Service

Workshop Manual
Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive
Edition 10.2013

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
44 - Wheels, tyres, vehicle geometry
48 - 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.

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 A0056006120

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Proper disposal procedures for oil-filled and gas-filled components . . . . . . . . . . . . . . . . . . 2
2.1 Releasing gas from shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Draining steering damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Draining power steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Checking shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Leaks at shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Noises from shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Checking shock absorbers when removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 Checking shock absorbers on shock tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Subframe/body mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Repairing damaged threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Repairing threads in longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Mount with transverse brace, connection of upper links to wheel bearing housing . . . . . . 12
2.1 Exploded view of mount with transverse brace, connection of upper links to wheel bearing
housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Removing and installing mount with transverse brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Separating upper links from wheel bearing housing (steel) . . . . . . . . . . . . . . . . . . . . . . . . 15
3 Suspension strut, explanatory notes on factory codes (PR nos.) . . . . . . . . . . . . . . . . . . . . 19
3.1 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Servicing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.3 Explanatory notes on weight codes used in production (PR numbers) . . . . . . . . . . . . . . . . 25
4 Steel wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.1 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2 Removing and installing front wheel bearing with wheel bearing housing removed . . . . . . 28
4.3 Removing and installing front wheel bearing with wheel bearing housing installed . . . . . . 34
5 Aluminium wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1 Removing and installing aluminium wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . 38
5.2 Servicing front wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.3 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6 Lightweight wheel hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.1 Servicing lightweight wheel hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7 Servicing mounting bracket (steel wheel bearing housing) . . . . . . . . . . . . . . . . . . . . . . . . 49
7.1 Removing and installing mounting bracket (steel wheel bearing housing) . . . . . . . . . . . . . . 49
7.2 Replacing bush, front and rear upper link (steel wheel bearing housing) . . . . . . . . . . . . . . 52
8 Servicing mounting bracket (aluminium wheel bearing housing) . . . . . . . . . . . . . . . . . . . . 54
8.1 Removing and installing
Protected by copyright. Copying formounting bracket
private or commercial (aluminium
purposes, in part or in wheel bearing housing) . . . . . . . .
whole, is not 54
9 Servicing subframe . . .of. information
. . . . . . in. .this
. .document.
. . . . . .Copyright
. . . . .by. .AUDI
. . .AG.
.......................... 58
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness
9.1 Removing and installing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.2 Pre-tensioned bushes (4-cyl.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.3 Renewing subframe bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10 Track control link (steel wheel bearing housing), vehicle level sender . . . . . . . . . . . . . . . . 66
10.1 Removing and installing track control link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Contents i
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

10.2 Renewing bush for track control link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

10.3 Vehicle level senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
11 Track control link (aluminium wheel bearing housing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
11.1 Removing and installing track control link (aluminium wheel bearing housing) . . . . . . . . . . 74
12 Guide link (steel wheel bearing housing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
12.1 Removing and installing guide link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
12.2 Renewing guide link bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
13 Guide link (aluminium wheel bearing housing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
13.1 Removing and installing guide link (aluminium wheel bearing housing) . . . . . . . . . . . . . . 79
14 Anti-roll bar, connecting link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
14.1 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
14.2 Coupling rod with rubber bushes in place of coupling rod with ball joint was introduced for
Model Year '99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
15 Front axle (allroad) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
15.1 Exploded view of front axle (allroad) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
15.2 Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
15.3 Transverse brace/support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
16 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
16.1 Removing and installing 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
87
17 Servicing drive shaft with with inner constant
respect to velocity
the correctness jointin this
of information . . document.
. . . . . .Copyright
. . . . .by. AUDI
. . . AG.
........... 89
17.1 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
18 Servicing drive shafts with triple roller joint AAR 2900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
18.1 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
18.2 Servicing outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
18.3 Dismantling and assembling triple roller joint AAR 2900 . . . . . . . . . . . . . . . . . . . . . . . . . . 99
19 Servicing drive shafts with triple roller joint AAR 3300 i . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
19.1 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
19.2 Servicing outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
19.3 Dismantling and assembling triple roller joint AAR 3300 i . . . . . . . . . . . . . . . . . . . . . . . . . . 109

42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.2 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.3 Repairing threads in longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2 Rear axle, mounting bracket, vehicle level sender (front-wheel drive vehicles) . . . . . . . . . . 118
2.1 Exploded view of rear axle, mounting bracket, vehicle level sender (front-wheel drive
vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.2 Removing and installing rear axle with mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.3 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.4 Vehicle level sender in vehicles with automatic headlight range control, front-wheel drive
vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3 Wheel bearing (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.1 Exploded view of wheel bearing (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.2 Removing and installing wheel bearing/wheel hub unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4 Shock absorber/spring (front-wheel drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.1 Removing and installing shock absorber/spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.2 Servicing shock absorber (front-wheel drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5 Rear axle (four-wheel drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.1 Exploded view of rear axle (four-wheel drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.2 Removing and installing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.3 Aligning subframe with vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.4 Replacing bonded rubber bushes for subframe (steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.5 Replacing bonded rubber bushes for subframe (aluminium) . . . . . . . . . . . . . . . . . . . . . . . . 144

