
S6 4.2)
Max. perm. difference between the two sides max. 30′ max. 30′

2. Wheel alignment 149

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Front axle Standard running gear Sports running gear

(1BA) (1BE)
Self-levelling suspen‐
sion (1BG)
Toe-out on turns at 20 degrees –1° 10′ ± 30′ –1° 10′ ± 30′
Caster (not adjustable) +55′ ± 40′ +55′ ± 40′
Max. perm. difference between the two sides max. 1° max. 1°

Rear axle Standard running gear (1BA)

Self-levelling suspension (1BG)
Sports running gear (1BE)
Camber –15′ ± 15′
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Max. perm.permitted
difference between
unless authorised by the
AUDI two sides
AG. AUDI AG does not guarantee or accept any liability max. 30′
Toe per wheel with specified camber +5′ + 5′
with respect to the correctness of information in this document. Copyright by AUDI AG.

Overall toe with specified camber +10′ ± 10′

2.5 Wheel alignment specifications - Audi S6 Plus

Front axle Sports running gear 1BE
Overall toe (no pressure) –15′ ± 10′
Camber –50′ +20′ / –40′
Max. perm. difference between the two sides max. 30′
Toe-out on turns at 20 degrees –1° 10′ ± 30′
Caster (not adjustable) +55′ ± 40′
Max. perm. difference between the two sides max. 1°

Rear axle Sports running gear 1BE

Camber –30′ ± 15′
Max. perm. difference between the two sides max. 30′
Toe per wheel with specified camber +5′ + 5′
Overall toe with specified camber +10′ ± 10′

2.6 Adjusting front axle camber

The camber is to be adjusted by moving the suspension strut in
the elongated holes of the suspension strut mount with the vehicle
standing on its wheels.
Sequence of operations
– Detach the trim cap.
– Unfasten the nuts -arrows-.
– Move the suspension strut in the elongated holes.
– Tighten the nuts and check the camber (correct if necessary).
– Check and if necessary adjust the toe.

150 Rep. Gr.44 - Wheels, tyres, vehicle geometry

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

2.7 Adjusting front axle toe

Special tools and workshop equipment required
♦ Steering centring tool -3076-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

The toe is always to be adjusted at both track rods and only with
optical wheel alignment equipment using the steering centring
tool -3076- .

Sequence of operations
• Wheel alignment specifications ⇒ page 149
– Move the wheels to the straight-ahead position.
– Insert the steering centring tool -3076- in the steering box.
– Check whether the steering wheel spoke is horizontal; if nec‐
essary re-position the steering wheel and set it straight.
– Halve the total specified value, set this value at the left and
right track rod and secure the track rods.
– Remove the steering centring tool -3076- .
– Perform a test drive.

Note

If slight steering wheel skew is found after the test drive, this is to
be corrected by way of even adjustment of the track rods on both
sides.

Example:
If the steering wheel spoke hangs slightly to the right, lengthen
the right track rod slightly and shorten the left track rod by the
same amount. Check the toe again if necessary.

2. Wheel alignment 151

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

For right-hand drive vehicles:

– When using the steering centring tool -3076- on right-hand
drive vehicles, set the gauge to “R” -arrow-.

2.8 Checking rear axle camber - Front-

wheel drive vehicles
• Wheel alignment specifications ⇒ page 149
On front-wheel drive vehicles, the camber can be checked but not
adjusted.

Note

If the measured values are outside the permitted tolerance, check

the axle beam for damage and replace if necessary.

2.9 Adjusting rear axle camber - Four-wheel

drive vehicles
Sequence of operations
• Wheel alignment specifications ⇒ page 149
– Unfasten the lock nuts -arrows-.

– Turn the threaded sleeve -arrow- accordingly.

– Tighten the nut, check theProtected
camber value again and correct if
by copyright. Copying for private or commercial purposes, in part or in whole, is not
necessary. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.10 Adjusting rear axle toe - Four-wheel

drive vehicles
Special tools and workshop equipment required

152 Rep. Gr.44 - Wheels, tyres, vehicle geometry

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ Toe adjusting lever -3134-

Sequence of operations
• Wheel alignment specifications ⇒ page 149
• Before adjusting the toe, always check and if necessary adjust
the camber setting ⇒ page 152 .
– Unfasten the nuts -arrows-.

– Insert the toe adjusting lever -3134- .

– Move the mounting bracket in the trapezium link accordingly.
– Tighten the nuts, check the camber value again and correct if
necessary.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Wheel alignment 153

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

48 – Steering
1 Power-assisted steering
⇒ “1.1 General ”, page 154
⇒ “1.2 Exploded view of power-assisted steering”, page 154
⇒ “1.3 Exploded view of track rods”, page 157
⇒ “1.4 Removing and installing power-assisted steering box”,
page 159

1.1 General

Note

♦ Heed the general information ⇒ page 2 .

♦ Heed the safety precautions for vehicles with airbags
⇒ page 191 .
♦ If the power-assisted steering box has been removed and in‐
stalled, centring of the corrugated tube must be checked be‐
fore securing the universal joint on the steering pinion.
Procedure for centring corrugated tube ⇒ page 207 .

Rules for cleanliness

♦ Absolute cleanliness is essential when working on the power-
assisted steering.
♦ Thoroughly clean joints and surrounding areas prior to dis‐
connection.
♦ Place parts removed on a clean surface and cover over if re‐
pair work is not to be performed immediately.
♦ Only use lint-free cloths.
♦ Do not remove replacement parts from their wrapping until
immediately prior to installation.
♦ Always use genuine wrapped parts.
♦ The hydraulic fluid drained off is not to be re-used.

1.2 Exploded view of power-assisted steering

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

154 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Power-assisted steering
box
❑ Removing and installing
⇒ page 159
❑ Adjusting ⇒ page 179
❑ Disposal ⇒ page 5
❑ If the power-assisted
steering box has been
removed and installed,
centring of the corruga‐
ted tube must be
checked before secur‐
ing the universal joint on
the steering pinion. Pro‐
cedure for centring cor‐
rugated tube
⇒ page 207 .
2 - Washer
❑ 3 mm thick
3 - Bolt
4 - Banjo bolt, 40 Nm
❑ Different versions ⇒
Electronic parts cata‐
logue
5 - Expansion hose
❑ Bolt to rotary slide valve
housing
❑ Different versions ⇒
Electronic parts cata‐
logue
6 - Seals
❑ Always replace after re‐
moving
7 - Seals
❑ Always replace after removing
8 - Return hose
❑ Bolt to rotary slide valve housing
❑ Different versions ⇒ ElectronicProtected
parts by catalogue
copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
9 - Self-locking nut, 25 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Always replace after removing

10 - Washer
11 - Washer
12 - Self-locking nut, 25 Nm
❑ Always replace after removing
13 - Steering column
14 - Universal joint
❑ Take out to remove steering box
❑ Attach to steering pinion and secure with bolt ⇒ Item 15 (page 155)
15 - Bolt
16 - Seal
❑ Take out before removing steering box
❑ Pay attention to correct positioning in bulkhead

1. Power-assisted steering 155

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

17 - Bolt, 50 Nm
18 - Bolt, 50 Nm
19 - Left wheel housing
20 - Left track rod
❑ Exploded view ⇒ page 157
21 - Threaded section
❑ Adjusting toe at both track rods ⇒ page 151
22 - Left track rod end
❑ Exploded view ⇒ page 157
❑ Pressing off ⇒ page 157
23 - Self-locking nut, 50 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Always replace after removing with respect to the correctness of information in this document. Copyright by AUDI AG.

24 - Lock nut, 50 Nm
25 - Holder
❑ Pay attention to correct positioning in bellows
❑ Turn through 180° for fitting on right-hand drive vehicles (centring hole faces to right)
26 - Locking plate
❑ Always replace after removing
27 - Bolt
28 - Bolt, 80 Nm
❑ The vehicle must be standing on its wheels when tightening
29 - Right track rod
❑ Exploded view ⇒ page 157
30 - Nut, 40 Nm
31 - Self-locking nut, 50 Nm
❑ Always replace after removing
32 - Right track rod end
❑ Exploded view ⇒ page 157
❑ Pressing off ⇒ page 157
33 - Self-locking nut, 25 Nm
❑ Always replace after removing
❑ As of vehicle ident. no. PN 050 668, higher grade bolted joint of strength class 10.9 (can be seen from
label 10.9 on bolt head of ⇒ Item 3 (page 155) )
❑ New tightening torque: 35 Nm
❑ Tightening torque for M10 bolted joint: 55 Nm
❑ If a new steering box (10 mm hole) is fitted in old bodywork, a spring pin for the M8 bolted joint must be
driven into the steering box ⇒ page 157 and ⇒ page 157
34 - Washer

156 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Pressing off track rod end

Driving in spring pin

– Insert soft jaws in the vice, mount the steering box and use a
hammer to carefully drive in the spring pin (2nd mechanic re‐
quired).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Installation position of spring pin

• The slot of the spring pin must be perpendicular to the steering
axis -arrow-.

1.3 Exploded view of track rods

1. Power-assisted steering 157

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Eye of track rod arm

❑ Offset faces in direction
of travel ⇒ page 158
2 - Track rod
❑ Different versions; for
assignment refer to ⇒
Electronic parts cata‐
logue
❑ Offset track rod: Offset
faces road surface
⇒ page 159
3 - Right track rod end
❑ Offset faces in direction
of travel ⇒ page 158
4 - Left track rod end
❑ Offset faces in direction
of travel ⇒ page 158

Note

When fitting the two track rod ends

or adjusting the toe, make sure the
two joints are not tilted forwards or
backwards with respect to the joint
pins.

Attaching track rods to steering box

Note the position of the offset
Protected at the Copying
by copyright. eyes for
of private
the track rod arms
or commercial purposes, in part or in whole, is not
-arrow 1- and at the track rod
permitted ends
unless -arrow
authorised 2-. AG. AUDI AG does not guarantee or accept any liability
by AUDI
with respect to the correctness of information in this document. Copyright by AUDI AG.

158 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Offset track rods

The offsets -arrows- face downwards towards the road surface.

1.4 Removing and installing power-assisted

steering box
Special tools and workshop equipment required
♦ Hose clamps up to 25 mm -3094-

Removing
If the power-assisted steering box has been removed
Protected and Copying
by copyright. instal‐for private or commercial purposes, in part or in whole, is not
led, centring of the corrugated tube must bepermitted
checked before
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

securing the universal joint on the steering pinion. Procedure for

with respect to the correctness of information in this document. Copyright by AUDI AG.

centring corrugated tube ⇒ page 207 .

Note

Removal and installation are described on the basis of a vehicle

with 6-cyl. engine, air conditioner and ABS.

Vehicles with airbag:

WARNING

Move the steering wheel to the centre position and do not turn
during repair work, as this could damage the coil connector of
the airbag unit.

– Disconnect the battery ⇒ Rep. Gr. 27 .

1. Power-assisted steering 159

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Prise the cover off the noise insulation.

– Unscrew the nuts -arrows-.
– Unscrew the crankcase breather hoses at the valve covers
and detach.
– Press the noise insulation to the rear and at the same lift it up.
– Detach the vacuum hose from the noise insulation and take
out the noise insulation.

– Use an extraction bottle to draw off as much brake fluid as

possible from the brake fluid reservoir.
– Detach the supply hose for the clutch master cylinder
-right arrow-.
– Pull out the vacuum pipe of the brake servo.
– Unscrew the brake pipes at the brake master cylinder
-centre arrows-.
– Unplug the connector for the brake fluid indicator -left arrow-.

– Remove the brake pipe -arrow 1- between the hydraulic unit

and the adapter -3-.

Note

After removing the brake pipes, seal all holes with plugs from the
repair set -1H0 698 311 A- .

– Unclip the brake pipe -2- from the mounts at the wheel housing
and bulkhead -arrows-.
– Carefully press the brake pipe in the direction of travel until it
does not impede removal of the brake servo.

– Unscrew the holder for the vacuum unit from the left valve
cover and lay aside.
– Remove the bottom left storage compartment ⇒ Rep. Gr. 70 .
– Take out the air vent in the footwell on the left.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

160 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Unscrew and lay aside the relay carrier -arrows-.

– Take out the cover for the relay carrier.
– Take the pin out of the clevis for the brake servo.
– Carefully fold back the soundproofing mat around the pedal
bracket such that the pedal bracket nuts can be unscrewed.
– Unclip the fuel pipe on the left of the bulkhead from the mount
and press slightly in direction of travel.
– Take out the brake servo with brake master cylinder to the
front.

– Screw out the bolts of the universal joint -arrows-.

– Detach the universal joint from the steering box.
– Take out the bulkhead collar.

– Pinch off the suction and return pipes with hose clamps
-3094- .

– Unscrew the expansion hose and return hose from the rotary
slide valve housing.
– Route the expansion hose upwards to the plenum chamber.
– Vehicles with Servotronic: Unplug the connector at the Ser‐
votronic valve.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Power-assisted steering 161

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Bend open the tabs of the locking plate and unscrew the track
rods -arrows-.
– Cut off the cable tie securing the wiring harness at the right
wheel housing.
– Screw out the right steering box bolt.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

162 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Unclip the connector of the speed sensor wire on the left from
the holder.
– Unscrew the holder for the speed sensor wire from the wheel
housing.
– Unscrew the front wheels.
– Unscrew the steering box bolts on the left side at the wheel
housing.
– Slide the steering box to the left into the wheel housing open‐
ing until the wiring harness on the right side of the steering box
can be pressed to the rear.
– Take out the steering box through the opening in the right
wheel housing by turning it accordingly (two mechanics re‐
quired).

Note

Take care not to damage the bellows when taking out the steering
box.

Installing
Install in reverse order, paying attention to the following:
– Insert the locking plate in the bellows of the steering box and
fix in position with both bolts.
– Insert the steering box through the opening in the right wheel
housing (two mechanics required).
– Pay attention to correct routing of the wiring harness and re-
install the cable tie.
– Carefully insert the bulkhead collar.
– Attach the steering box to the left and right wheel housing.
– Screw in the holder for the speed sensor on the left and clip in
the speed sensor.
– Screw the left bolt out of the holder for track rod attachment.
– Insert the left track rod in the holder and loosely screw in the
bolt.
– Screw the right bolt out of the holder for track rod attachment.
– Insert the right track rod in the holder and loosely screw in the
bolt.
– Only tighten the two bolts to torque with the vehicle standing
on its wheels.
– Pay attention to correct positioning of theCopying
Protected by copyright. holder in theorbellows.
for private commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Attach the return hose and expansion
with hose to ofthe
respect to the correctness rotaryinslide
information this document. Copyright by AUDI AG.
valve housing such that neither makes any contact.
– Detach the hose clamps -3094- from the return hose and suc‐
tion hose.
– Check for correct positioning of the Procon-ten cable in the
support bracket.
– Carefully position insulating mats beneath the pedal cluster.
– Fit the brake pipes in line with the designations on the hy‐
draulic unit.
– Insert the brake pipes and fuel pipe in the holders.

1. Power-assisted steering 163

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Bleed the brake system and check for leaks ⇒ Rep. Gr. 47 .
– Check the position of the steering wheel and perform front axle
wheel alignment if necessary.
– Connect the battery ⇒ Rep. Gr. 27 .
– Check the hydraulic fluid level and replenish the fluid if nec‐
essary.
– Check the return hose and expansion hose at the rotary slide
valve housing for leaks.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

164 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

2 Power-assisted steering - Audi S4/S6

⇒ “2.1 General ”, page 165
⇒ “2.2 Exploded view of power-assisted steering”, page 165
⇒ “2.3 Exploded view of track rods”, page 169
⇒ “2.4 Removing and installing power-assisted steering box”,
page 170

2.1 General

Note

♦ Heed the general information ⇒ page 2 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

♦ Heed the safety precautions for vehicles with

withairbags
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ page 191 .
♦ If the power-assisted steering box has been removed and in‐
stalled, centring of the corrugated tube must be checked be‐
fore securing the universal joint on the steering pinion.
Procedure for centring corrugated tube ⇒ page 207 .