ii Contents
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

6 Subframe, final drive (four-wheel drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

6.1 Exploded view of subframe, final drive (four-wheel drive vehicles) . . . . . . . . . . . . . . . . . . 151
6.2 Pressing out/pressing in bonded rubber bush for cross member . . . . . . . . . . . . . . . . . . . . 152
6.3 Pressing out/pressing in bonded rubber bush for gearbox support . . . . . . . . . . . . . . . . . . 153
7 Shock absorber/spring (four-wheel drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
7.1 Removing and installing shock absorber/spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
7.2 Dismantling and assembling suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.3 Retrofitting dust sleeve for shock absorber piston rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
8 Wheel bearing housing (steel), upper link, lower link, vehicle level sender , coupling rod for
anti-roll bar (four-wheel drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
8.1 Exploded view of wheel bearing housing (steel), upper link, lower link, vehicle level sender ,
coupling rod for anti-roll bar (four-wheel drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
8.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
8.3 Pressing rear wheel bearing out and in with wheel bearing housing removed . . . . . . . . . . 164
8.4 Pressing rear wheel bearing out and in with wheel bearing housing fitted . . . . . . . . . . . . . . 168
8.5 Removing and installing bonded rubber bush for wheel bearing housing . . . . . . . . . . . . . . 171
8.6 Removing and installing upper suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
8.7 Renewing bonded rubber bush for upper link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
8.8 Removing and installing lower wishbone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
8.9 Servicing lower link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
8.10 Vehicle level sender in vehicles with automatic headlight range control . . . . . . . . . . . . . . 179
8.11 Removing and installing coupling rod for anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
9 Servicing wheel bearing housing (aluminium), wheel bearing unit, coupling rod and link (four-
wheel drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
9.1 Exploded view of wheel bearing housing (aluminium), wheel bearing unit, coupling rod and
link (four-wheel drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
9.2 Removing and installing bonded rubber bush for wheel bearing housing (aluminium) . . . . 185
9.3 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
9.4 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
9.5 Removing and installing coupling rod (plastic) for anti-roll bar . . . . . . . . . . . . . . . . . . . . . . 193
10 Lightweight wheel hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
10.1 Servicing lightweight wheel hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
11 Stone deflector, spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
11.1 Removing and installing stone deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
11.2 Spacers - allroad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
12 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
12.1 Removing and installing drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
13 Servicing drive shaft with constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
13.1 Exploded view of drive shaft with constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . 200
13.2 Servicing drive shaft with constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
14 Servicing rear drive shaft - allroad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
14.1 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
14.2 Servicing inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
14.3 Servicing outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
14.4 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
14.5 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

43 - Self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

1 Pneumatic adaptive rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
1.1 Electrical/electronic Protected
components and
by copyright. fitting
Copying for locations . . . purposes,
private or commercial . . . . . .in .part
. .or. in. whole,
. . . .is. not
......... 218
1.2 Air supply unit . . . .permitted
. . . . . unless
. . . .authorised
. . . . . .by. AUDI
. . . AG.
. . .AUDI
. . .AG
. .does
. . .not
. .guarantee
. . . . . or
. .accept
. . . .any. .liability
........... 219
1.3 Fault indication by way of adaptive suspension warning lamp K134 . . . . . . . . . . . . . . . . 219
with respect to the correctness of information in this document. Copyright by AUDI AG.

1.4 Layout of sound insulation box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

2 Servicing self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
2.1 Exploded view: Air supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Contents iii
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

2.2 Performing basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

2.3 Assignment of ground clearances (setting dimensions) for adaptive suspension . . . . . . . . 222
2.4 Charging system - 2-wheel air suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
2.5 Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
2.6 Exploded view: Unit retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
2.7 Exploded view: Front-wheel drive wire routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
2.8 Exploded view: Air spring damper (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
2.9 Removing and installing air spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
2.10 Removing and installing shock absorber/spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
2.11 Exploded view of vehicle level sender (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . 234
2.12 Removing and installing vehicle level sender (front-wheel drive) . . . . . . . . . . . . . . . . . . . . 235
2.13 Exploded view: All-wheel drive wire routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
2.14 Exploded view: All-wheel drive air spring damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
2.15 Removing and installing shock absorber/spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2.16 Exploded view of vehicle level sender (four-wheel drive)
Protected by copyright.. Copying
. . . . .for. .private
. . . or. .commercial
. . . . . .purposes,
. . . . . in. part
. 240or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2.17 Removing and installing vehicle level sender (four-wheel with respect to thedrive)
correctness. of. .information
. . . . . in. .this. .document.
. . . . .Copyright
. . . 241 by AUDI AG.

3 Pneumatic adaptive suspension - allroad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

3.1 Fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3.2 Exploded view: Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
3.3 Removing and installing vehicle level sender at rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . 243
3.4 Basic setting procedure (allroad) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
3.5 System charging (allroad) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
3.6 System bleeding (allroad) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
4 Compressor (allroad) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
4.1 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
4.2 Removing and installing compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
5 Adaptive suspension control unit J197 (allroad) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
5.1 Removing and installing adaptive suspension control unit J197 (allroad) . . . . . . . . . . . . . . 258
6 Front axle suspension strut (allroad) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
6.1 Removing and installing front axle suspension strut (allroad) . . . . . . . . . . . . . . . . . . . . . . 260
6.2 Removing and installing mounting bracket (allroad) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
6.3 Unbolting upper link from allroad mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
6.4 Removing and installing air spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
7 Rear axle air spring damper (allroad) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
7.1 Exploded view: Rear axle air spring damper (allroad) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
7.2 Removing and installing shock absorber/spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
8 Dynamic Ride Control DRC -RS 6- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
8.1 Fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
8.2 Central valve and pipe connections for suspension struts . . . . . . . . . . . . . . . . . . . . . . . . . . 271
8.3 DRC fault-finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
8.4 DRC system pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
8.5 Discharging and charging Dynamic Ride Control (DRC) . . . . . . . . . . . . . . . . . . . . . . . . . . 275
8.6 Removing and installing central valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
8.7 Service installation of dust sleeve for shock absorber piston rod . . . . . . . . . . . . . . . . . . . . 286

44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

1 Wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
2 Tyre Pressure Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
2.1 Overview of Tyre Pressure Monitoring System components . . . . . . . . . . . . . . . . . . . . . . . . 288
2.2 Servicing Tyre Pressure Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
2.3 Removing and installing receiving aerials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
2.4 Activating and deactivating Tyre Pressure Monitoring System . . . . . . . . . . . . . . . . . . . . . . 293
3 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
3.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

iv Contents
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

3.2 Sequence of operations for checking and adjusting wheel alignment . . . . . . . . . . . . . . . . 295
3.3 Checking centre position of steering rack (mechanical method) . . . . . . . . . . . . . . . . . . . . 295
3.4 Vehicles with Electronic Stabilising Program (ESP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
3.5 Explanatory notes on factory codes (PR nos.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
3.6 Wheel alignment must be performed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
3.7 Wheel alignment specifications, front-wheel drive vehicles except V8 engine . . . . . . . . . . 298
3.8 Wheel alignment specifications, four-wheel drive vehicles except V8 engine . . . . . . . . . . 300
3.9 Wheel alignment specifications, vehicles with V8 engines . . . . . . . . . . . . . . . . . . . . . . . . . . 302
3.10 Requirements for test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
3.11 Measurement procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3.12 Adjusting toe-in curve at front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
3.13 Move vehicle into starting position for measuring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
3.14 Checking rear axle camber (FWD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
3.15 Centralising toe setting at rear wheels (front-wheel drive vehicles) . . . . . . . . . . . . . . . . . . 310
3.16 Adjusting camber at rear wheels (four-wheel drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . 310
3.17 Adjusting rear axle toe (four-wheel drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
3.18 Centralising camber at front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
3.19 Adjusting toe-constant “S” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3.20 Adjusting toe setting at front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
1 Steering wheel with airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
1.1 Removing and installing driver's airbag unit with standard steering wheel . . . . . . . . . . . . 314
1.2 Removing and installing driver’s airbag unit for sports steering wheel . . . . . . . . . . . . . . . . 315
1.3 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
1.4 Remove steering column switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
2 Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
2.1 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
2.2 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
2.3 Removing and installing steering lock housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
3 Electrically adjustable steering column, steering column/belt height adjustment control unit
J352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
3.1 Exploded view of electrically adjustable steering column . . . . . . . . . . . . . . . . . . . . . . . . . . 325
3.2 Description of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
3.3 Electrical adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
3.4 Steering column/belt height adjustment control unit J352 . . . . . . . . . . . . . . . . . . . . . . . . . . 327
4 Power-assisted steering rack (left-hand drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
4.1 Exploded view of power steering rack, left-hand drive vehicles including Model Year '98
........................................................................ 328
4.2 Exploded view of power steering rack, left-hand drive vehicles as of Model Year '99 . . . . 330
4.3 Removing and installing power steering rack (left-hand drive vehicles) . . . . . . . . . . . . . . . . 331
4.4 Removing and installing power steering rack (Audi RS 6) . . . . . . . . . . . . . . . . . . . . . . . . . . 336
5 Power-assisted steering rack (right-hand drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . 337
5.1 Exploded view of power steering rack, right-hand drive vehicles up to and including Model
Year '98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
5.2 Exploded view of power steering rack, right-hand drive vehicles as of Model Year '99 . . . . 338
5.3 Removing and installing power steering rack (right-hand drive vehicles) . . . . . . . . . . . . . . 338
5.4 Removing Protectedand installing
by copyright. power
Copying steering
for private rack,purposes,
or commercial right-hand
in part orvehicles with 8-cyl. Petrol engine
in whole, is not
. . . . .permitted
. with
. . .respect
. unless
. . .to.authorised
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by AUDI AG. AUDI AG does not guarantee or accept any liability
the correctness of information in this document. Copyright by AUDI AG.
. . . . .................... 344
5.5 Removing and installing power steering rack (Audi RS 6) . . . . . . . . . . . . . . . . . . . . . . . . . . 357
6 Servicing power steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
6.1 Steering rack without/with integrated steering damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
6.2 Steering rack with external steering damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
7 Servotronic steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
7.1 Servotronic steering rack - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
7.2 Servicing Servotronic steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