Rules for cleanliness

♦ Absolute cleanliness is essential when working on the power-
assisted steering.
♦ Thoroughly clean joints and surrounding areas prior to dis‐
connection.
♦ Place parts removed on a clean surface and cover over if re‐
pair work is not to be performed immediately.
♦ Only use lint-free cloths.
♦ Do not remove replacement parts from their wrapping until
immediately prior to installation.
♦ Always use genuine wrapped parts.
♦ The hydraulic fluid drained off is not to be re-used.

2.2 Exploded view of power-assisted steering

Note

The illustration corresponds to the Audi S4 4.2.

2. Power-assisted steering - Audi S4/S6 165

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Power-assisted steering
box
❑ Removing and installing
⇒ page 170
❑ Adjusting ⇒ page 179
❑ Disposal ⇒ page 5
❑ If the power-assisted
steering box has been
removed and installed,
centring of the corruga‐
ted tube must be
checked before secur‐
ing the universal joint on
the steering pinion. Pro‐
cedure for centring cor‐
rugated tube
⇒ page 207 .
2 - Bolt
3 - Washer
❑ 3 mm thick
4 - Right wheel housing
5 - Self-locking nut, 35 Nm
❑ Always replace after re‐
moving
❑ Tightening torque for
M10 bolted joint: 55 Nm
❑ If a new steering box (10
mm hole) is fitted in old
bodywork, a spring pin
for the M8 bolted joint
must be driven into the
steering box
⇒ page 168 and
⇒ page 168
6 - Bolt, 40 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
7 - Steering damper with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Can be replaced with steering box in position

❑ Disposal ⇒ page 5
❑ For checking, unscrew from the bracket at the right wheel housing
❑ Checking operation: Squeeze the steering damper by hand; when doing so, it must be possible to slide
in the piston rod smoothly and with uniform force over the entire distance.
❑ Given proper functioning, slight traces of shock absorber oil are not grounds for replacement
8 - Bushing
9 - Holder
10 - Right track rod end
❑ Exploded view ⇒ page 169
❑ Pressing off ⇒ page 168
11 - Self-locking nut, 50 Nm
❑ Always replace after removing
12 - Right track rod
❑ Exploded view ⇒ page 169
❑ Different versions; for assignment refer to ⇒ Electronic parts catalogue

166 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

13 - Bolt, 80 Nm
❑ The vehicle must be standing on its wheels when tightening
14 - Bolt
15 - Locking plate
❑ Always replace after removing
16 - Holder
❑ Pay attention to correct positioning in bellows
❑ Turn through 180° for fitting on right-hand drive vehicles (centring hole faces to right)
17 - Bushing
18 - Nut, 40 Nm
19 - Seals
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Always replace after removing
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
20 - Banjo bolt, 40 Nm
❑ Different versions; for assignment refer to ⇒ Electronic parts catalogue
21 - Expansion hose
❑ Bolt to rotary slide valve housing
❑ Different versions; for assignment refer to ⇒ Electronic parts catalogue
22 - Return hose
❑ Bolt to rotary slide valve housing
❑ Different versions; for assignment refer to ⇒ Electronic parts catalogue
23 - Self-locking nut, 25 Nm
❑ Always replace after removing
24 - Washer
25 - Bolt
26 - Steering column
27 - Universal joint
❑ Take out to remove steering box
❑ Attach to steering pinion and secure with bolt ⇒ Item 28 (page 167)
28 - Bolt
29 - Washer
30 - Self-locking nut, 25 Nm
❑ Always replace after removing
31 - Seal
❑ Take out before removing steering box
❑ Pay attention to correct positioning in bulkhead
32 - Bolt, 50 Nm
33 - Left wheel housing
34 - Left track rod
❑ Note on assembly ⇒ page 169
35 - Threaded section
❑ Adjusting toe at both track rods ⇒ page 151
36 - Left track rod end
❑ Exploded view ⇒ page 169
❑ Pressing off ⇒ page 157

2. Power-assisted steering - Audi S4/S6 167

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

37 - Self-locking nut, 50 Nm
❑ Always replace after removing
38 - Lock nut, 50 Nm

Pressing off track rod end

Driving in spring pin

– Insert soft jaws in the vice.
– Mount the steering box and use a hammer to carefully drive in
the spring pin (two mechanics required).

Installation position of spring pin

• The slot of the spring pin must be perpendicular to the steering
axis -arrow-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

168 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

2.3 Exploded view of track rods

1 - Eye of track rod arm

❑ Offset faces in direction
of travel ⇒ page 169
2 - Track rod
❑ Different versions; for
assignment refer to ⇒
Electronic parts cata‐
logue
❑ Offset track rod: Offset
faces road surface
⇒ page 170
3 - Right track rod end
❑ Offset faces in direction
of travel ⇒ page 169
4 - Left track rod end Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Offset faces in direction permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
of travel ⇒ page 169 with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

When fitting the two track rod ends

or adjusting the toe, make sure the
two joints are not tilted forwards or
backwards with respect to the joint
pins.

Attaching track rods to steering box

– Note the position of the offset at the eyes of the track rod arms
-arrow 1- and at the track rod ends -arrow 2-.

2. Power-assisted steering - Audi S4/S6 169

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Offset track rods

The offsets -arrows- face downwards towards the road surface.

2.4 Removing and installing power-assisted

steering box
Special tools and workshop equipment required
♦ Hose clamps up to 25 mm -3094-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Removing
If the power-assisted steering box has been removed and instal‐
led, centring of the corrugated tube must be checked before
securing the universal joint on the steering pinion. Procedure for
centring corrugated tube ⇒ page 207 .

Note

Removal and installation are described on the basis of an Audi

S4 4.2.

Vehicles with airbag:

WARNING

Move the steering wheel to the centre position and do not turn
during repair work, as this could damage the coil connector of
the airbag unit.

– Disconnect the battery ⇒ Rep. Gr. 27 .

– Unscrew the front wheels.

170 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Remove the anti-roll bar -right arrows-.

– Unscrew the air pipe holders on the right and left
-left arrows-.
– Detach the air pipes.

– Remove the top part of the air cleaner.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unscrew the bottom part of the air cleaner -arrows-, press to

the rear and lift out.
– Remove the right and left distributor cap.

– Unfasten the cable tie -bottom arrow-, remove the steering

damper -top arrow- and lift out.

2. Power-assisted steering - Audi S4/S6 171

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Bend open the tabs of the locking plate and unscrew the track
rods -arrows-.
– Unscrew the nuts from the track rod ends.

– Press the track rods off the steering arm.

– Prise both track rods out of the holder and the locking plate.
– Take out the track rods through the opening in the corre‐
sponding wheel housing.
– Take out the locking plate with holder.
– Remove the bottom left storage compartment.
– Take out the air vent in the footwell on the left.

– Screw out the bolts of the universal joint -arrows-.

– Detach the universal joint from the steering box.
– Take out the bulkhead collar.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Pinch off the suction and return pipes with hose clamps
-3094- .

172 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Unscrew the expansion hose -1- and return hose -2- from the
rotary slide valve housing.
– Vehicles with Servotronic: Unplug the connector at the Ser‐
votronic valve.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Whilst providing support at the T-piece, unscrew the return

pipe of the brake servo -1- from the T-piece.
– Unscrew the expansion hose -2- from the pressure pipe.
– Seal the T-piece and pressure pipe with a dummy plug.
– Push the expansion hose aside.

– Unscrew both bolts of the steering box in the left wheel housing
-arrows-.

– Screw out the right steering box bolt -arrow-.

– Screw out the bolts of the Procon-ten mounting bracket on the
right side and press aside the mounting bracket downwards.

2. Power-assisted steering - Audi S4/S6 173

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Unfasten the cable tie for attaching the wiring harness from
the bulkhead.
– Take the steering box out of the mounting bracket and guide
the wiring harness round the steering box to the rear.
– Take out the steering box to the right through the wheel hous‐
ing (two mechanics required).

Note

Take care not to damage the bellows of the steering box, the
steering pinion splines and the refrigerant pipes of the air condi‐
tioner.

Installing
– Insert the steering box, paying attention to correct positioning
of the wiring harnesses.
– Carefully re-insert the bulkhead collar.
– Fasten the holder into the bellows.
– Screw both bolts for track rod attachment loosely into the hold‐
er.
– Plug in the connector for the Servotronic valve.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

174 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Provide the annular nipples for the expansion hose -1- and the
return hose -2- with new seals and screw the banjo bolts
loosely into the rotary slide valve housing.
– Insert the steering box in the bulkhead collar and the bracket
on the right.
– Insert the right steering box bolt.
– Insert and tighten the left steering box bolts.
– Tighten the right bolt.
– Screw the expansion hose to the pressure pipe whilst provid‐
ing support at the hexagon of the expansion hose.
– Whilst providing support at the T-piece, screw the return pipe
of the brake servo into the T-piece and secure.
– Attach the return hose and expansion hose to the rotary slide
valve housing such that neither makes any contact.
– Detach the hose clamps -3094- from the return hose and suc‐
tion hose.
– Fit the Procon-ten mounting bracket (insert the lower bolt first
and then the upper bolt).
– Tighten the lower and then the upper bolt to 75 Nm.

Note

Make sure the cables are correctly positioned.

– Screw the left bolt out of the holder for track rod attachment.
– Insert the left track rod in the holder and loosely screw in the
bolt.
– Screw the right bolt out of the holder for track rod attachment.
– Insert the right track rod in the holder and loosely screw in the
bolt.
– Only tighten the two bolts to torque with the vehicle standing
on its wheels.
– Pay attention to correct positioning of the holder in the bellows.
– Install the steering damper:
♦ Pay attention to the different lengths of the spacer sleeves.
The shorter sleeve is installed between the holder and the
steering damper.
♦ Press down the bolt in the holder slightly to insert the steering
damper.
– Attach the wiring harnesses with cable ties to the bulkhead
and cable holders. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Fit and secure the right and left
withdistributor cap.
respect to the correctness of information in this document. Copyright by AUDI AG.

– Slip the universal joint onto the steering pinion.

– Insert and tighten the steering column/universal joint bolts.
– Insert and tighten the new universal joint/steering pinion
clamping bolt.
– Screw on the front wheels.
– Lower the vehicle and tighten the wheel nuts to 120 Nm.

2. Power-assisted steering - Audi S4/S6 175

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Tighten the bolts, track rods and steering box to the specified
torque and secure.
– Connect the battery ⇒ Rep. Gr. 27 .
– Check the hydraulic fluid level and replenish the fluid if nec‐
essary.
– Bleed the brake system and check for leaks ⇒ Rep. Gr. 47 .
– Fit the air cleaner.
– Fit the anti-roll bar.
– Check the position of the steering wheel and perform front axle
wheel alignment if necessary.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

176 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

3 Power-assisted steering box

⇒ “3.1 General ”, page 177
⇒ “3.2 Exploded view of power-assisted steering box”,
page 177
⇒ “3.3 Adjusting steering box”, page 179

3.1 General

Note

♦ Heed the general information ⇒ page 2 .

♦ Moisten all sealing elements with hydraulic fluid before instal‐
ling.
♦ The hydraulic fluid drained off is not to be re-used.
♦ If the power-assisted steering box has been removed and in‐
stalled, centring of the corrugated tube must be checked be‐
fore securing the universal joint on the steering pinion.
Procedure for centring corrugated tube ⇒ page 207 .

3.2 Exploded view of power-assisted steering box

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3. Power-assisted steering box 177

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Banjo bolt, 20 Nm
2 - Seals
❑ Always replace after re‐
moving
3 - Banjo bolt, 20 Nm
4 - Holder
❑ Insert between the
pipes
5 - Pipe
6 - Pipe with vibration damper
7 - Adjusting screw
❑ Adjusting ⇒ page 179
8 - Bolt, 20 Nm
9 - Seal
❑ Always replace after re‐
moving Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
10 - Cover with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Installation position:
The two adjacent holes
face in the direction of
travel
11 - Seal
❑ Always replace after re‐
moving
12 - Compression spring
13 - Washer
14 - Spring pin
❑ Slotted side faces in lon‐
gitudinal direction of
rack
15 - Thrust pieces
16 - Steering box
❑ Lubricate the rack with steering box grease; for steering box grease, refer to ⇒ Electronic parts catalogue
❑ Replace the steering box in the event of piston rod seal leakage
❑ If the power-assisted steering box has been removed and installed, centring of the corrugated tube must
be checked before securing the universal joint on the steering pinion. Procedure for centring corrugated
tube ⇒ page 207 .
17 - Clamp
❑ Always replace after removing
❑ Tensioning ⇒ page 179
18 - Bellows
❑ Replacement involves removing the steering box
❑ Lubricate the rack with steering box grease -A0F 063 000 04-
❑ Installation position ⇒ page 179
19 - Spacer sleeve
20 - Clamp
❑ Always replace after removing

178 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Installation position of bellows

• Take care not to twist the bellows on installation.
• The manufacturing mark/coloured identification line must run
in parallel with the steering box.

Tensioning clamp
• Dimension -a- = 15 ± 2 mm

3.3 Adjusting steering box

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

Two mechanics are required to perform adjustment. Adjustment

work is to be performed with the engine switched off and the ve‐
hicle standing on its wheels.

Sequence of operations
– Wheels in straight-ahead position
– Moving the steering wheel from side to side (roughly 30°
around the centre axis) will produce a rattling noise in the event
of excessive steering play.
– Have the second mechanic carefully screw the adjusting
screw -arrow- into the cover until the rattling noise disappears
inside the vehicle.
– The adjusting screw is then to be screwed in by a further ap‐
prox. 45° (= 1/8 of a turn).
– Carry out a test drive. In doing so, make sure the steering re‐
turns smoothly and automatically to the straight ahead position
after manoeuvring or cornering.
– Screw out the adjusting screw by approx. 15° if the steering
does not return automatically to the straight ahead position.

3. Power-assisted steering box 179

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

4 Servotronic
⇒ “4.1 General ”, page 180
⇒ “4.2 Exploded view of Servotronic”, page 180
⇒ “4.3 Checking power supply for Servotronic - Vehicles up to
Model Year 1993”, page 182
⇒ “4.4 Checking power supply for Servotronic - Vehicles as of
Model Year 1994”, page 183
⇒ “4.5 Checking Servotronic solenoid valve N119 - Vehicles up
to Model Year 1993”, page 183
⇒ “4.6 Checking Servotronic solenoid valve N119 - Vehicles as of
Model Year 1994”, page 184
⇒ “4.7 Checking vehicle speed signal - Vehicles as of Model Year
1994”, page 185
⇒ “4.8 Checking wiring between Servotronic control unit J236 and
connector point 1 - Vehicles up to Model Year 1993”, page 186
⇒ “4.9 Checking wiring between Servotronic solenoid valve N119
and connector point 1 - Vehicles up to Model Year 1993”,
page 187
⇒ “4.10 Checking valve wiring for short to voltage”, page 188
⇒ “4.11 Checking valve wiring for short to earth”, page 189

4.1 General
On vehicles with Servotronic, the steering assistance is regulated
electronically as a function of vehicle speed.
In the event of failure of the electronics, the steering operates in
the same manner as conventional power-assisted steering.
Failure is indicated by:
♦ The need for more steering force than usual when manoeu‐
vring the vehicle.
♦ Steering unusually light at high vehicle speeds
If the power-assisted steering is heavy on one side, e.g. light
steering to right but heavy steering to left, this is an indication of
a hydraulic fault.

Note

In such cases the steering box must be replaced.