Contents v
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

7.3 Checking voltage supply for servotronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

7.4 Checking speed signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
7.5 Checking servotronic solenoid valve N119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
8 Adjusting power steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
9 Removing and installing track rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
10 Checking fluid level, bleeding steering system and checking for leaks . . . . . . . . . . . . . . . . 369
10.1 Checking fluid level of power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
10.2 Bleeding steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
10.3 Checking steering system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
11 Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 4-cylinder
petrol and diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
11.1 Exploded view - vehicles with 4-cyl. petrol and diesel engine . . . . . . . . . . . . . . . . . . . . . . 371
11.2 Checking delivery pressure of power steering pump, vehicles with 4-cyl. petrol and diesel
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
11.3 Exploded view of power steering pump, vehicles with 4-cyl. petrol and diesel engine . . . . 376
11.4 Removing and installing power steering pump - vehicles with 4-cyl. petrol and diesel
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
12 Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
12.1 Exploded view - vehicles with 6-cyl. Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
12.2 Checking delivery pressure of power steeringProtected pump,byvehicles with for
copyright. Copying 6-cyl.
privateDiesel engine
or commercial . . in part
purposes, 383 or in whole, is not

12.3 Exploded view of power steering pump, vehicles with 6-cyl. Diesel engine . . . . . . . . . . . . 386
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.
12.4 Removing and installing power steering pump - vehicles with 6-cyl. Diesel engine . . . . . . 387
13 Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder
petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
13.1 Exploded view, vehicles with 6 cyl. 2.7 l petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
13.2 Checking delivery pressure of power steering pump, vehicles with 6 cyl. 2.7 l petrol engine
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
13.3 Exploded view of power steering pump, vehicles with 6 cyl. 2.7 l petrol engine . . . . . . . . 397
13.4 Removing and installing power steering pump, vehicles with 6-cyl. 2.7 l petrol engine . . . . 399
13.5 Exploded view - vehicles with 6-cyl. 2.4l, 2.8l and 3.0l petrol engine . . . . . . . . . . . . . . . . . . 404
13.6 Checking delivery pressure of power steering pump - vehicles with 6-cyl. 2.4l, 2.8l and 3.0l
petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
13.7 Exploded view of power steering pump - vehicles with 6-cyl. 2.4l, 2.8l and 3.0l petrol
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
13.8 Removing and installing power steering pump - vehicles with 6-cyl. 2.4l, 2.8l and 3.0l petrol
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
14 Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder
petrol engine, biturbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
14.1 Exploded view - vehicles with 6-cyl. petrol engine, biturbo . . . . . . . . . . . . . . . . . . . . . . . . 416
14.2 Checking delivery pressure of power steering pump - vehicles with 6-cyl. petrol engine,
biturbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
14.3 Exploded view of power steering pump - vehicles with 6-cyl. petrol engine, biturbo . . . . . . 420
14.4 Removing and installing power steering pump - vehicles with 6-cyl. petrol engine, biturbo
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
15 Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder
petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
15.1 Exploded view - vehicles with 8-cyl. petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
15.2 Checking delivery pressure of power steering pump - vehicles with 8-cyl. petrol engine . . 429
15.3 Exploded view of power steering pump - vehicles with 8-cyl. petrol engine . . . . . . . . . . . . 431
15.4 Removing and installing power steering pump - vehicles with 8-cyl. petrol engine . . . . . . 433
16 Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder
petrol engine with chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
16.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
16.2 Removing and installing power steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
17 Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder
petrol engine, biturbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446

vi Contents
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

17.1 Exploded view - vehicles with 8-cyl. petrol engine, biturbo . . . . . . . . . . . . . . . . . . . . . . . . 446
17.2 Checking delivery pressure of power steering pump - vehicles with 8-cyl. petrol engine,
biturbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
17.3 Exploded view of power steering pump - vehicles with 8-cyl. petrol engine, biturbo . . . . . . 451
17.4 Removing and installing power steering pump - vehicles with 8-cyl. petrol engine, biturbo
........................................................................ 453

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.

Contents vii
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

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.

viii Contents
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

00 – Technical data
1 Technical data
(ARL003537; Edition 10.2013)
⇒ “1.1 Running gear”, page 1
⇒ “1.2 Steering”, page 1

1.1 Running gear

Front-wheel drive Four-wheel drive
Front axle Independent wheel suspension, four-link axle, tubular anti-roll bar,
twin-tube gas-filled shock absorber and coil spring, rebound buffer spring,
subframe, guide link with mount providing hydraulic cushioning
Rear axle Torsion beam axle Double wishbone axle
Anti-roll bar Anti-roll bar
Wheelbase mm 2765 1) 1 2758
Front/rear mm Refer to tables Refer to tables ⇒ page 294
track width ⇒ page 294
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1) 1 Vehicles with PR number K8L have a 90 mm longer wheelbase
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 Steering
Front-wheel drive Four-wheel drive
Steering rack Servotronic or power-assisted maintenance-free rack-and-pinion steering
Maximum steering an‐
gle at:
wheel on inside of curve 38°7′
wheel on outside of 31°36′
curve
Turning circle diameter Approx. 10.5 m

1. Technical data 1
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

2 Proper disposal procedures for oil-fil‐

led and gas-filled components
⇒ “2.1 Releasing gas from shock absorbers”, page 2
⇒ “2.2 Draining steering damper”, page 3
⇒ “2.3 Draining power steering rack”, page 3

2.1 Releasing gas from shock absorbers

A - Drilling open
– Clamp gas-filled shock absorber vertically in vice, with piston
rod pointing downwards.

WARNING

Safety goggles must be worn when drilling.

– Drill a 3 mm ∅ hole -arrow A- through outer tube of shock ab‐

sorber.

Note

♦ Gas will escape during drilling.

♦ Continue drilling until inner tube is fully penetrated (approx.
25 mm deep).
♦ Drill a second 6 mm ∅ hole -arrow B- through outer and inner
tubes of shock absorber.
♦ Hold shock absorber over a drip tray and move piston rod up
and down several times through entire stroke until no more
fluid comes out.
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
B - Opening with pipe cutter with respect to the correctness of information in this document. Copyright by AUDI AG.

WARNING

Safety goggles must be worn while drilling and cutting.

– Drill a 3 mm ∅ hole -arrow- through outer tube of shock ab‐

sorber, or saw through side of tube.

Note

♦ Gas will escape when drilling or sawing.

♦ Apply pipe cutter (e.g. Stahlwille Express 150/3) as shown and
cut through outer tube.
♦ Pull the piston rod upwards, at the same time holding the inner
tube securely with pliers and pressing it downwards, so that it
remains in the outer tube when the piston rod is slowly pulled
upwards.
♦ Pull piston rod off inner tube.
♦ Drain damper tube.

2 Rep. gr.00 - Technical data

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

2.2 Draining steering damper

– Clamp the steering damper horizontally in a vice.

WARNING

Goggles must be worn whilst sawing.

– Saw the steering damper at the points marked.

♦ Arrow A = 30 mm from end of tube
♦ Arrow B = 10 mm from end of tube
– Hold shock absorber over a drip tray and move piston rod up
and down several times through entire stroke until no more
fluid comes out.

2.3 Draining power steering rack

Note

Room temperature should be at least 20°C when draining the

steering rack.

– Hold power steering rack over drip tray and allow hydraulic
fluid to drain off.
– Clamp power steering rack horizontally into vice with connec‐
tions facing downwards.
– Place drip tray underneath power steering rack.
– By pushing and pulling track rod, move rack approx. 6 times
backwards and forwards between its end positions.
– Dispose of power steering rack.

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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. Proper disposal procedures for oil-filled and gas-filled components 3

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

3 Checking shock absorbers

⇒ “3.1 Leaks at shock absorbers”, page 4
⇒ “3.2 Noises from shock absorbers”, page 4
⇒ “3.3 Checking shock absorbers when removed”, page 4
⇒ “3.4 Checking shock absorbers on shock tester”, page 5

3.1 Leaks at shock absorbers

Shock absorbers are often replaced because of externally visible
leakage. Inspections on the test rig and in the vehicle have shown
that in the majority of cases this replacement is not justified.
Slight loss of fluid (“sweating”) at the piston rod seal is not a rea‐
son for replacing a shock absorber. A shock absorber with slight
fluid leakage can be accepted as "OK" under the following con‐
ditions:
♦ Fluid seepage (as shown in the shaded part of the illustration)
is visible, but the fluid is dull and possibly dried
Protected by dust
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ The fluid seepage extends only from thewithtop shock
respect absorber
to the correctness of information in this document. Copyright by AUDI AG.
seal (piston rod seal) down to the bottom spring plate
-arrow-.

Note

Slight fluid leakage is actually beneficial, as it lubricates the piston

rod oil seal and thus extends the life of the shock absorber. This
applies to shock absorbers on both the front and rear axles.

3.2 Noises from shock absorbers

Shock absorbers are often replaced because of noises (rumbling,
etc.) experienced by the customer. Inspections on the test rig and
in the vehicle have shown that in approx. 70% of these cases the
complaints and subsequent replacement are not justified.
In the case of complaints regarding rumbling or knocking noises
please proceed as follows:
– Carry out a road test with the customer - if possible on a dry,
uneven road - to establish when, where and how the noises
occur.

Note

These noises are only very rarely caused by the shock absorbers.

3.3 Checking shock absorbers when re‐

moved
Defective shock absorbers can be identified by loud rumbling
noises when driving, caused by wheel hopping, especially on bad
roads. Heavy fluid leakage is an additional visual indication.

4 Rep. gr.00 - Technical data

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Note

Shock absorbers are maintenance-free; shock absorber fluid can‐

not be topped up.