4.2 Exploded view of Servotronic

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

180 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Servotronic control unit -

J236-
❑ Checking power supply
⇒ page 182
❑ Checking vehicle speed
signal ⇒ page 185
Fitting location up to Model
Year 1993
❑ On passenger's side be‐
hind glove box
❑ Removing ⇒ page 182
Fitting location as of Model Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Year 1994 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Relay carrier 1 in ple‐
num chamber, position
16
2 - Holder
❑ Discontinued as of Mod‐
el Year 1994
3 - Self-tapping screw
❑ Discontinued as of Mod‐
el Year 1994
4 - Speed nut
❑ Discontinued as of Mod‐
el Year 1994
5 - Connector for Servotronic
control unit
❑ Discontinued as of Mod‐
el Year 1994
❑ Checking wiring
⇒ page 186
6 - Connector point “1”
❑ Fitting location up to Model Year 1993: On driver's side beneath dash panel insert ⇒ page 182
❑ No longer of relevance to Servotronic as of Model Year 1994
7 - Connector for Servotronic solenoid valve -N119-
❑ Up to Model Year 1993 connected to dash panel wiring harness at connector point “1” ⇒ page 182
❑ Checking wiring ⇒ page 186
❑ As of Model Year 1994 connected to relay carrier 1 in plenum chamber
8 - Strainer
9 - Seal
❑ Always replace
10 - Seal
❑ Always replace
11 - Servotronic solenoid valve -N119-
❑ Remove vacuum brake servo to clean or replace ⇒ Rep. Gr. 47
❑ On vehicles with hydraulic brake servo this does not have to be removed
❑ Checking up to Model Year 1993 ⇒ page 183
❑ Checking as of Model Year 1994 ⇒ page 184

4. Servotronic 181
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

12 - Bolt, 3 Nm
13 - Steering box
❑ Audi 100/A6 exploded view ⇒ page 154
❑ Audi S4/S6 exploded view ⇒ page 165

Removing Servotronic control unit -J236- - vehicles up to Model

Year 1993
– Remove the glove box ⇒ Rep. Gr. 70 .
– Remove the holder with the Servotronic control unit -arrows-.
– Unplug the connector from the Servotronic control unit.
– Detach the Servotronic control unit from the holder.

Note

On vehicles with cruise control, the cruise control unit is attached

to the same holder as the Servotronic control unit.

Connector point “1” - vehicles up to Model Year 1993

Fitting location: Driver's side, beneath dash panel.
9 - Orange connector for Servotronic and ambient temperature

4.3 Checking power supply for Servotronic -

Vehicles up to Model Year 1993
Special tools and workshop equipment required
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Portable multimeter -V.A.G 1526D- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Sequence of operations
– Remove the glove box ⇒ Rep. Gr. 70 .
– Unplug the connector from the Servotronic control unit -J236- .
– Switch on ignition.
– Set the portable multimeter to the up to 20 V measuring range.

182 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Take the measurement at the relay connector between con‐

tacts “2” and “7”.
• Specification: approx. 12 V
– If the reading does not match the specification, check the wir‐
ing ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.

4.4 Checking power supply for Servotronic -

Vehicles as of Model Year 1994
Special tools and workshop equipment required
♦ Portable multimeter -V.A.G 1526D-

Sequence of operations
– Open the box in the passenger's footwell.
– Disconnect the Servotronic control unit -J236- relay from relay
carrier 1, position 16.
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– Switch on permitted
ignition unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Set the portable multimeter to the up to 20 V measuring range.
– Take the measurement at the relay connector between con‐
tacts “6” and “8”.
• Specification: approx. 12 V
– If the reading does not match the specification, check the wir‐
ing ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.

4.5 Checking Servotronic solenoid valve -

N119- - Vehicles up to Model Year 1993
Special tools and workshop equipment required

4. Servotronic 183
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ Portable multimeter -V.A.G 1526D-

♦ Adapter set -V.A.G 1594C-

Sequence of operations
– Remove the vacuum brake servo ⇒ Rep. Gr. 47 .

Note

On vehicles with hydraulic brake servo this does not have to be

removed.

– Unplug the connector from the Servotronic solenoid valve -

N119- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Set the portable multimeter to the resistance measuring range
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

up to 200 Ω.
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Take the measurement between the contacts of the Servo‐

tronic solenoid valve -N119- .
• Specification: 6 ... 12 Ω.
– If the reading does not match the specification, replace the
Servotronic solenoid valve -N119- .

4.6 Checking Servotronic solenoid valve -

N119- - Vehicles as of Model Year 1994
Special tools and workshop equipment required

184 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ Portable multimeter -V.A.G 1526D-

♦ Adapter set -V.A.G 1594C-

Sequence of operations
– Open the box in the passenger's footwell.
– Disconnect the Servotronic control unit -J236- relay from relay
carrier 1, position 16.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Set the portable multimeter to the
permitted unless resistance
authorised by AUDImeasuring
AG. AUDI AG does range
not guarantee or accept any liability
up to 200 Ω. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Take the measurement at the relay connector between con‐

tacts “2” and “5”.
• Specification: 6 ... 12 Ω.
If the reading does not match the specification:
– Unplug the connector from the Servotronic solenoid valve -
N119- .
– Check for short circuit and open circuit in the wiring between
the relay connector and the connector for the Servotronic
valve ⇒ Current flow diagrams, Electrical fault finding and Fit‐
ting locations.
– If the wiring is OK, replace the Servotronic solenoid valve -
N119- .

4.7 Checking vehicle speed signal - Vehi‐

cles as of Model Year 1994
Sequence of operations
The vehicle speed signal comes from the dash panel insert.

4. Servotronic 185
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– If the power supply, the Servotronic solenoid valve -N119- and

the speedometer reading are OK, check the wiring between
contact “4” and the dash panel insert ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– If the wiring between contact “4” and the dash panel insert is
OK, replace the Servotronic relay.

4.8 Checking wiring between Servotronic

control unit -J236- and connector point
“1” - Vehicles up to Model Year 1993
Special tools and workshop equipment required
♦ Portable multimeter -V.A.G 1526D-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Adapter set -V.A.G 1594C-

Sequence of operations
– Remove the glove box and storage compartment on the driv‐
er's side ⇒ Rep. Gr. 70 .
– Unplug the connector from the Servotronic control unit -J236- .
– At connector point “1” unplug the orange connector -arrow-.

186 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Set the portable multimeter to the resistance measuring range.

– Take the measurement between contacts “8” and “11” at the
connector of the Servotronic control unit -J236- .
• Specification: ∞ Ω.
– If the reading does not match the specification, check the wir‐
ing ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.

– If the reading matches the specification, use the adapter set

to jumper contacts “5” and “6” at the orange connector at con‐
nector point “1”.
• Specification: 0 Ω.
– If the reading does not match the specification, check the wir‐
ing ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.

4.9 Checking wiring between Servotronic

solenoid valve -N119- and connector
point “1” - Vehicles up to Model Year
1993
Special tools and workshop equipment required
♦ Portable multimeter -V.A.G 1526D-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Adapter set -V.A.G 1594C-

4. Servotronic 187
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Sequence of operations
– Remove the driver's storage compartment ⇒ Rep. Gr. 70 .
– At connector point “1” unplug the orange connector -arrow-.
– Remove the vacuum brake servo ⇒ Rep. Gr. 47 .

Note

On vehicles with hydraulic brake servo this does not have to be

removed.

– Unplug the connector from the Servotronic solenoid valve -

N119- .

– Set the portable multimeter to the resistance measuring range.

– Take the measurement between contacts “1” and “2” at the
connector of the Servotronic solenoid valve -N119- .
• Specification: ∞ Ω.
– If the reading does not match the specification, check the wir‐
ing ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.

– If the reading matches the specification, use the adapter set

to jumper contacts “5” and “6” at the orange connector at con‐
nector point “1”.
• Specification: 0 Ω.
– If the reading does not match the specification, check the wir‐
ing ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.

4.10 Checking valve wiring for short to volt‐

age
Special tools and workshop equipment required
♦ Portable multimeter -V.A.G 1526D-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

188 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ Adapter set -V.A.G 1594C-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Sequence of operations with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove the glove box ⇒ Rep. Gr. 70 .

– Unplug the connector from the Servotronic control unit -J236- .
– Set the portable multimeter to the resistance measuring range.
– Take the measurement between contacts “7” and “8” or “7”
and “11” at the connector of the Servotronic control unit -
J236- .
• Specification: ∞ Ω.
– If the reading does not match the specification, check the wir‐
ing ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.

4.11 Checking valve wiring for short to earth

Special tools and workshop equipment required
♦ Portable multimeter -V.A.G 1526D-

♦ Adapter set -V.A.G 1594C-

4. Servotronic 189
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Sequence of operations
– Remove the glove box and storage compartment on the driv‐
er's side ⇒ Rep. Gr. 70 .
– Unplug the connector from the Servotronic control unit -J236- .
– Set the portable multimeter to the resistance measuring range.
– Take the measurement between contacts “2” and “11”, as well
as “2” and “8” at the connector of the Servotronic control unit
-J236- .
• Specification: ∞ Ω.
– If the reading does not match the specification, check the wir‐
ing ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

190 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

5 Steering wheels
⇒ “5.1 Safety precautions when working on airbag”, page 191
⇒ “5.2 Exploded view of steering wheel with airbag”, page 191
⇒ “5.3 Removing and installing steering wheel with airbag”, page
192
⇒ “5.4 Exploded view of steering wheel without airbag”,
page 193
⇒ “5.5 Removing and installing steering wheel”, page 194
⇒ “5.6 Removing and installing steering column switch”,
page 195
⇒ “5.7 Exploded view of steering column switch for adjustable
steering column”, page 195
⇒ “5.8 Removing and installing steering column switch for adjust‐
able steering column”, page 196

5.1 Safety precautions when working on air‐

bag
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ permitted
Testing, fitting
unless andbyservicing
authorised AUDI AG. AUDI work arenotonly
AG does to be
guarantee performed
or accept by
any liability
qualified personnel.
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ The battery earth strap must be disconnected when working

on the airbag system. No waiting time is necessary after dis‐
connecting the battery. Make sure there is no-one in the
vehicle when connecting the airbag system to a voltage
source.
♦ Never perform tests using a test lamp, voltmeter or ohmmeter.
♦ The airbag system is only to be checked in situ with the ⇒ Ve‐
hicle diagnosis, testing and information system VAS 5051.
♦ Airbag units are never to be left unattended.
♦ Following removal, airbag units are to be stored with the cush‐
ioned side facing upwards.
♦ Airbag units which have been dropped onto a hard surface or
reveal signs of damage are no longer to be fitted.
♦ Non-triggered airbag units are to be marked and returned to
the manufacturer for disposal (using airbag unit transportation
container).
♦ Airbag units must be installed immediately following removal
from their transportation containers.
♦ The airbag unit must be returned to its transportation container
if work has to be interrupted.
♦ Airbag components are not to be opened or repaired. Always
use new components.
♦ Airbag units are not to be treated with grease, cleaning agents
or the like.
♦ Airbag units are never to be exposed to temperatures in ex‐
cess of 100° C (even for brief periods).

5.2 Exploded view of steering wheel with airbag

5. Steering wheels 191

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Bolt, 6 Nm
❑ Torx “T30”
2 - Steering wheel
❑ Attach in centre position
❑ Removing and installing
⇒ page 192
3 - Nut, 40 Nm
4 - Airbag unit
❑ Heed safety precau‐
tions ⇒ page 191

5.3 Removing and installing steering wheel

with airbag
Heed the safety precautions for working on airbags ⇒ page 191 .

WARNING

The following prerequisites must be satisfied before removing

the steering wheel:
♦ Disconnect the earth
Protected by copyright. strap
Copying from
for private the battery.
or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Make
withsure
respectthe
to thewheels are
correctness in straight-ahead
of information in this document.position.
Copyright by AUDI AG.

If the steering wheel has been removed, the coil connector in

the steering wheel is never to be turned.
Non-compliance with the above could lead to subsequent air‐
bag system failure.
Before fitting the steering wheel, move the turn signal indicator
switch to the zero position to ensure that the reset cam of the
switch is not damaged.

192 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Removing
– Disconnect the battery earth strap ⇒ Rep. Gr. 27 .
– Use a Torx insert to unscrew the airbag unit on the left and
right of the steering wheel from the rear.

– Fold the airbag unit forwards.

– Disengage the safety catch if fitted.
– Unplug the connector of the airbag unit.
– Detach the airbag unit.

– Unscrew and detach the upper steering column switch trim.

– Unplug the connector -arrow- (if fitted, detach the foam sheath
from the connector).
– Unscrew and detach the steering wheel.
Installing
Install in reverse order.

WARNING

Make sure there is no-one in the vehicle when connecting the

battery earth strap.

5.4 Exploded view of steering wheel without airbag

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5. Steering wheels 193

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Steering column switch

❑ Removing and installing
⇒ page 195
❑ Apply a small quantity of
grease to the slip ring
2 - Coil connector with slip ring
3 - Steering wheel
❑ Removing and installing
⇒ page 194
❑ Attach in centre position
❑ On attachment, the turn
signal indicator stalk
must be in the centre po‐
sition
4 - Spring lock washer
5 - Nut, 40 Nm
6 - Trim cap

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5.5 Removing and installing steering wheel

Removing
– Release the trim cap from the attachment points by tugging on
the upper and lower half.
– Press the trim cap to one side and detach.

Note

Failure to comply with the above will result in the fasteners break‐
ing off.

– Move the steering wheel to centre position (wheels straight

ahead).
– Unscrew and detach the steering wheel.
Installing
– Press on the trim cap by hand and let it engage.

194 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

5.6 Removing and installing steering col‐

umn switch
Removing
– Remove the steering wheel: Vehicles without airbag
⇒ page 194 , vehicles with airbag ⇒ page 192 .
– Unscrew and detach the upper steering column switch trim.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Unfasten the clamp at the steering column switch.
– Unplug the connectors from the steering column switch and
detach the steering column switch with the lower trim.
Installing

Note

Make sure the wheels are in straight ahead position before fitting
the steering wheel.

– Install the steering wheel: Vehicles without airbag

⇒ page 194 , vehicles with airbag ⇒ page 192 .

5.7 Exploded view of steering column switch for adjustable steering column

5. Steering wheels 195

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Angle adjustment lever

❑ Detach before removing
steering column switch
2 - Spring clip
3 - Longitudinal adjustment
lever
❑ Detach before removing
steering column switch
❑ Prise out spring clip
⇒ Item 2 (page 196) to
detach
4 - Bellows
❑ To install, start by insert‐
ing upper hooks in dash
panel, then engage at
bottom
5 - Upper trim
6 - Steering column switch with
lower trim
❑ Removing and installing
⇒ page 196
7 - Bolt
❑ For attaching upper trim
to lower trim
8 - Bolt
❑ For attaching lower trim
and bellows

5.8 Removing and installing steering col‐

umn switch for adjustable steering col‐
umn
Removing
– Remove the steering wheel: Vehicles without airbag
⇒ page 194 , vehicles with airbag ⇒ page 192 .
– Swivel down the longitudinal adjustment lever and prise off the
springProtected
clip with a screwdriver.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Detach with
therespect
longitudinal adjustment
to the correctness lever.
of information in this document. Copyright by AUDI AG.

196 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Slacken off the hexagon socket head bolt and detach the angle
adjustment lever.

– Unscrew and detach the upper steering column switch trim.

– Screw out the bolt for the bellows.

– Unfasten the clamp at the steering column switch.

– Unplug the connectors from the steering column switch -1-.
– Detach the steering column switch with lower trim.
– Disengage the bellows from the dash panel and detach.
Installing

Note

Make sure the wheels are in straight ahead position before fitting
the steering wheel.

– On vehicles with an airbag, engage -arrow- the connector for

the airbag at the appropriate location on the bellows before
fitting the top part of the steering column switch.
– Install the steering wheel: Vehicles without airbag
⇒ page 194 , vehicles with airbag ⇒ page 192 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5. Steering wheels 197

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

6 Steering column with column tube

⇒ “6.1 Exploded view of steering column with column tube”, page
198
⇒ “6.2 Removing and installing column tube with steering col‐
umn”, page 199

6.1 Exploded view of steering column with column tube

1 - Bolt
❑ Always replace after re‐
moving
2 - Universal joint
3 - Steering column
❑ Removing and installing
⇒ page 199
4 - Steering pinion of steering
box
5 - Bolt
6 - Washer
7 - Bracket
❑ Provided with elongated
holes for moving column
tube upwards or down‐
wards slightly if required
8 - Washer
9 - Self-locking nut, 35 Nm
❑ Always replace after re‐
moving
10 - Bolt
11 - Self-locking nut, 25 Nm
❑ Always replace after re‐
moving
12 - Bushing
❑ Insert in steering col‐
umn
13 - Procon cable
❑ Insert in column tube at
top
❑ Insert with rubber grommet in bulkhead at bottom
❑ For further information on cable routing, refer to ⇒ Rep. Gr. 68
❑ If the slightest misalignment (accident) is found between the top and bottom parts of the column tube or
if the coloured dot has sheared off, the cable is to be replaced
14 - Bushing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Insert with collarpermitted
facingunless
steering wheel
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
15 - Spacer bush
❑ Insert in bushing ⇒ Item 14 (page 198)
16 - Washer
17 - Self-locking nut, 25 Nm
❑ Always replace after removing

198 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

18 - Column tube
❑ Consists of top and bottom part
❑ Replacement part is supplied with both mounts
❑ Top and bottom parts filled with plastic; never exert force (e.g. hammer blows) in axial or radial direction
❑ Avoid temperatures in excess of 100 °C
❑ Can be moved slightly in elongated holes of bracket

Note

♦ The top and bottom part of the

column tube are provided with a
red dot.
♦ The column tube is to be re‐
placed if this coloured dot has
sheared off.