After removal, a shock absorber can be checked by hand as fol‐

lows:
– Compress shock absorber by hand.
♦ The piston rod should move smoothly over the entire stroke
with uniform resistance and without jolts.
– Release piston rod.
♦ If the shock absorber has sufficient gas pressure the piston
rod will return by itself to its original position.

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
♦ If this is not the case, the shock absorber does not necessarily
with respect to the correctness of information in this document. Copyright by AUDI AG.
need to be renewed. Provided there has been no major loss
of fluid, it will still be as effective as a conventional shock ab‐
sorber.
♦ Even without gas pressure, the shock absorber will provide full
damping effect as long as there has been no major loss of fluid.
However, it may produce more noise.

3.4 Checking shock absorbers on shock

tester
The shock tester allows shock absorbers to be tested without re‐
moving them from the vehicle. The damping effect can be as‐
sessed on the basis of the pointer deflection or the print-out.
Special tools and workshop equipment required
♦ Boge shock tester
♦ or
♦ Sachs shock tester - V.A.G 1975-
♦ or
♦ Maha shock absorber tester - VAS 1990-

Note

♦ Temperature: +10 ... +40 ℃.

♦ Driver in vehicle.
♦ Correct tyre inflation pressure.
♦ Wheels of vehicle in a central and straight position on the tyre
contact plates.
♦ Front wheels in straight-ahead position.
♦ Handbrake not applied, brake pedal not depressed.

Test results
The condition of the shock absorbers can only be evaluated as
follows:

3. Checking shock absorbers 5

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Satisfactory damping effect

or
♦ Unsatisfactory damping effect

Note

♦ It is not possible to obtain more detailed readings specifying

the exact degree of impairment of damping effect.
♦ A forecast of the remaining service life is not permissible.
♦ Test results will be falsified if the suspension contacts the
bump stops when the readings are taken.

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 Rep. gr.00 - Technical data

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

The following values apply only to tests conducted on the test

equipment listed above. If the stated values are exceeded, the
shock absorber action has deteriorated to such an extent that re‐
placement is recommended.
Example:
Maximum value = 70
♦ a = higher than 70: Unsatisfactory damping effect
♦ by
Protected a copyright.
= lowerCopyingthan for
70: Satisfactory
private or commercial damping effect
purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Maximum
with respect to the values “a”
correctness in mm in this document. Copyright by AUDI AG.
of information

Note

♦ If the reading is higher than the maximum value “a” listed in

the table, the damping effect is unsatisfactory ⇒ renew the
shock absorber.
♦ If the reading is lower than the maximum value “a” listed in the
table, the damping effect is satisfactory ⇒ the shock absorber
does not have to be renewed.
♦ The vehicle level setting has no influence on testing.

3. Checking shock absorbers 7

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Model/ver‐ Front axle Rear axle Remarks

sion
A6 4-cyl. 55 65 Normal running
Front gear
A6 6-cyl. 50 65 Normal running
Front gear
A6 4-cyl. 45 55 Sports running gear
Front
A6 6-cyl. 45 55 Sports running gear
Front
A6 4-cyl. 50 50 Heavy duty running
Front gear
A6 6-cyl. 50 50 Heavy duty running
Front gear
A6 4-cyl. 55 65 Normal running
Front/adap‐ gear / HA level
tive suspen‐
sion
A6 6-cyl. 50 65 Normal running
Front/adap‐ gear / HA level
tive suspen‐
sion
A6 4-cyl. 55 65 Normal running
quattro gear
A6 4-cyl. 45 50 Sports running gear
quattro
A6 4-cyl. 50 60 Heavy duty running
quattro gear
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
A6 4-cyl. 50 50 Normal unless
permitted runningauthorised by AUDI AG. AUDI AG does not guarantee or accept any liability
quattro/adap‐ gear / HA level
with respect to the correctness of information in this document. Copyright by AUDI AG.

tive suspen‐
sion
A6 6-cyl. 50 65 Normal running
quattro gear
A6 6-cyl. 45 50 Sports running gear
quattro
A6 6-cyl. 50 60 Heavy duty running
quattro gear
A6 6-cyl. 50 50 Normal running
quattro/adap‐ gear / HA level
tive suspen‐
sion
A6 8-cyl. 50 65 Normal running
quattro gear
A6 8-cyl. 45 50 Sports running gear
quattro
A6 8-cyl. 50 50 Normal running
quattro/adap‐ gear / HA level
tive suspen‐
sion
A6 allroad 45 55 Measurement at
normal level, unla‐
den, tank full

8 Rep. gr.00 - Technical data

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

4 Subframe/body mountings
⇒ “4.1 Repairing damaged threads”, page 9

4.1 Repairing damaged threads

Damaged threads can be repaired with wire inserts (Helicoil).
Refer to exploded views for information on which threads can be
repaired.
Metal particles remaining in the vehicle body must be embedded
in wax.

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. Subframe/body mountings 9
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

40 – Front suspension
1 General notes
⇒ “1.1 General information”, page 10
⇒ “1.2 Contact corrosion”, page 10
⇒ “1.3 Repairing threads in longitudinal member”, page 11

1.1 General information

All contact surfaces must be cleaned when installing wax-coated
components. The contact surfaces must be free of wax and
grease.
Tightening torques refer to unoiled bolts and nuts.
Load-bearing components and other suspension parts must not
be welded or straightened.
Do not subject coil springs to hammer blows or weld spatter and
do not make any new paint markings.
Do not perform welding or cutting operations (using power grind‐
ers) near the coil springs or suspension struts. Cover up coil
springs or suspension struts if necessary.
Do not attempt to move the vehicle without the drive shafts fitted;
this would result in wheel bearing damage. If the vehicle does
have to be moved, always note the following points:
– Fit an outer joint in place of the drive shaft.
– Tighten the outer joint to 115 Nm (M14 bolt) or 190 Nm (M16
bolt).
Bonded rubber bushes can only be turned to a limited extent. The
suspension must therefore always be in the unladen position or
the reference position when the suspension link attachments are
tightened.
If the wheel alignment has to be checked and adjusted at a later
stage, all bolts and nuts which need to be slackened to make ad‐
justments should initially only be tightened to the specified torque
figure. After wheel alignment has been checked and adjusted,
bolts and nuts must then be fully tightened by turning them
through the specified angle.

WARNING

All bolts and nuts must be fully tightened according to specifi‐

cations before the vehicle is driven on public roads.

1.2 Contact corrosion

Contact corrosion can occur if unsuitable fasteners (bolts, nuts,
washers ...) are used.
For this reason, all the fastening components have received a
special surface treatment (Dacromet). These elements can be
recognised by their greenish colour.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
In addition, rubber parts, plastic parts and adhesives
permitted are by
unless authorised made
AUDI AG.of AUDI AG does not guarantee or accept any liability
non-conductive material. with respect to the correctness of information in this document. Copyright by AUDI AG.

Always fit new components if you are not sure that the old com‐
ponents can be safely re-installed.

10 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Please note:
Always use genuine parts. These have been tested and are com‐
patible with aluminium.
All accessories must be approved by AUDI AG.
Damage caused by contact corrosion is not covered by the war‐
ranty.

1.3 Repairing threads in longitudinal mem‐

ber
Under certain circumstances it is possible to repair the threads in
the captive nuts in the longitudinal member.
♦ Each thread can only be repaired once.
♦ If a second repair is needed, the captive nut must be renewed.

WARNING

Always wear safety goggles when drilling.

♦ Have all thread repairs checked by foreman or supervisor.

♦ The thread insert must be of the same length as the thread in
the body.
♦ Repair any damage to the underseal; for the appropriate in‐
formation, refer to the booklet ⇒ Body repairs; Corrosion
protection measures .

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. General notes 11
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

2 Mount with transverse brace, con‐

nection of upper links to wheel bear‐
ing housing
⇒ “2.1 Exploded view of mount with transverse brace, connection
of upper links to wheel bearing housing”, page 12
⇒ “2.2 Removing and installing mount with transverse brace”,
page 15
⇒ “2.3 Separating upper links from wheel bearing housing (steel)”,
page 15

2.1 Exploded view of mount with transverse brace, connection of upper links to
wheel bearing housing

1 - Hexagon bolt, 75 Nm
2 - Washer
3 - HexagonProtected
bolt Mby10 x 62
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 with
renew
respectafter
to the re‐
correctness of information in this document. Copyright by AUDI AG.
moving
4 - Upper link (rear)
❑ Replace bush
❑ Separate from wheel
bearing housing
5 - Hexagon bolt, 5 Nm
❑ Always renew after re‐
moving
❑ For adjusting toe con‐
stant “S”
6 - Bolt
7 - Self-locking nut
❑ Always renew after re‐
moving
❑ 40 Nm for steel wheel
bearing housing
❑ 45 Nm for aluminium
wheel bearing housing
8 - Hexagon bolt M 10 x 100
9 - Self-locking nut, 40 Nm
❑ Always renew after re‐
moving
10 - Upper link (front)
❑ Can only be removed to‐
gether with mounting
bracket
❑ Removing and installing
mounting bracket
❑ Replace bush
❑ Separate from wheel bearing housing
11 - Suspension strut
❑ Heed the different spring/damper versions (refer to vehicle data sticker)
❑ Removing and installing

12 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

❑ Servicing
12 - Hexagon bolt M 12 x 1.5 x 120
❑ 70 Nm and turn 180° further
❑ Always renew after removing
13 - Guide link (bottom)
❑ Leaking hydro-bushes must be replaced
❑ For correct version refer to ⇒ Electronic parts catalogue “ETKA”
14 - Self-locking nut
❑ 100 Nm for steel wheel bearing housing
❑ 110 Nm for aluminium wheel bearing housing
❑ Always renew after removing
15 - Wheel bearing housing
❑ Version with and without groove for ring at track rod end ⇒ Electronic parts catalogue “ETKA” (only new
version available)
❑ Heed the removal and installation instructions for vehicles with headlight range control
❑ Removing and installing
❑ Servicing
❑ Separate from upper link
16 - splash plate
17 - Hexagon bolt
❑ Always renew after removing
❑ The vehicle must be standing on the ground when tightening
Tightening torque for M14 bolt:
❑ 115 Nm and turnProtected
180° further
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
Tightening torque for M16 bolt:
with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ 190 Nm and turn 180° further