19 - Spring
❑ Attach to steering column
20 - Clamping washer

WARNING
Washers are pre-ten‐
sioned.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Prise off with a screwdriver
❑ Pressing on ⇒ page 199
21 - Torx bolt, 7 Nm
❑ To screw out, use a Torx insert with a hole in the end face, e.g. Hazet Torx T30H
22 - Steering lock housing
❑ Insert in column tube

Attaching clamping washers to steering column

– Attach spring with clamping washer to steering lock housing.
– Screw the tensioning tool -3168- onto the steering column as
far as it will go with spindle -a-.
– Provide support for the spindle -a- and tighten the nut -b- until
the spring windings are in contact with one another.

Note

The spring is not to be over-compressed as otherwise the mounts

could be damaged.

– Unfasten the nut -b-.

– Unscrew the spindle -a- from the steering column.

6.2 Removing and installing column tube

with steering column
Removing
– Remove the steering wheel: Vehicles without airbag
⇒ page 194 , vehicles with airbag ⇒ page 192 .

6. Steering column with column tube 199

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Remove the steering column switch: Vehicles without adjust‐

able steering column ⇒ page 195 , vehicles with adjustable
steering column ⇒ page 196 .
– Remove the driver's storage compartment ⇒ Rep. Gr. 70 .
– Take out the air vent in the footwell on the left.
– Screw out the bolts -2- (2x).
– Detach the trim -1-.

– Screw out the three bolts -arrows-.

– Pull the dash panel insert out of the dash panel.
– Unclip the connector and detach the dash panel insert.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Detach permitted
the connector housing
unless authorised from
by AUDI the AG
AG. AUDI ignition/starter
does not guaranteeswitch.
or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Screw out the bolts of the universal joint -arrows-.

– Screw out the steering lock Torx bolt, e.g. using Hazet T30 H.
– Unscrew the column tube from the bracket and pull out the
bolts.
– Push the column tube downwards, turn it slightly to the left,
pull the steering lock housing out of the column tube and re‐
move.
– Disengage the cable at the column tube.
– Lift out the column tube with steering column.
Installing
– Insert the column tube with steering column from above in the
dash panel.
– Engage the cable in the column tube.
– Insert the steering lock housing in the column tube.
– Insert the column tube in the bracket.

200 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Insert the bolts in the bracket and column tube.

– Screw in the Torx bolt -left arrow-.
– Insert the ignition key in the steering lock.
– Release the steering lock so that the steering column can be
turned as required.
– Attach the universal joint to the steering column.
– By moving it upwards or downwards in the bracket, align the
column tube such that the cylinder of the steering lock is cen‐
tred with the hole in the dash panel.
– Attach the column tube to the bracket.
– Fit the dash panel insert in the dash panel.
– Fit the trim strip for the dash panel insert.
– Fit the air vent in the footwell on the left.
– Attach the connector housing to the ignition/starter switch.
– Install the driver's storage compartment ⇒ Rep. Gr. 70 .
– Fit the dash panel trim strip.
– Install the steering column switch: Vehicles without adjustable
steering column ⇒ page 195 , vehicles with adjustable steering
column ⇒ page 196 .
– Install the steering wheel: Vehicles without airbag
⇒ page 194 , vehicles with airbag ⇒ page 192 .
– Connect the battery ⇒ Rep. Gr. 27 Protected
. by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Check operation of the steering column
withswitch.
respect to the correctness of information in this document. Copyright by AUDI AG.

Note

The steering wheel spoke must be horizontal with the wheels in

straight ahead position.

6. Steering column with column tube 201

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

7 Adjustable steering column with col‐

umn tube up to Model Year 1994
⇒ “7.1 General ”, page 202
⇒ “7.2 Exploded view of adjustable steering column with column
tube”, page 202
⇒ “7.3 Removing and installing column tube with adjustable steer‐
ing column”, page 205
⇒ “7.4 Replacing steering column adjustment cable”, page 208
⇒ “7.5 Adjusting steering column adjustment cable”, page 210

7.1 General
♦ The adjustable steering column is maintenance-free.
♦ The replacement part is supplied with pre-tensioned spring for
angle adjustment and a pre-adjusted cable.
♦ The pre-tension is designed for vehicles with airbag
⇒ page 205 .
♦ The spring pre-tension is to be reduced on installation in ve‐
hicles with no airbag ⇒ page 205 .
♦ Never perform any assembly work other than replacement and
adjustment of the cable.
♦ The steering column is to be installed using the fitting sleeve
⇒ Electronic parts catalogue . The purpose of this is to centre
the corrugated tube.

7.2 Exploded view of adjustable steering column with column tube

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

202 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Bolt
❑ Always replace after re‐
moving
2 - Steering pinion of steering
box
3 - Bolt
4 - Washer
5 - Bracket
❑ Provided with elongated
holes for moving column
tube upwards or down‐
wards slightly if required

Note

If the bracket connection

⇒ Item 3 (page 203) /
⇒ Item 7 (page 203) is unfastened,
use must be made of the centring
tool (fitting sleeve
⇒ Item 18 (page 204) ) on re-tight‐
ening the connection ⇒ page 207 .

6 - Washer
7 - Self-locking nut, 35 Nm
❑ On tightening make use
of the centring tool (fit‐
ting sleeve
⇒ Item 18 (page 204) )
⇒ page
Protected by copyright. 207 for private or commercial purposes, in part or in whole, is not
Copying
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
8 -respect
with Torxtobolt, 7 Nm of information in this document. Copyright by AUDI AG.
the correctness

❑ To unscrew, use a Torx

insert with a hole in the
end face, e.g. Hazet
Torx T30H
9 - Steering lock housing
❑ Insert in column tube
10 - Nut, 5 Nm
11 - Wiring harness for steering column switch, right
12 - Clip
❑ On installation make sure the wiring harness is not crushed by the bolted joint
❑ Also secure the earth cable
13 - Steering column
❑ Removing and installing ⇒ page 205
❑ Modified spring pre-tension for steering column angle adjustment on vehicles with no airbag
⇒ page 205
❑ Consists of top and bottom part
❑ Replacement part is supplied with both mounts
❑ Top and bottom parts filled with plastic; never exert force (e.g. hammer blows) in axial or radial direction
❑ Avoid temperatures in excess of 100 °C
❑ Can be moved slightly in elongated holes of bracket

7. Adjustable steering column with column tube up to Model Year 1994 203
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Note

♦ The top and bottom part of the

column tube are provided with a
red dot.
♦ The steering column is to be re‐
placed if this coloured dot has
sheared off.

14 - Wiring harness for steering column switch, left

15 - Clip
16 - Nut, 5 Nm
17 - Procon cable
❑ Insert in column tube at top
❑ Insert with rubber grommet in bulkhead at bottom
❑ For further information on cable routing, refer to ⇒ Rep. Gr. 68

Note

If the slightest misalignment (acci‐

dent) is found between the top and
bottom parts of the column tube or if
the coloured dot has sheared off,
the cable is to be replaced.

18 - Fitting sleeve
❑ Available as replacement part ⇒ Electronic parts catalogue
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Insert prior to re-installation if the steering column permitted
has been removed
unless authorised byor unfastened
AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Do not remove until the steering column has been installed
19 - Longitudinal adjustment cable
❑ Replacing ⇒ page 208
❑ Adjusting ⇒ page 210
20 - Bushing
❑ Insert with collar facing steering wheel
21 - Bushing
❑ Insert in steering column
22 - Self-locking nut, 25 Nm
❑ Always replace
23 - Bolt
24 - Self-locking nut, 25 Nm
25 - Washer
26 - Spacer bush
❑ Insert in bushing ⇒ Item 14 (page 198)
27 - Universal joint

204 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Spring pre-tension for steering column angle adjustment on ve‐

hicles with no airbag
– Reduce the spring pre-tension by engaging the lug of the
sleeve -arrow- in the hole provided.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Spring pre-tension for steering column angle adjustment on ve‐
hicles with airbag

7.3 Removing and installing column tube

with adjustable steering column
Removing
– Remove the steering wheel: Vehicles without airbag
⇒ page 194 , vehicles with airbag ⇒ page 192 .
– Remove the steering column switch: Vehicles without adjust‐
able steering column ⇒ page 195 , vehicles with adjustable
steering column ⇒ page 196 .
– Remove the driver's storage compartment ⇒ Rep. Gr. 70 .
– Take out the air vent in the footwell on the left.
– Screw out the bolts -arrows- (2x).
– Detach the trim.

7. Adjustable steering column with column tube up to Model Year 1994 205
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Screw out the three bolts -arrows-.

– Pull the dash panel insert out of the dash panel.
– Unclip the connector and detach the dash panel insert.
– Detach the connector housing from the ignition/starter switch.

– Unscrew the nuts -arrows-.

– Detach the wiring harness with clip on the left and right from
the studs.

– Screw out the bolts of the universal joint -arrows-.

– Screw out the steering lock Torx bolt, e.g. using Hazet T30 H.
– Unscrew the column tube from the bracket and pull out the
bolts.
– Push the column tube downwards, turn it slightly to the left,
pull the steering lock housing out of the column tube and re‐
move.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Disengage the
with respect cable
to the at the
correctness columnintube.
of information this document. Copyright by AUDI AG.

– Lift out the column tube with steering column.

206 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Installing
– Before re-installing a removed steering column, slide the fitting
sleeve -A- onto the corrugated tube -B- and press home in the
steering column -C-.

– Install the steering column before removing the fitting sleeve

-D-.
– Move the column tube -A- on the steering column -B- until di‐
mension -C- (approx. 20 mm) is attained.
Dimension -C- is required for inserting the Procon cable.
– Insert the column tube with steering column from above.
– Insert the steering lock housing in the column tube.

– Screw in the steering lock Torx bolt, e.g. using Hazet T30 H.
– Attach the connector housing to the ignition/starter switch.
– Engage the cable in the column tube.

Note

After inserting the Procon cable, press home the steering column
in the direction of travel and lock.

– Insert the column tube in the bracket and initially screw on by

hand only.
– Insert the ignition key in the steering lock.
– Release the steering lock so that the steering column can be
turned as required.

Note

Should it not be possible on installing a new steering column to

attach it to the universal joint, slacken off the clamping bolt and
move the universal joint on the steering pinion such that stress-
free installation of the steering column is possible.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

7. Adjustable steering column with column tube up to Model Year 1994 207
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Attach the universal joint to the steering column.

– By moving it upwards or downwards in the bracket, align the
column tube such that the cylinder of the steering lock is cen‐
tred with the hole in the dash panel.
– Tighten the column tube/bracket bolted joint.
– Take out the fitting sleeve.
– Fit the dash panel insert in the dash panel.
– Fit the trim strip for the dash panel insert.

– Secure the wiring harness with clips on the left and right (se‐
cure the earth wire as well on the right).
– Insert the bellows in the dash panel.
– Install the steering column switch: Vehicles without adjustable
steering column ⇒ page 195 , vehicles with adjustable steering
column ⇒ page 196 .
– Install the steering wheel: Vehicles without airbag Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ page 194 , vehicles with airbag ⇒ page 192 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Install the driver's storage compartment ⇒ Rep. Gr. 70 .
– Connect the battery ⇒ Rep. Gr. 27 .
– Check operation of the steering column switch.

Note

The steering wheel spoke must be horizontal with the wheels in

straight ahead position.

– Vehicles with adjustable steering column: Check and if nec‐

essary correct the angle and longitudinal adjustment
⇒ page 210 .

7.4 Replacing steering column adjustment

cable
Sequence of operations
– Remove the steering column with column tube ⇒ page 205 .
– After unfastening the lock nut -2-, screw the adjusting screw
-1- into the adjusting element -3- to slacken off the cable.

208 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Sever the cable behind the adjusting screw and detach.

– Check the new cable to establish whether dimension -A- be‐

tween the adjusting screw and lock nut is set to 8 to 10 mm
and correct if necessary.
– Pre-tension the compensating spring -B- (e.g. with insulating
tape) until the spring windings make contact with one another.
– Slide the cable through the plastic guide at the column tube.

– Push the cable through the adjusting mechanism and crimp

(approx. 8 mm) the clamping sleeve at the end of the cable
using a commercially available tool.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Attach the eccentric lever -1- of the cable to the pin at the col‐
umn tube and insert the cable at the support bracket -arrow-.
– Slacken off the compensating spring (remove the insulating
tape).
– Adjust the cable ⇒ page 210 .
– Fit the column tube with steering column ⇒ page 205 .
– Check the longitudinal adjustment again and adjust the cable
setting if necessary ⇒ page 210 .

7. Adjustable steering column with column tube up to Model Year 1994 209
 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

7.5 Adjusting steering column adjustment

cable
Sequence of operations

Note

♦ For ease of illustration, cable adjustment is shown with the

steering column removed.
♦ Lock the steering column to adjust gap -A-.

– Remove the driver's storage compartment ⇒ Rep. Gr. 70 .

– Unfasten the lock nut -2-.
– Turn the adjusting screw -1- until the idle travel of the adjusting
element -3- in gap -A- is approx. 2 mm.

– Check the longitudinal adjustment.

– Swivel down the longitudinal adjustment lever -3- and push the
steering column -5- forwards and backwards in the column
tube -4-.
– Correct the setting if the steering column catches slightly in the
column tube. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Lock the adjusting screw -1- with
with lock
respectnut
to the-2-.
correctness of information in this document. Copyright by AUDI AG.

– Install the driver's storage compartment ⇒ Rep. Gr. 70 .

210 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

8 Adjustable steering column - Vehi‐

cles as of Model Year 1995
⇒ “8.1 General ”, page 211
⇒ “8.2 Exploded view of adjustable steering column ”, page 211
⇒ “8.3 Replacing steering column adjustment cable”, page 213
⇒ “8.4 Adjusting steering column adjustment cable”, page 214

8.1 General
♦ As of Model Year 1995 all vehicles are equipped with an airbag
and there is thus no Procon cable.
♦ The adjustable steering column is maintenance-free.
♦ The replacement part is supplied with pre-tensioned spring for
angle adjustment and a pre-adjusted cable.
♦ Never perform any assembly work other than replacement and
adjustment of the cable.
♦ The steering column is to be installed using the fitting sleeve
⇒ Electronic parts catalogue . The purpose of this is to centre
the corrugated tube.

8.2 Exploded view of adjustable steering column

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

8. Adjustable steering column - Vehicles as of Model Year 1995 211

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Self-locking nut, 20 Nm
❑ Always replace after re‐
moving
2 - Washer
3 - Bolt
4 - Bolt
5 - Washer
6 - Bracket
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑permitted
Provided with elongated
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
holes
with for
respect moving
to the column
correctness of information in this document. Copyright by AUDI AG.
tube upwards or down‐
wards slightly if required

Note

If the bracket connection

⇒ Item 4 (page 212) /
⇒ Item 7 (page 212) is unfastened,
use must be made of the centring
tool (fitting sleeve
⇒ Item 16 (page 213) ) on re-tight‐
ening the connection ⇒ page 207 .

7 - Self-locking nut, 30 Nm
❑ On tightening make use
of the centring tool (fit‐
ting sleeve
⇒ Item 16 (page 213) )
⇒ page 207
8 - Torx bolt, 7 Nm
❑ To unscrew, use a Torx
insert with a hole in the
end face, e.g. Hazet
Torx T30H
9 - Steering lock housing
❑ Insert in column tube
10 - Nut, 5 Nm
11 - Wiring harness for steering column switch, right
12 - Clip
❑ On installation make sure the wiring harness is not crushed by the bolted joint
❑ Also secure the earth cable
13 - Steering column
❑ Removing and installing ⇒ page 205
❑ Replacement part is supplied with both mounts
❑ Top and bottom parts filled with plastic; never exert force (e.g. hammer blows) in axial or radial direction
❑ Avoid temperatures in excess of 100 °C
❑ Can be moved slightly in elongated holes of bracket

Note

♦ The top and bottom part of the

column tube are provided with a
red dot.

212 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ The steering column is to be re‐

placed if this coloured dot has
sheared off.

14 - Wiring harness for steering column switch, left

15 - Longitudinal adjustment cable
❑ Replacing ⇒ page 213
❑ Adjusting ⇒ page 214
16 - Fitting sleeve
❑ Available as replacement part ⇒ Electronic parts catalogue
❑ Insert prior to re-installation if the steering column has been removed or unfastened
❑ Do not remove until the steering column has been installed
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

8.3 Replacing steering column adjustment

cable
Sequence of operations
– Remove the steering column with column tube ⇒ page 205 .
– Unfasten the adjusting nut -1- to slacken off the cable.

– Sever the cable behind the adjusting nut and detach.

– Check the new cable to establish whether dimension -A- be‐

tween the adjusting nut -1- and mating piece -2- is set to
approx. 15 mm and correct if necessary.

8. Adjustable steering column - Vehicles as of Model Year 1995 213

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Push the new cable through the adjusting mechanism and

crimp (approx. 8 mm) the clamping sleeve at the end of the
cable using a commercially available tool.

– Attach the eccentric lever -1- of the cable to the pin at the col‐
umn tube and insert the cable at the support bracket -arrow-.
– Adjust the cable ⇒ page 214 .
– Insert the column tube with steering column in the vehicle
⇒ page 205 .
– Check the longitudinal adjustment again and adjust the cable
setting if necessary ⇒ page 214 .

8.4 Adjusting steering column adjustment

cable
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Sequence of operations
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

♦ For ease of illustration, cable adjustment is shown with the

steering column removed.
♦ Lock the steering column to adjust gap -A-.

– Remove the driver's storage compartment ⇒ Rep. Gr. 70 .

– Pull the cable -1- in -arrow direction- such that there is no
movement of the locking mechanism -3-.
– Check dimension -A- (3 to 3.5 mm) and adjust if necessary
with the adjusting nut -2-.

– Check the longitudinal adjustment.

– Swivel down the longitudinal adjustment lever -1- and push the
steering column -4- forwards and backwards in the column
tube -3-.
– Correct the setting if the steering column catches slightly in the
column tube.
– Secure the adjusting nut with locking compound to stop it turn‐
ing.
– Install the driver's storage compartment ⇒ Rep. Gr. 70 .

214 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

9 Hydraulic pipes, reservoir

⇒ “9.1 General ”, page 215
⇒ “9.2 Exploded view of hydraulic fluid circuit for power-assisted
steering”, page 215
⇒ “9.3 Exploded view of reservoir”, page 217

9.1 General
With the exception of extension of the hydraulic pipes from left to
right at the steering box, the fluid circuit of right-hand drive vehi‐
cles corresponds to that of the left-hand drive version.
♦ Always check the steering system for leaks if there is a lack of
fluid in the reservoir.
♦ If a leak is found in the area of the pipe connections, start by
checking the pipes/pipe connections for leaks, re-tighten if
necessary and wipe dry.
♦ Replacement pumps have no fluid fill. Prior to installation they
are therefore to be filled with hydraulic fluid and cranked by
hand to avoid the possibility of noise whilst driving or pump
damage.
♦ Hydraulic fluid ⇒ Electronic parts catalogue
When the fluid circuit has been opened, always:
♦ Check all unions for leaks,Protected
start the engine
by copyright. andforperform
Copying a vis‐ purposes, in part or in whole, is not
private or commercial
ual inspection. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Check the fluid level ⇒ page 276 .

9.2 Exploded view of hydraulic fluid circuit for power-assisted steering

9. Hydraulic pipes, reservoir 215

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Return pipe
❑ Rotary slide valve hous‐
ing - reservoir
2 - Power-assisted steering
box
3 - Reservoir
❑ Smaller on vehicles
without self-levelling
suspension
❑ Fresh fill capacities:
❑ Without self-levelling
suspension: approx. 1 l
❑ With self-levelling sus‐
pension: approx. 2.5 l
❑ Hydraulic fluid ⇒ Elec‐
tronic parts catalogue
❑ Checking hydraulic fluid
level with vehicle unla‐
den ⇒ page 276
4 - Coolant hose
5 - Suction hose
❑ Reservoir - vane pump/
tandem pump
6 - Clamp
❑ For attaching return
pipe and suction hose to
reservoir
7 - Bolt, 20 Nm
8 - Holder
9 - Return hose
❑ Only fitted on vehicles
with oil cooler and 5, 6 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
and 8-cyl. engines permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
10 - Oil cooler
❑ Only fitted on vehicles with 5, 6 and 8-cyl. engines
11 - Bolt, 10 Nm
12 - Oil cooler mount
13 - Expansion hose
❑ Vane pump - rotary slide valve housing

216 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

9.3 Exploded view of reservoir

1 - Cap with dipstick

❑ Fluid level: Between
min. and max. mark
2 - Seal
3 - Compression spring
4 - Dished washer
5 - Strainer
6 - Reservoir
❑ Fresh fill capacities:
❑ Without self-levelling
suspension: approx. 1 l
❑ With self-levelling sus‐
pension: approx. 2.5 l
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Hydraulic fluid ⇒ Elec‐
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
tronic parts cataloguewith respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Checking hydraulic fluid

level with vehicle unla‐
den ⇒ page 276
7 - Bolt, 10 Nm
8 - Holder
❑ Bolt to wheel housing
9 - Clamp
10 - Suction hose
11 - Return hose
12 - Clamp

9. Hydraulic pipes, reservoir 217

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

10 Vane pump
⇒ “10.1 General ”, page 218
⇒ “10.2 Exploded view of vane pump - Vehicles with 4-cyl. en‐
gine”, page 218
⇒ “10.3 Exploded view of vane pump - Vehicles with 5-cyl. en‐
gine”, page 221
⇒ “10.4 Exploded view of vane pump - Vehicles with 6-cyl. 2V
engine”, page 222
⇒ “10.5 Removing and installing vane pump - Vehicles with 6-cyl.
2V engine”, page 224
⇒ “10.6 Exploded view of vane pump - Vehicles with 6-cyl. 5V
engine”, page 226
⇒ “10.7 Removing and installing vane pump - Vehicles with 6-cyl.
5V engine”, page 227
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

10.1 General
with respect to the correctness of information in this document. Copyright by AUDI AG.

There is no provision for vane pump servicing. In the event of

problems, establish the cause by way of a pressure and leak test.
Replace the vane pump if a fault is found.
♦ Always check the steering system for leaks if there is a lack of
fluid in the reservoir.
♦ If a leak is found in the area of the pipe connections, start by
checking the pipes/pipe connections for leaks, re-tighten if
necessary and wipe dry.
♦ Replacement pumps have no fluid fill. Prior to installation they
are therefore to be filled with hydraulic fluid and cranked by
hand to avoid the possibility of noise whilst driving or pump
damage.
♦ Hydraulic fluid ⇒ Electronic parts catalogue
♦ Always replace self-locking bolts and nuts.
♦ The hydraulic fluid drained off is not to be re-used.
♦ Replace seals.

10.2 Exploded view of vane pump - Vehicles with 4-cyl. engine

218 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Bolt, 20 Nm
2 - Bolt, 20 Nm
3 - Holder
4 - Vane pump
❑ Checking delivery pres‐
sure ⇒ page 231
❑ Fill with fluid before in‐
stalling ⇒ page 218
❑ Cannot be serviced
❑ Attach hose clamp
-3094- to the suction
and return hose before
unscrewing the suction
and expansion hose at Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
the vane pump permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

Use is made of vane pumps from

various manufacturers. Any of these
may be fitted on pump replacement;
for assignment, refer to ⇒ Electronic
parts catalogue .

5 - Front swivel mount

❑ Bolt to vane pump
6 - Self-locking nut, 20 Nm
❑ Always replace after re‐
moving
7 - Bolt, 20 Nm
8 - Bolt, 20 Nm
9 - V-belt
❑ Tensioning, replace‐
ment ⇒ Maintenance ; Booklet 401
10 - Bolt with tensioning nut
11 - Bolt, 25 Nm
12 - V-belt pulley
❑ When installing the V-belt pulley, make sure the V-belt pulleys of the crankshaft and vane pump are in
alignment
13 - Bolt, 25 Nm
14 - Washer
❑ Thickness 4 mm
15 - Tensioning bar
16 - Seal
❑ Always replace after removing
❑ Different versions; for assignment refer to ⇒ Electronic parts catalogue
17 - Washer
❑ Thickness 2.5 mm

10. Vane pump 219

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

18 - Bolt, 25 Nm
19 - Bolt, 25 Nm
20 - Spacer
❑ Only fitted with ZF vane pumps
21 - Rear swivel mount
22 - Washer
❑ Thickness 4 mm
23 - Bolt, 25 Nm
24 - Washer
❑ Thickness 2.5 mm
25 - Bolt
26 - Washer
❑ Thickness 4 mm
27 - Bolt, 25 Nm
28 - Expansion hose
❑ Replacement involves removing brake servo
❑ Different seal versions; for assignment refer to ⇒ Electronic parts catalogue
29 - Banjo bolt, 50 Nm
❑ Different seal versions; for assignment refer to ⇒ Electronic parts catalogue
30 - Seal
❑ Always replace after removing
❑ Different versions; for assignment refer to ⇒ Electronic parts catalogue
31 - Suction hose
❑ Different banjo union designs with regard to seals; for assignment refer to ⇒ Electronic parts catalogue
❑ If the vane pump is provided with a screw connection, the suction hose is secured by means of a clamp
⇒ Item 12 (page 221) , ⇒ Item 13 (page 222) and ⇒ Item 14 (page 222)
32 - Banjo bolt/screw connection, 50 Nm
❑ Different seal versions; for assignment refer to ⇒ Electronic parts catalogue

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

220 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

10.3 Exploded view of vane pump - Vehicles with 5-cyl. engine

1 - Expansion hose
❑ Replacement involves
removing brake servo
❑ Different seal versions;
for assignment refer to
⇒ Electronic parts cata‐
logue
2 - Banjo bolt, 50 Nm
❑ Different seal versions;
for assignment refer to
⇒ Electronic parts cata‐
logue
3 - Seal
❑ Always replace after re‐
moving
❑ Different versions; for
assignment refer to ⇒
Electronic parts cata‐
logue
4 - Vane pump
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Checking delivery pres‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
sure ⇒ page 233 with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Fill with fluid before in‐

stalling ⇒ page 218
❑ Cannot be serviced
❑ Attach hose clamp
-3094- to the suction
and return hose before
unscrewing the suction
and expansion hose at
the vane pump

Note

Use is made of vane pumps from

various manufacturers. Any of these
may be fitted on pump replacement;
for assignment, refer to ⇒ Electronic
parts catalogue .

5 - Pulley
❑ Slackening off poly V-belt ⇒ page 222
6 - Bolt, 25 Nm
❑ Slacken off before removing vane pump
7 - Bolt, 25 Nm
8 - Bolt, 25 Nm
9 - Washer
10 - Holder
11 - Seal
❑ Always replace after removing
❑ Different versions; for assignment refer to ⇒ Electronic parts catalogue
12 - Screw connection, 50 Nm
❑ Different seal versions; for assignment refer to ⇒ Electronic parts catalogue

10. Vane pump 221

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

13 - Clamp
14 - Suction hose
15 - Bolt, 25 Nm
16 - Bolt, 25 Nm
17 - Bolt, 25 Nm

Slackening off poly V-belt

Note

Mark the direction of the poly V-belt with chalk or a felt-tip pen
prior to removal. Running a used belt in the opposite direction
could destroy it. Pay attention to correct positioning on pulleys
when fitting the belt.

– To slacken off the poly V-belt, press the open-ended wrench

in -arrow direction-.
– Detach the poly V-belt from the pulley.

10.4 Exploded view of vane pump - Vehicles with 6-cyl. 2V engine

1 - Expansion hose with pipe

❑ Different seal versions;
for assignment refer to
⇒ Electronic parts cata‐
logue
❑ Replacement involves
removing brake servo
❑ Refer to:
⇒ “1.4 Removing and in‐
stalling power-assisted
steering box”, page 159
Section on “Removing
brake servo with brake
master cylinder”
2 - Combi bolt, 8 Nm
3 - Hole at intake pipe
4 - Vane pump
❑ Checking delivery pres‐
sure ⇒ page 235
❑ Fill with fluid before in‐
stalling ⇒ page 218
❑ Cannot be serviced Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Attach hose clamp permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
-3094- to the suction with respect to the correctness of information in this document. Copyright by AUDI AG.

and return hose before

unscrewing the suction
and expansion hose at
the vane pump
❑ Removing and installing
⇒ page 224
5 - Pulley
❑ Slackening off poly V-
belt on vehicles up to
Model Year 1991

222 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

⇒ page 225 , vehicles as of Model Year 1992 ⇒ page 225

6 - Bolt, 25 Nm
7 - Bolt, 25 Nm
8 - Bolt, 25 Nm
9 - Holder
❑ Bushing installed on left in direction of travel with bolt discontinued as of vehicle ident no. PN 009 632
10 - Ignition coils with holder
11 - Bolt, 25 Nm
12 - Banjo bolt, 50 Nm
❑ Different seal versions; for assignment refer to ⇒ Electronic parts catalogue
13 - Seal
❑ Always replace
14 - Seal
❑ Always replace
15 - Screw connection, 50 Nm
16 - Clamp
17 - Bolt, 25 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
18 - Slotted bushing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
19 - Bolt, 25 Nm
20 - Holder
❑ Bolted to cylinder head
21 - Suction hose
❑ Section with pipe
22 - Combi bolt, 8 Nm

10. Vane pump 223

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

10.5 Removing and installing vane pump - Vehicles with 6-cyl. 2V engine

1 - Vane pump
Removing

– Detach the engine top

cover ⇒ page 224 .

– Detach the poly V-belt

cover ⇒ page 225 .

– Slacken off the poly V-

belt: Up to Model Year
1991 ⇒ page 225 , as of
Model Year 1992
⇒ page 225 .

– Support the pulley with a

water pump wrench -
V.A.G 1590- if applica‐
ble and unscrew.

– Pull the ignition cables

out of the ignition coils
-Item 10-.

– Pinch off the suction

pipe with hose clamps
-3094- .

– Detach the pressure

and suction pipe.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Unscrew the holder
with respect to the correctness of information in this document. Copyright by AUDI AG.
-Item 9- and remove to‐
gether with the vane
pump.

– Take out the vane pump

with holder.

– Screw the vane pump

bolts out of the holder
and take out the vane pump.

Installing

Install in reverse order.

– The ignition cables must be assigned in line with the numbering ⇒ page 225

Unclipping and detaching the engine top cover

224 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Unscrewing poly V-belt cover

Assignment of ignition cables 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
The ignition cables are marked 1 ... 6.
– Assign ignition cables 6 Protected
and 1 by tocopyright.
ignitionCopying
coil -C-.
for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Assign ignition cables 2, 3,with4 respect
and 5to in
the the sameof manner.
correctness information in this document. Copyright by AUDI AG.

Slackening off poly V-belt - up to Model Year 1991:

Note

Mark the direction of the poly V-belt with chalk or a felt-tip pen
prior to removal. Running a used belt in the opposite direction
could destroy it. Pay attention to correct positioning on pulleys
when fitting the belt.

– Unscrew the ignition coils with holder and remove the upper
belt guard.
– To slacken off the poly V-belt, swivel the poly V-belt tensioner
in -arrow direction- using a 15 mm ring spanner.
– Insert the mandrel -3204- to secure.
– Detach the poly V-belt from the pulley.

Slackening off poly V-belt - as of Model Year 1992:

Note

Mark the direction of the poly V-belt with chalk or a felt-tip pen
prior to removal. Running a used belt in the opposite direction
could destroy it. Pay attention to correct positioning on pulleys
when fitting the belt.

– To slacken off the poly V-belt, swivel the poly V-belt tensioner
in -arrow direction- using a 10 mm Allen key.
– Lock the tensioner in position by inserting the mandrel -3204-
in the locating holes -A- and -B-.
– Detach the poly V-belt.

10. Vane pump 225

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

10.6 Exploded view of vane pump - Vehicles with 6-cyl. 5V engine

1 - Expansion hose
❑ Part section with pipe,
routed to steering box
2 - Bolt, 6 Nm
3 - Bolt, 9 Nm
4 - Ignition coils with holder
5 - Seal
❑ Always replace
6 - Screw connection, 50 Nm
7 - Clamp
❑ Always replace
❑ Tensioning
⇒ page 227
❑ Can also be replaced by
screw-type clamp
8 - Suction hose
❑ Pay attention to the
mark -P- for the pump-
end hose connection.
9 - Pipe for suction hose
10 - Bolt, 25 Nm
❑ Attachment of vane
pump to holder at rear
11 - Slotted bushing
❑ For tolerance compen‐
sation
12 - Bolt, 25 Nm
❑ For attaching vane
pump holder to crank‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
case with respect to the correctness of information in this document. Copyright by AUDI AG.

13 - Bolt, 25 Nm
❑ Attachment of vane pump to holder at front
14 - Holder for vane pump
15 - Bolt, 25 Nm
❑ Provide support for pulley with pin wrench -3212- when slackening off and tightening
16 - Pulley
17 - Vane pump
❑ Checking delivery pressure ⇒ page 237
❑ Removing and installing ⇒ page 227
❑ Prior to installation, fill with hydraulic fluid on suction end and crank by hand until fluid emerges on delivery
end
18 - Seal
❑ Always replace
19 - Banjo bolt, 50 Nm

226 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Tensioning clamp with hose clamp pliers -V.A.G 1275-

10.7 Removing and installing vane pump -

Vehicles with 6-cyl. 5V engine
Special tools and workshop equipment required
♦ Hose clamps up to 25 mm -3094-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Locking pin -3204-

♦ Pin wrench -3212-

10. Vane pump 227

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Removing
– Remove the noise insulation.
– Unclip the engine top cover and detach.

– Slacken off the poly V-belt for the vane pump, viscous fan and
alternator.
– Secure with a pin wrench -3212- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Note

Mark the direction of the poly V-belt prior to removal. Running a

used belt in the opposite direction could destroy it. Ensure correct
belt positioning in pulleys when fitting.

– Detach the poly V-belt from the pulley.

– Pinch off the suction and return pipes with hose clamps
-3094- .

– Unplug the 5-pin connector at the ignition coils.

– Unplug the three rear connectors -A- from the ignition coils.
– Screw out the four bolts.
– Swivel the ignition coil holder to the rear.

228 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Provide support with a pin wrench -3212- and unscrew the

vane pump pulley.

– Screw out the bolt -arrow-.

– Unfasten theunless
clamp -1- and detach the
AG suction hose.or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted authorised by AUDI AG. AUDI does not guarantee

– Unscrew the expansion hose -2-.

with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unscrew the vane pump holder.

– Take out the holder with pump.
– Then unscrew the vane pump from the holder.
Installing
♦ Before fitting a new pump, pour in hydraulic fluid on the suction
end and crank by hand until fluid emerges on the delivery end.
♦ Clean fouled areas in the engine compartment.
– Screw the pump to the holder.

10. Vane pump 229

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Insert the pump with holder.

– Fit all bolts, tighten the two at the front and then the two at the
rear.
– Attach new seals to the banjo bolt.

– Tighten the banjo bolt for the pressure hose -2-.

– Screw the pipe of the expansion hose to the cylinder head (bolt
⇒ Item 2 (page 226) ).
– Fit the suction hose -1-.
– Pay attention to the mark -P- for the pump-end hose connec‐
tion.
– Detach the hose clamps -3094- .

– Tighten the hexagon socket head bolts of the pulleys for the
vane pump.
– Fit the poly V-belt ⇒ Rep. Gr. 13 .
– Fit the holder for the ignition coils.
– Connect the ignition cables to the ignition coils.
– Check the hydraulic fluid level ⇒ page 276 .
– Bleed the steering system ⇒ page 276 .
– Check the steering system for leaks ⇒ page 277 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

230 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

11 Vane pump delivery pressure

⇒ “11.1 Checking delivery pressure of vane pump - Vehicles with
4-cyl. engine”, page 231
⇒ “11.2 Checking delivery pressure of vane pump - Vehicles with
5-cyl. engine”, page 233
⇒ “11.3 Checking delivery pressure of vane pump - Vehicles with
6-cyl. 2V engine”, page 235
⇒ “11.4 Checking delivery pressure of vane pump - Vehicles with
6-cyl. 5V engine”, page 237
⇒ “11.5 Checking delivery pressure of vane pump - Audi S4/S6
and Audi S6 Plus with 8-cyl. engine”, page 239

11.1 Checking delivery pressure of vane pump - Vehicles with 4-cyl. engine

Special tools and workshop

equipment required
♦ Hose clamps up to 25 mm
-3094-
♦ Power steering tester -
V.A.G 1402-
♦ Adapter -V.A.G 1402/3-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

11. Vane pump delivery pressure 231

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Sequence of operations
– Pinch off the suction and return pipes with hose clamps
-3094- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Unscrew the expansion hose from the vanewith

pump.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
respect to the correctness of information in this document. Copyright by AUDI AG.

– Attach seal -N 013 844 4- to adapter -V.A.G 1402/3- .

– Screw the adapter -V.A.G 1402/3- into the vane pump in place
of the banjo bolt.

232 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Screw the hose of the pressure gauge -V.A.G 1402- onto the
adapter -V.A.G 1402/3- .
– Close the pressure gauge shutoff valve (lever to left).
– Detach the hose clamp and top up the fluid level in the reser‐
voir if necessary.
Heed the following to avoid damaging the pump:
♦ Do not run the engine for more than 10 seconds when per‐
forming this check.
♦ Start the engine without accelerating and let it idle.
♦ Take the pump pressure reading at idle immediately after
starting (have a second mechanic take the reading if neces‐
sary).
♦ The highest pressure displayed is definitive, as the pressure
drops in the course of the test.
Specifications
To determine the specifications, heed the pump pressure given
on the rating plate of the vane pump.
• Stated pump pressure 100 bar: Specification 100 ... 110 bar
• Stated pump pressure 120 bar: Specification 120 ... 130 bar
– Start the engine.
If the reading does not match the specification, replace the vane
pump ⇒ page 218 .
– Check the hydraulic fluid level ⇒ page 276 .
– Check the steering system for leaks ⇒ page 277 .
– Bleed the steering system ⇒ page 276 .

11.2 Checking delivery pressure of vane pump - Vehicles with 5-cyl. engine

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

11. Vane pump delivery pressure 233

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Special tools and workshop

equipment required
♦ Hose clamps up to 25 mm
-3094-
♦ Power steering tester -
V.A.G 1402-
♦ Adapter -V.A.G 1402/3-

Sequence of operations
– Pinch off the suction and return pipes with hose clamps
-3094- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

234 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Unscrew the expansion hose from the vane pump.

– Attach seal -N 013 844 4- to adapter -V.A.G 1402/3- .

– Screw the adapter -V.A.G 1402/3- into the vane pump in place
of the banjo bolt.

– Screw the hose of the pressure gauge -V.A.G 1402- onto the
adapter -V.A.G 1402/3- .
– Close the pressure gauge shutoff valve (lever to left).
– Detach the hose clamp and top up the fluid level in the reser‐
voir if necessary.
Heed the following to avoid damaging the pump:
♦ Do not run the engine for more than 10 seconds when per‐
forming this check.
♦ Start the engine without accelerating and let it idle.
♦ Take the pump pressure reading at idle immediately after
starting (have a second mechanic take the reading if neces‐
sary).
♦ The highest pressure displayed is definitive, as the pressure
drops in the course of the test.
– Start the engine.
• Specification: 120 ... 130 bar
If the reading does not match the specification, replace the vane
pump ⇒ page 221 .
– Check the hydraulic fluid level ⇒ page 276 .
– Check the steering system for leaks ⇒ page 277 .
– Bleed the steering system ⇒ page 276 .

11.3 Checking delivery pressure of vane pump - Vehicles with 6-cyl. 2V engine
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

11. Vane pump delivery pressure 235

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Special tools and workshop

equipment required
♦ Hose clamps up to 25 mm
-3094-
♦ Power steering tester -
V.A.G 1402-
♦ Adapter -V.A.G 1402/3-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Sequence of operations
– Pinch off the suction and return pipes with hose clamps
-3094- .
– Press the connector spring clip and unplug the connector from
the injector.

236 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Provide support at the hexagon of the pressure hose and un‐

screw the pipe from the pressure hose -arrow-.

– Screw the adapter -V.A.G 1402/3- into the vane pump in place
of the banjo bolt.

– Screw the hose of the pressure gauge -V.A.G 1402- onto the
adapter -V.A.G 1402/3- .
– Close the pressure gauge shutoff valve (lever to left).
– Plug in the injector connector.
– Detach the hose clamp and top up the fluid level in the reser‐
voir if necessary.
Heed the following to avoid damaging the pump:
♦ Do not run the engine for more than 10 seconds when per‐
forming this check.
♦ Start the engine without accelerating and let it idle.
♦ Take the pump pressure reading at idle immediately after
starting (have a second mechanic take the reading if neces‐
sary).
♦ The highest pressure displayed is definitive, as the pressure
drops in the course of the test.
– Start the engine.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Specification: 120 ... 130
permitted barauthorised by AUDI AG. AUDI AG does not guarantee or accept any liability
unless
with respect to the correctness of information in this document. Copyright by AUDI AG.
If the reading does not match the specification, replace the vane
pump ⇒ page 222 .
– Check the hydraulic fluid level ⇒ page 276 .
– Check the steering system for leaks ⇒ page 277 .
– Bleed the steering system ⇒ page 276 .

11.4 Checking delivery pressure of vane

pump - Vehicles with 6-cyl. 5V engine
Special tools and workshop equipment required

11. Vane pump delivery pressure 237

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

♦ Hose clamps up to 25 mm -3094-

♦ Power steering tester -V.A.G 1402-

Sequence of operations
– Unclip the engine top cover and detach.
– Pinch off the suction and return pipes with hose clamps
-3094- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Provide support at the hexagon of the expansion hose and

unscrew the pipe from the expansion hose -arrow-.
– Screw the hose of the pressure gauge -V.A.G 1402- to the
section of the expansion hose leading to the pump.

238 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Close the pressure gauge shutoff valve (lever to left).

– Detach the hose clamps.
– If necessary, top up the fluid in the reservoir.
Heed the following to avoid damaging the pump:
♦ Do not run the engine for more than 10 seconds when per‐
forming this check.
♦ Start the engine without accelerating and let it idle.
♦ Take the pump pressure reading at idle immediately after
starting (have a second mechanic take the reading if neces‐
sary).
♦ The highest pressure displayed is definitive, as the pressure
drops in the course of the test.
– Start the engine.
• Specification: 120 ... 130 bar
If the reading does not match the specification, replace the vane
pump ⇒ page 227 .
– Check the hydraulic fluid level ⇒ page 276 .
– Check the steering system for leaks ⇒ page 277 .
– Bleed the steering system ⇒ page 276 .

11.5 Checking delivery pressure of vane pump - Audi S4/S6 and Audi S6 Plus
with 8-cyl. engine

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

11. Vane pump delivery pressure 239

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Special tools and workshop

equipment required
♦ Hose clamps up to 25 mm
-3094-
♦ Power steering tester -
V.A.G 1402-
♦ Adapter -V.A.G 1402/3-

Sequence of operations Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Pinch off the suction and return pipes with hose clamps
with respect to the correctness of information in this document. Copyright by AUDI AG.

-3094- .
– Unscrew the expansion hose -arrow- from the vane pump.

240 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Attach seal -N 013 844 4- to adapter -V.A.G 1402/3- .

– Screw the adapter -V.A.G 1402/3- into the vane pump in place
of the banjo bolt.

Note

On the 8-cyl. engine, this may lead to problems. Use an appro‐

priate banjo union in place of the adapter -V.A.G 1402/3- .

– Screw the hose of the pressure gauge -V.A.G 1402- onto the
adapter -V.A.G 1402/3- .
– Close the pressure gauge shutoff valve (lever to left).
– Plug in the injector connector.
– Detach the hose clamp and top up the fluid level in the reser‐
voir if necessary.
Heed the following to avoid damaging the pump:
♦ Do not run the engine for more than 10 seconds when per‐
forming this check.
♦ Start the engine without accelerating and let it idle.
♦ Take the pump pressure reading at idle immediately after
starting (have a second mechanic take the reading if neces‐
sary).
♦ The highest pressure displayed is definitive, as the pressure
drops in the course of the test.
– Start the engine.
• Specification: 120 ... 130 bar
If the reading does not match the specification, replace the tan‐
dem pump: Audi S4/S6 ⇒ page 266 ; Audi S6 Plus
⇒ page 271 .
– Check the hydraulic fluid level ⇒ page 276 .
– Check the steering system for leaks ⇒ page 277 .
– Bleed the steering system ⇒ page 276 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

11. Vane pump delivery pressure 241

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

12 Tandem pump
⇒ “12.1 General ”, page 242
⇒ “12.2 Exploded view - Vehicles with 4-cyl. engine”, page 242
⇒ “12.3 Exploded view - Vehicles with 5-cyl. engine”, page 245
⇒ “12.4 Exploded view - Audi S4/S6 with 5-cyl. turbo engine”,
page 247
⇒ “12.5 Exploded view - Vehicles with 6-cyl. engines”,
page 249
⇒ “12.6 Removing and installing tandem pump - Vehicles with 6-
cyl. engines”, page 251
⇒ “12.7 Exploded view - Audi S4/S6 and Audi S6 Plus with 8-cyl.
engine”, page 253

12.1 General
There is no provision for tandem pump servicing. In the event of
problems, establish the cause by way of a pressure and leak test.
Replace the tandem pump if a fault is found.
♦ Always check the steering system for leaks if there is a lack of
fluid in the reservoir.
♦ If a leak is found in the area of the pipe connections, start by
checking the pipes/pipe connections for leaks, re-tighten if
necessary and wipe dry.
♦ Replacement pumps have no fluid fill. Prior to installation they
are therefore to be filled with hydraulic fluid G 002 000 Protected
and by copyright. Copying for private or commercial purposes, in part or in whole, is not
cranked by hand to avoid the possibility of noise whilst driving
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

or pump damage.
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Hydraulic fluid ⇒ Electronic parts catalogue

♦ Always replace self-locking bolts and nuts.
♦ The hydraulic fluid drained off is not to be re-used.

12.2 Exploded view - Vehicles with 4-cyl. engine

242 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

1 - Bolt, 20 Nm
2 - Bolt, 20 Nm
3 - Holder
4 - Tandem pump
❑ Consists of plunger and
vane pump (piston
pump for self-levelling
suspension, vane pump
for power-assisted
steering)
❑ Checking delivery pres‐
sure of vane pump
⇒ page 231
❑ Checking delivery of
plunger pump
⇒ page 255
❑ Fill with fluid before in‐
stalling ⇒ page 242
❑ Cannot be serviced
❑ Attach hose clamp
-3094- to the suction
and return hose before
unscrewing the suction
and expansion hose at
the vane pump
5 - Front swivel mount
❑ Bolt to tandem pump
6 - Self-locking nut, 20 Nm
❑ Always replace after re‐
moving
7 - Bolt, 20 Nm
8 - Bolt, 20 Nm
9 - Poly V-belt
❑ Tensioning, replacement ⇒ Maintenance ; Booklet 401
10 - Bolt with tensioning nut
11 - Bolt, 25 Nm
12 - Pulley
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ When installing the pulley, make
permitted sure thebypulleys
unless authorised AUDI AG. AUDIof the crankshaft
AG does and
not guarantee vaneanypump
or accept liability are in alignment
with respect to the correctness of information in this document. Copyright by AUDI AG.
13 - Bolt, 25 Nm
14 - Washer
❑ Thickness 4 mm
15 - Tensioning bar
16 - Seal
❑ Always replace after removing
❑ Different versions; for assignment refer to ⇒ Electronic parts catalogue
17 - Washer
❑ Thickness 2.5 mm

12. Tandem pump 243

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

18 - Bolt, 25 Nm
19 - Bolt, 25 Nm
20 - Spacer
21 - Rear swivel mount
22 - Washer
❑ Thickness 4 mm
23 - Bolt, 25 Nm
24 - Washer
❑ Thickness 2.5 mm
25 - Bolt
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
26 - Washer permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

❑ Thickness 4 mm
with respect to the correctness of information in this document. Copyright by AUDI AG.

27 - Bolt, 25 Nm
28 - High-pressure hose
29 - Expansion hose
❑ Replacement involves removing brake servo
❑ Different seal versions; for assignment refer to ⇒ Electronic parts catalogue
30 - Banjo bolt, 50 Nm
❑ Different seal versions; for assignment refer to ⇒ Electronic parts catalogue
31 - Seal
❑ Always replace after removing
❑ Different versions; for assignment refer to ⇒ Electronic parts catalogue
32 - Banjo bolt, 25 Nm
❑ Always replace after removing
33 - Seal
❑ Always replace after removing
34 - Suction hose
❑ Different banjo union designs with regard to seals; for assignment refer to ⇒ Electronic parts catalogue
❑ If the tandem pump is provided with a screw connection, the suction hose is secured by means of a clamp
⇒ Item 12 (page 246) , ⇒ Item 13 (page 246) and ⇒ Item 14 (page 246)
35 - Banjo bolt/screw connection, 50 Nm
❑ Note different seal versions

244 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

12.3 Exploded view - Vehicles with 5-cyl. engine

1 - Pulley
❑ Slackening off poly V-
belt ⇒ page 246
2 - Tandem pump
❑ Consists of plunger and
vane pump (piston
pump for self-levelling
suspension, vane pump
for power-assisted
steering)
❑ Checking delivery pres‐
sure of vane pump
⇒ page 233
❑ Checking delivery of
plunger pump
⇒ page 256
❑ Fill with fluid before in‐
stalling ⇒ page 242
❑ Cannot be serviced
❑ Attach hose clamp
-3094- to the suction
and return hose before
unscrewing the suction
and expansion hose at
the vane pump
❑ Removing and instal‐
ling, c.f. 5-cyl. turbo en‐
gine ⇒ page 262
3 - Seal
❑ Always replace after re‐
moving
❑ Different versions; for
assignment refer to ⇒
Electronic parts cata‐
logue
4 - Banjo bolt, 25 Nm
❑ Always replace after removing
❑ Different seal versions; for assignment refer to ⇒ Electronic parts catalogue
5 - Expansion hose
❑ Replacement involves removing brake servo
❑ Different seal versions; for assignment refer to ⇒ Electronic parts catalogue
6 - Banjo bolt, 50 Nm
❑ Different seal versions; for assignment refer to ⇒ Electronic parts catalogue
7 - Seal
❑ Always replace after removing
❑ Different versions; for assignment refer to ⇒ Electronic parts catalogue
8 - Bolt, 20 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
9 - Washer permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
10 - High-pressure hose
11 - Seal
❑ Always replace after removing

12. Tandem pump 245

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

❑ Different versions; for assignment refer to ⇒ Electronic parts catalogue

12 - Screw connection, 50 Nm
❑ Different seal versions; for assignment refer to ⇒ Electronic parts catalogue
13 - Clamp
14 - Suction hose
15 - Bolt, 25 Nm
16 - Bolt, 25 Nm
17 - Bolt, 25 Nm
18 - Holder
19 - Washer
20 - Bolt, 25 Nm
21 - Bolt, 25 Nm
❑ For attaching holder to engine block
22 - Bolt, 25 Nm
❑ Screw out before removing pump

Slackening off poly V-belt

Note

Mark the direction of the poly V-belt with chalk or a felt-tip pen
prior to removal. Running a used belt in the opposite direction
could destroy it. Pay attention to correct positioning on pulleys
when fitting the belt.

– To slacken off the poly V-belt, press the open-ended wrench

in -arrow direction-.
– Detach the poly V-belt from the pulley.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

246 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

12.4 Exploded view - Audi S4/S6 with 5-cyl. turbo engine

1 - Pulley
❑ Unscrew to remove the
vane pump; this in‐
volves slackening off
the poly V-belt
⇒ page 248
2 - Tandem pump
❑ Consists of plunger and
vane pump (piston
pump for self-levelling
suspension and hy‐
draulic brake servo,
vane pump for power-
assisted steering)
❑ Checking delivery of
plunger pump
⇒ page 256
❑ Checking delivery pres‐
sure of vane pump
⇒ page 233
❑ Fill with fluid before in‐
stalling ⇒ page 242
❑ Cannot be serviced
❑ Attach hose clamp
-3094- to the suction
and return hose before
unscrewing the suction
and expansion hose at Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
the vane pump permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Removing and installing with respect to the correctness of information in this document. Copyright by AUDI AG.

⇒ page 262
3 - Seal
❑ Always replace after re‐
moving
❑ Different versions; for
assignment refer to ⇒
Electronic parts catalogue
4 - Banjo bolt, 25 Nm
❑ Always replace after removing
5 - Expansion hose
❑ Different seal versions; for assignment refer to ⇒ Electronic parts catalogue
6 - Banjo bolt, 50 Nm
❑ Different seal versions; for assignment refer to ⇒ Electronic parts catalogue
7 - Seal
❑ Always replace after removing
❑ Different versions; for assignment refer to ⇒ Electronic parts catalogue
8 - Bolt, 20 Nm
❑ For attaching high-pressure hose/tandem pump
9 - Washer
10 - High-pressure hose
11 - Seal
❑ Always replace after removing

12. Tandem pump 247

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

❑ Different versions; for assignment refer to ⇒ Electronic parts catalogue

12 - Screw connection, 50 Nm
❑ Different seal versions; for assignment refer to ⇒ Electronic parts catalogue
13 - Clamp
14 - Suction hose
15 - Bolt, 25 Nm
16 - Bolt, 25 Nm
17 - Bolt, 25 Nm
18 - Holder
19 - Washer
20 - Bolt, 25 Nm
21 - Bolt, 25 Nm
❑ For attaching holder to engine block
22 - Bolt, 25 Nm
❑ Screw out before removing pump
23 - Cap Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Slackening off poly V-belt

Note

Mark the direction of the poly V-belt with chalk or a felt-tip pen
prior to removal. Running a used belt in the opposite direction
could destroy it. Pay attention to correct positioning on pulleys
when fitting the belt.

– Remove the upper belt guard.

– To slacken off the poly V-belt, press the open-ended wrench
in -arrow direction-.
– Insert the mandrel -3204- to secure.
– Detach the poly V-belt from the pulley.

248 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

12.5 Exploded view - Vehicles with 6-cyl. engines

1 - Expansion hose with pipe

❑ Different seal versions;
for assignment refer to
⇒ Electronic parts cata‐
logue
❑ Replacement involves
removing brake servo
❑ Refer to:
⇒ “1.4 Removing and in‐
stalling power-assisted
steering box”, page 159
Section on “Removing
brake servo with brake
master cylinder”
2 - Combi bolt, 8 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Hole at intake pipe authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless
with respect to the correctness of information in this document. Copyright by AUDI AG.
4 - Banjo bolt, 25 Nm
❑ Always replace after re‐
moving
❑ With strainer at end face
5 - Seal
❑ Always replace after re‐
moving
❑ Different versions; for
assignment refer to ⇒
Electronic parts cata‐
logue
6 - High-pressure hose
❑ Screwed with tab to
holder
⇒ Item 25 (page 250)
7 - Pulley
Up to Model Year 1991
❑ Slackening off poly V-belt ⇒ page 252
As of Model Year 1992
❑ Slackening off poly V-belt ⇒ page 253
8 - Bolt, 25 Nm
9 - Bolt, 25 Nm
10 - Bolt, 25 Nm
11 - Bolt, 25 Nm
12 - Holder
❑ Bushing installed on left in direction of travel with bolt discontinued as of vehicle ident no. PN 009 632
13 - Ignition coils with holder
14 - Bolt, 25 Nm
15 - Banjo bolt, 50 Nm
❑ Different seal versions; for assignment refer to ⇒ Electronic parts catalogue
16 - Seal
❑ Always replace after removing

12. Tandem pump 249

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

❑ Insert seals on both sides in banjo union of expansion hose

17 - Tandem pump
❑ Consists of plunger and vane pump (piston pump for self-levelling suspension, vane pump for power-
assisted steering)
❑ Checking delivery of plunger pump ⇒ page 257
❑ Checking delivery pressure of vane pump ⇒ page 235
❑ Fill with fluid before installing ⇒ page 242
❑ Cannot be serviced
❑ Removing and installing ⇒ page 251
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

18 - Seal
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Always replace
❑ Different versions; for assignment refer to ⇒ Electronic parts catalogue
19 - Screw connection, 50 Nm
❑ Different seal versions; for assignment refer to ⇒ Electronic parts catalogue
20 - Clamp
21 - Bolt, 25 Nm
22 - Bolt, 25 Nm
❑ Bolt installed on left in direction of travel with bushing discontinued as of vehicle ident no. PN 009 632
23 - Suction hose
❑ Section with pipe
❑ Screwed with tab to holder ⇒ Item 25 (page 250)
24 - Combi bolt, 8 Nm
25 - Holder
❑ Bolted to cylinder head

250 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

12.6 Removing and installing tandem pump - Vehicles with 6-cyl. engines

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Removing
– Detach the engine top cover ⇒ page 252 .
– Detach the poly V-belt cover ⇒ page 252 .
– Slacken off the poly V-belt: Vehicles up to 1991
⇒ page 252 , vehicles as of 1992 ⇒ page 253
– Support the pulley with a water pump wrench -V.A.G 1590- if
applicable and unscrew.
– Pull the ignition cables out of the ignition coils -13-.
– Pinch off the suction pipe with a hose clamp -3094- .
– Detach the pressure and suction pipe.
– Unscrew the holder -12- and remove together with the tandem
pump.
– Take out the tandem pump with holder.
– Screw the tandem pump bolts out of the holder and take out
the vane pump.

12. Tandem pump 251

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Installing
Install in reverse order.
The ignition cables must be assigned in line with the numbering
⇒ page 252 .
Unclipping and detaching the engine top cover

Unscrewing poly V-belt cover

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Assignment of ignition cables 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
The ignition cables are marked 1 ... 6.
– Assign ignition cables 6 and 1 to ignition coil -C-.
– Assign ignition cables 2, 3, 4, 5 in the same manner.

Up to Model Year 1991:

Note

Mark the direction of the poly V-belt with chalk or a felt-tip pen
prior to removal. Running a used belt in the opposite direction
could destroy it. Pay attention to correct positioning on pulleys
when fitting the belt.

– Unscrew the ignition coils with holder and remove the upper
belt guard.
– To slacken off the poly V-belt, swivel the poly V-belt tensioner
in -arrow direction- using a 15 mm ring spanner.
– Insert the mandrel -3204- to secure.
– Detach the poly V-belt from the pulley.

252 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

As of Model Year 1992:

Note

Mark the direction of the poly V-belt with chalk or a felt-tip pen
prior to removal. Running a used belt in the opposite direction
could destroy it. Pay attention to correct positioning on pulleys
when fitting the belt.

– To slacken off the poly V-belt, swivel the poly V-belt tensioner
in -arrow direction- using a 10 mm Allen key.
– Lock the tensioner in position by inserting the mandrel -3204-
in the locating holes -A- and -B-.
– Detach the poly V-belt.

12.7 Exploded view - Audi S4/S6 and Audi S6 Plus with 8-cyl. engine

1 - Tandem pump Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Consists of plunger and permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
vane pump (piston
pump for self-levelling
suspension and hy‐
draulic brake servo,
vane pump for power-
assisted steering)
❑ Checking delivery of
plunger pump
⇒ page 259
❑ Checking delivery pres‐
sure of vane pump
⇒ page 239
❑ Fill with fluid before in‐
stalling ⇒ page 242
❑ Removing and instal‐
ling, Audi S4/S6 4.2
⇒ page 266
❑ Removing and instal‐
ling, Audi S6 Plus
⇒ page 271
2 - Shims
❑ Select such that pulleys
of air conditioner com‐
pressor and vane pump
are mutually aligned
❑ Checking and adjusting
poly V-belt alignment,
Audi S4/S6
⇒ page 270
❑ Checking and adjusting
poly V-belt alignment,
Audi S6 Plus
⇒ page 274
3 - Pulley
4 - Bolt, 25 Nm
5 - Poly V-belt
❑ Mark direction of poly V-belt. Running in opposite direction could destroy belt

12. Tandem pump 253

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

6 - Bolt, 25 Nm
7 - Slotted bushing
❑ For tolerance compensation
8 - Bolt, 25 Nm
9 - Banjo bolt, 25 Nm
❑ Always replace after removing
❑ With strainer at end face
10 - Seal
❑ Always replace after removing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
11 - High-pressure hoseunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted

❑ Plunger pump - pressure container

with respect to the correctness of information in this document. Copyright by AUDI AG.

12 - Banjo bolt, 50 Nm
13 - Seal
❑ Always replace after removing
14 - Expansion hose
❑ Vane pump - steering box
❑ Pay attention to clearance with respect to surrounding components
15 - Suction hose
❑ Vane pump - reservoir
❑ Pay attention to clearance with respect to surrounding components
16 - Banjo bolt, 50 Nm
17 - Seal
❑ Always replace after removing

254 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

13 Plunger pump delivery

⇒ “13.1 Checking delivery of plunger pump - Vehicles with 4-cyl.
engine”, page 255
⇒ “13.2 Checking delivery of plunger pump - Vehicles with 5-cyl.
engine”, page 256
⇒ “13.3 Checking delivery of plunger pump - Vehicles with 6-cyl.
2V and 5V engine”, page 257
⇒ “13.4 Checking delivery of plunger pump - Audi S4/S6 and Audi
S6 Plus with 8-cyl. engine”, page 259

13.1 Checking delivery of plunger pump - Ve‐

hicles with 4-cyl. engine
Special tools and workshop equipment required
♦ Self-levelling suspension system tester -V.A.G 1354-

Sequence of operations
– Unscrew the pressure pipe from the pump -arrows- and route
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

it upwards.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Screw the hose of the self-levelling suspension system tester

-V.A.G 1354- with the genuine banjo bolt and the metal seals
-N 013 808 3- to the pump.
– Unscrew the cap from the reservoir.

13. Plunger pump delivery 255

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Insert the end of the pipe of the self-levelling suspension sys‐

tem tester -V.A.G 1354- in the reservoir.
– Leave the engine idling until the pipe has been bled.
– Switch off the ignition and hold the end of the pressure limiter
pipe over a graduated beaker.
– Leave the engine idling.
• Delivery specification: at least 0.2 l/min.
– If the reading does not match the specification, replace the
tandem pump.
– Check the hydraulic fluid level ⇒ page 276 .
– Check the steering system for leaks ⇒ page 277 .
– Bleed the steering system ⇒ page 276 .

13.2 Checking delivery of plunger pump - Ve‐

hicles with 5-cyl. engine
Special tools and workshop equipment required
♦ Self-levelling suspension system tester -V.A.G 1354-

Sequence of operations
Vehicles with hydraulic brake servo:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Dissipate the operating pressure by pressingpermitted
the brake unless pedal
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
approx. 20 times with the engine switched off. with respect to the correctness of information in this document. Copyright by AUDI AG.
– The operating pressure has been dissipated when extremely
high back pressure is felt at the brake pedal and the brake
pedal travel is noticeably shorter.
All vehicles (continued):
– Unscrew the pressure pipe with holder from the pump
-arrows-.

256 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Screw the hose of the self-levelling suspension system tester

-V.A.G 1354- with the genuine banjo bolt and the metal seals
-N 013 808 3- to the pump.
– Unscrew the cap from the reservoir.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Insert the end of the pipe of the self-levellingpermitted
suspension sys‐ by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
tem tester -V.A.G 1354- in the reservoir. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Leave the engine idling until the pipe has been bled.
– Switch off the ignition and hold the end of the pressure limiter
pipe over a graduated beaker.
– Leave the engine idling.
• Delivery specification: at least 0.2 l/min.
– If the reading does not match the specification, replace the
tandem pump.
– Check the hydraulic fluid level ⇒ page 276 .
– Check the steering system for leaks ⇒ page 277 .
– Bleed the steering system ⇒ page 276 .

13.3 Checking delivery of plunger pump - Ve‐

hicles with 6-cyl. 2V and 5V engine
Special tools and workshop equipment required
♦ Self-levelling suspension system tester -V.A.G 1354-

Sequence of operations
– Unclip the engine top cover and detach.

13. Plunger pump delivery 257

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– 2V engine: Unscrew the poly V-belt cover.

– Detach the ignition coils with holder: 2V engine ⇒ page 222 ,
5V engine ⇒ page 228 .
– Swivel the ignition coil holder to the rear.

– Unscrew the pressure pipe with holder from the pump

-arrows-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Screw the hose of the self-levelling suspension system tester

-V.A.G 1354- with the genuine banjo bolt and the metal seals
-N 013 808 3- to the pump.
– If applicable, reconnect the ignition cables to the ignition coils.
– Unscrew the cap from the reservoir.

258 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Insert the end of the pipe of the self-levelling suspension sys‐

tem tester -V.A.G 1354- in the reservoir.
– Leave the engine idling until the pipe has been bled.
– Switch off the ignition and hold the end of the pressure limiter
pipe over a graduated beaker.
– Leave the engine idling.
• Delivery specification: at least 0.2 l/min.
– If the reading does not match the specification, replace the
tandem pump: Vehicles with 2V engine ⇒ page 251 , vehicles
with 5V engine ⇒ page 227 .
– Check all unions for leaks, start the engine and perform a vis‐
ual inspection.
– Fit the ignition coils with holder.
– Fit the engine top cover and the poly V-belt cover.
– Check the hydraulic fluid level ⇒ page 276 .
– Check the steering system for leaks ⇒ page 277 .
– Bleed the steering system ⇒ page 276 .

13.4 Checking delivery of plunger pump - Au‐

di S4/S6 and Audi S6 Plus with 8-cyl.
engine
Special tools and workshop equipment required
♦ Hose clamps up to 25 mm -3094-

♦ Self-levelling suspension system tester -V.A.Gpermitted

1354-unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

with respect to the correctness of information in this document. Copyright by AUDI AG.

Sequence of operations
– Dissipate the operating pressure by pressing the brake pedal
approx. 20 times with the engine switched off.

13. Plunger pump delivery 259

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– The operating pressure has been dissipated when extremely

high back pressure is felt at the brake pedal and the brake
pedal travel is noticeably shorter.
– Pinch off the suction and return pipes with hose clamps
-3094- .

– Unscrew the pressure pipe with holder from the pump

-arrow-.

– Screw the hose of the self-levelling suspension system tester

-V.A.G 1354- with the genuine banjo bolt and the metal seals
-N 013 808 3- to the pump.
– Unscrew the cap from the reservoir.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

260 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Insert the end of the pipe of the self-levelling suspension sys‐

tem tester -V.A.G 1354- in the reservoir.
– Leave the engine idling until the pipe has been bled.
– Switch off the ignition and hold the end of the pressure limiter
pipe over a graduated beaker.
– Leave the engine idling.
• Delivery specification: at least 0.2 l/min.
– If the reading does not match the specification, replace the
tandem pump: Audi S4/S6 ⇒ page 266 ; Audi S6 Plus
⇒ page 271 .
– Check the hydraulic fluid level ⇒ page 276 .
– Check the steering system for leaks ⇒ page 277 .
– Bleed the steering system ⇒ page 276 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

13. Plunger pump delivery 261

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

14 Removing and installing tandem

pump
⇒ “14.1 General ”, page 262
⇒ “14.2 Removing and installing tandem pump - Audi S4/S6 with
5-cyl. turbo engine”, page 262
⇒ “14.3 Removing and installing tandem pump - Audi S4/S6 with
8-cyl. engine”, page 266
⇒ “14.4 Checking and adjusting poly V-belt alignment - Audi S4/
S6 with 5-cyl. and 8-cyl. engine”, page 270
⇒ “14.5 Removing and installing tandem pump - Audi S6 Plus with
8-cyl. engine”, page 271

14.1 General
There is no provision for tandem pump servicing. In the event of
problems, establish the cause by way of a pressure and leak test.
Replace the tandem pump if a fault is found.
♦ Always check the steering system for leaks if there is a lack of
fluid in the reservoir.
♦ If a leak is found in the area of the pipe connections, start by
checking the pipes/pipe connections for leaks, re-tighten if
necessary and wipe dry.
♦ Replacement pumps have no fluid fill. Prior to installation they
are therefore to be filled with hydraulic fluid and cranked by
hand to avoid the possibility of noise whilst driving or pump
damage.
♦ Hydraulic fluid ⇒ Electronic parts catalogue

14.2 Removing and installing tandem pump - Audi S4/S6 with 5-cyl. turbo engine
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

262 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Special tools and workshop

equipment required
♦ Hose clamps up to 40 mm
-3093-
♦ Hose clamps up to 25 mm
-3094-
♦ Mandrel -3204-
♦ Torque wrench -V.A.G
1331-

Removing
– Pinch off the coolant hose with a hose clamp -3093-
Protected and Copying
by copyright. de‐ for private or commercial purposes, in part or in whole, is not
tach. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

14. Removing and installing tandem pump 263

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Remove the belt guard.

– Slacken off the pulley bolts; to do so, shorten the Allen key
appropriately.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– To slacken off the poly V-belt, press the open-ended wrench

in -arrow direction-.
– Insert the mandrel -3204- to secure.

Note

Mark the direction of the poly V-belt with chalk or a felt-tip pen
prior to removal. Running a used belt in the opposite direction
could destroy it. Pay attention to correct positioning on pulleys
when fitting the belt.

– Detach the poly V-belt from the pulley.

– Screw out the hexagon socket head bolts for the pulley and
detach the pulley.

– Pinch off the suction and return pipes with hose clamps
-3094- .

264 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Unscrew the high-pressure hose and expansion hose from the

pump.
– Seal the connecting holes with plugs.
– Unfasten the clamp and detach the suction hose.

– Screw out the bolts -arrows-.

– Take out the tandem pump.
Installing
♦ Before fitting a new pump, pour in hydraulic fluid on the suction
end and crank by hand until fluid emerges on the delivery end.
♦ Clean fouled areas in the engine compartment.
– Insert the tandem pump in the holder and tighten the bolts to
25 Nm.

– Screw the high-pressure hose and expansion hose to the

pump.
– Attach the suction hose to the screw connection and secure
with a clamp.

Note

Screw the screw connection for the suction hose out of the de‐
fective tandem pump and screw into the new tandem pump (50
Nm).

– Detach the hose clamps -3094- from the suction and return
hose.
– Screw in the pulley and flange bolts by hand.

– Carefully position the poly V-belt on the pulley and tension it;
to do so, press the tensioner in -arrow direction- and take out
the mandrel -3204- .
– Use a shortened Allen key to tighten the pulley bolts.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

14. Removing and installing tandem pump 265

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Carefully install the belt guard to avoid damage caused by the

pulley catching.

– Attach the coolant hose to the connection piece at the engine

block and secure with a clamp.
– Remove the hose clamp -3093- .
– Check the alignment of the poly V-belt ⇒ page 270 .
– Check the coolant level and top up if necessary ⇒ Mainte‐
nance ; Booklet 401 .

14.3 Removing and installing tandem pump - Audi S4/S6 with 8-cyl. engine

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

266 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Special tools and workshop

equipment required
♦ Hose clamps up to 25 mm
-3094-
♦ Mandrel -3204-
♦ Pin wrench -3212-
♦ Torque wrench -V.A.G
1331-

Removing
– Unscrew the air pipe on the left -arrows-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

14. Removing and installing tandem pump 267

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Unscrew the air duct on the left -arrows-.

– Vehicles with air conditioner: Unfasten the green connection
to the air conditioner compressor at the left longitudinal mem‐
ber.

– Pinch off the suction and return pipes with hose clamps
-3094- .

– Unscrew the high-pressure hose and expansion hose from the

pump.
– Seal the connecting holes with plugs.

– Remove the noise insulation.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

268 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Pull the poly V-belt firmly downwards.

– Insert the mandrel -3204- to secure.

Note

Mark the direction of the poly V-belt with chalk or a felt-tip pen
prior to removal. Running a used belt in the opposite direction
could destroy it. Pay attention to correct positioning on pulleys
when fitting the belt.

– Detach the poly V-belt from the pulley.

– Vehicles with air conditioner: Screw out the bolts at the air
conditioner compressor -arrows-.
– Hang up the air conditioner compressor to one side with a
piece of welding wire.
– Vehicles with no air conditioner: Remove the idler wheel with
holder.

– Unscrew the tandem pump pulley.

– Use a pin wrench -3212- to provide support.

Note

The engine has been removed in the illustration for greater clarity.

– Detach the suction hose.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Seal the permitted
connecting holes with
unless authorised plugs.
by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Take out the tandem pump.
Installing
♦ Before fitting a new pump, pour in hydraulic fluid on the suction
end and crank by hand until fluid emerges on the delivery end.
♦ Clean fouled areas in the engine compartment.
– Insert the tandem pump in the holder and tighten the bolts to
25 Nm.

14. Removing and installing tandem pump 269

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Screw the suction hose to the pump.

– Position the poly V-belt pulley on the tandem pump and tighten
the bolts.
– Vehicles with air conditioner: Fit the air conditioner compres‐
sor and tighten the bolts to 20 Nm. In doing so, make sure the
wiring of the air conditioner compressor is routed such that it
cannot catch on the poly V-belt.
– Check the alignment of the poly V-belt ⇒ page 270 .
– Vehicles with no air conditioner: Fit the idler wheel with holder
and tighten the bolts to 20 Nm.

14.4 Checking and adjusting poly V-belt

alignment - Audi S4/S6 with 5-cyl. and
8-cyl. engine
Special tools and workshop equipment required
♦ Alignment gauge -3201-

Sequence of operations
– Position the alignment gauge -3201- on the pulley of the air
conditioner compressor.
– The pump and air conditioner compressor pulleys must be
aligned.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
If the two pulleys are not in alignment: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Unscrew the pump pulley.

– Use the shims available from the replacement parts range to

adjust the gap such that the two pulleys are aligned.
– Move the high-pressure hose and expansion hose to assem‐
bly position.
– Carefully position the poly V-belt on the pulley and tension it;
to do so, press the tensioner against the stop and take out the
mandrel -3204- .
– Insert the noise insulation in the fastener and secure.

270 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Screw the high-pressure hose and expansion hose to the

pump.
– Detach the hose clamps -3094- from the suction and return
hose.
– Vehicles with air conditioner: Make the green connection to
the air conditioner compressor at the left longitudinal member.
– Fit the left air duct.
– Fit the left air pipe.
– Check the hydraulic fluid level ⇒ page 276 .
– Bleed the steering system ⇒ page 276 .
– Check the steering system for leaks ⇒ page 277 .

14.5 Removing and installing tandem pump - Audi S6 Plus with 8-cyl. engine

Special tools and workshop

equipment required
♦ Hose clamps up to 25 mm
-3094-
♦ Mandrel -3204-
♦ Pin wrench -3212-
♦ Torque wrench -V.A.G
1331-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

14. Removing and installing tandem pump 271

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Removing
– Remove the noise insulation.

– Pull the poly V-belt firmly downwards.

– Insert the mandrel -3204- to secure.

Note

Mark the direction of the poly V-belt with chalk or a felt-tip pen
prior to removal. Running a used belt in the opposite direction
could destroy it. Pay attention to correct positioning on pulleys
when fitting the belt.

– Detach the poly V-belt from the pulley.

– In the course of the following operation, the air conditioner
compressor has to be unscrewed and hung up to one side.

– So as not to damage the wire -1- for the magnetic clutch, the
cable tie -2- at the left longitudinal member is to be unfastened.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Pinch off the suction and return pipes with hose clamps
-3094- .

272 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Unscrew the air conditioner compressor -1-.

– Hang up the air conditioner compressor to one side with a
piece of welding wire.
– Take care not to strain the coolant hoses and wire -2-.

– Unscrew the tandem pump pulley.

– Use a pin wrench -3212- to provide support.

Note

For greater clarity, the engine has been removed in the illustra‐
tion.

– Unscrew the high-pressure hose -1-, expansion hose -2- and

suction hose -3- from the pump.
– Seal the connecting holes with plugs.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unscrew the tandem pump from the holder and take out.
Installing
♦ Before fitting a new pump, pour in hydraulic fluid on the suction
end and crank by hand until fluid emerges on the delivery end.
♦ Clean fouled areas in the engine compartment.

14. Removing and installing tandem pump 273

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Insert the pump in the holder and screw in all three bolts by
hand.
– Tighten the two front bolts first and then the rear bolt.
– Fit the expansion, high-pressure and suction hoses with new
seals.
– Detach the hose clamps -3094- .
– Screw on the pulley.

– Before fitting the air conditioner compressor, make sure the

guide rings -arrows- are correctly positioned.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Tighten the air conditioner compressor bolts -1- at the holder

to 20 Nm.
– Check the alignment of the poly V-belt ⇒ page 274 .

14.6 Checking and adjusting poly V-belt

alignment - Audi S6 Plus with 8-cyl. en‐
gine
Special tools and workshop equipment required
♦ Alignment gauge -3201-

274 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

Sequence of operations
– Position the alignment gauge -3201- on the pulley of the air
conditioner compressor.
– The pump and air conditioner compressor pulleys must be
aligned.
If the two pulleys are not in alignment:
– Unscrew the pump pulley.

– Use the shims available from the replacement parts range to

adjust the gap such that the two pulleys are aligned.
– Fit the poly V-belt and take out the mandrel -3204- .
– Check the hydraulic fluid level ⇒ page 276 .
– Bleed the steering system ⇒ page 276 .
– Check the steering system for leaks ⇒ page 277 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

14. Removing and installing tandem pump 275

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

15 Checking fluid level, bleeding steer‐

ing system, checking for leaks
⇒ “15.1 Checking power steering fluid level”, page 276
⇒ “15.2 Bleeding steering system”, page 276
⇒ “15.3 Checking steering system for leaks”, page 277

15.1 Checking power steering fluid level

Sequence of operations
• On vehicles with self-levelling suspension, the fluid level is
only to be checked in unladen condition.
– With the engine not running, move the front wheels to the
straight ahead position.
Cold fluid:
– Unscrew the cap.
– Wipe over the dipstick with a clean cloth.
– Screw in the cap hand-tight and screw off again.

Note

The level is only valid if the cap had been screwed on beforehand.

– Check the fluid level:

• The fluid level must be around the MIN mark (up to 2 mm
above or below the mark).
Warm fluid as of approx. 50 °C:
– Check the fluid level:
• The fluid level must be between the MIN and MAX marks.

Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Fluid must be drawn off if the level is above the stated range. with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ The hydraulic system must be checked for leaks if the fluid

level is below the stated range. It is not sufficient to merely
replenish the fluid.
♦ The hydraulic fluid drained off is not to be re-used.

15.2 Bleeding steering system

Sequence of operations
– Check the hydraulic fluid level and replenish the fluid if nec‐
essary.
– Raise the vehicle such that the front wheels are free.
– With the engine switched off, turn the steering wheel 10 times
from lock to lock.
– Check the hydraulic fluid level and replenish the fluid if nec‐
essary.
– Lower the vehicle.

276 Rep. Gr.48 - Steering

 Audi 100 1991 ➤ , Audi A6 1995 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 11.2008

– Start the engine and let it idle for approx. 2 minutes with the
front wheels in straight ahead position.
– Observe the fluid level in the reservoir; switch off the engine
as soon as no further bubbles rise to the surface in the reser‐
voir.
– Check the hydraulic fluid level and replenish the fluid if nec‐
essary.

Note

Any residual air in the steering system escapes automatically

whilst driving after 10 ... 20 km.

15.3 Checking steering system for leaks

Sequence of operations
– Start the engine.
– Turn the steering wheel to full lock on both sides and briefly
hold in this position.
• The maximum possible pressure is thus built up.
To avoid pump damage, do not run the engine for more than
10 seconds when performing this test.
Check the following components for leaks in this position:
♦ Steering pinion seal at steering box valve housing
♦ All pipe connections
♦ Rack seals
This test can only be performed with the bellows pushed back.
– Unfasten the clamp of the bellows.
– Push back the boot.
– The steering box must be replaced if fluid is visible in the
steering box housing and/or the boots.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

15. Checking fluid level, bleeding steering system, checking for leaks 277