18 - Hexagon socket head bolt, 10 Nm
19 - Self-locking nut
❑ 100 Nm for steel wheel bearing housing
❑ 110 Nm for aluminium wheel bearing housing
❑ Always renew after removing
20 - Hexagon bolt M 12 x 1.5 x 85
❑ 90 Nm and turn 90° further
21 - Self-locking nut
❑ Always renew after removing
22 - Coupling rod
❑ Arrow on coupling rod points in direction of travel
❑ Pay attention to modified connecting links and tightening torques
23 - Self-locking hexagon nut
❑ Always renew after removing
❑ 40 Nm and turn 90° further
❑ Underside of nut is ribbed
❑ Always use this special nut for replacement purposes.
24 - Hexagon bolt M 12 x 1.5 x 100
❑ 70 Nm and turn 180° further
❑ Always renew after removing

2. Mount with transverse brace, connection of upper links to wheel bearing housing 13
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

25 - Track control link (bottom)

❑ Heed the removal and installation instructions for vehicles with headlight range control
❑ Removing and installing
❑ Servicing
26 - Hexagon bolt M 12 x 1.5 x 110
❑ 110 Nm and turn 90° further
❑ Always renew after removing
❑ Thread in body can be repaired using wire thread insert according to DIN 8140 (Helicoil). The thread
insert must be of the same length as the thread in the body.
27 - Hexagon bolt M 10 x 70, 75 Nm
❑ Always renew after removing
28 - Self-locking nut
❑ Pay attention to the modified connecting links and tightening torques ⇒ page 81 .
❑ Underside of nut is ribbed
❑ Always renew after removing
❑ Always use this special nut for replacement purposes.
29 - Clip
❑ Inserted in track control link
❑ Always renew
30 - Subframe Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

❑ Heed the removal and installationwith

instructions for vehicles with headlight range control
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.
❑ Removing and installing
❑ Note that 4-cyl. engines have subframes with pre-tensioned engines
❑ Servicing
31 - Hexagon bolt
❑ Always renew after removing
❑ Heed the different bolt versions and tightening torques ⇒ page 15
32 - Subframe support
33 - Self-locking nut
❑ Always renew after removing
34 - Self-locking nut
❑ Always renew after removing
35 - Multi-point socket head bolt
Tightening torques:

Bolt M8 × 48: 40 Nm

Bolt M10 × 48: 70 Nm

36 - Lock plate
37 - Drive shaft
❑ Removing and installing
❑ Servicing
38 - Drive shaft with triple roller joint
❑ Servicing
39 - Twelve-point hexagon socket head bolt M 10 x 20, 70 Nm
❑ For vehicles with triple roller joint

14 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

40 - Hexagon bolt M 10 x 62
❑ Always renew after removing
41 - Mounting bracket
❑ Removing and installing
42 - Self-locking nut
❑ 50 Nm and turn 90° further
❑ Always renew after removing
43 - Flanged nut, self-locking, 20 Nm
❑ Always renew after removing

Bolt versions
Bolt -A-, not ribbed
Tightening torque: 25 Nm
Bolt -B-, ribbed
Tightening torque: 75 Nm
Bolt -C- with bolt head and ribbed washer
Tightening torque: 20 Nm and turn 90° further
All bolts must only be used once.

2.2 Removing and installing mount with

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
transverse brace
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.
– Removal and installation of the mount with transverse brace
involve screwing out the hexagon bolt -1- (1x behind bulk‐
head).
– Screw out the hexagon bolts -2- (4x).
Tightening torques
Hexagon bolt -1-: 30 Nm
Hexagon bolt -2-: 75 Nm

2.3 Separating upper links from wheel bear‐

ing housing (steel)
This operation is only necessary if the hexagon bolt for connecting
the upper links to the wheel bearing housing cannot be removed.
Special tools and workshop equipment required

2. Mount with transverse brace, connection of upper links to wheel bearing housing 15
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Torque wrench - V.A.G 1332-

♦ Remover - VAS 6085-

Removing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Components of the pressing-out tool - VASpermitted
6085-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 - Base
2 - Adapter
3 - Pressure screw M 10 x 1.25 x 95
4 - Threaded sleeve
5 - Press tool (length 78 mm)
6 - Press tool (length 98 mm)
7 - Press tool (length 118 mm)
8 - Nut

Note

The pressure screw , the press tools and the nut must be lubri‐
cated with polycarbamide grease - G 052 142 A2- before starting
work.

– Remove wheel.
– Pull ABS speed sensor wiring out of retainer on brake calliper.

16 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove nut -1-.

Bolts -3- and -4- are never to be slackened off.

– Position the base -1- on the wheel bearing housing. In doing

so, recesses engageProtected
beneath joints of
by copyright. links.
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

When inserting the base , take care not to damage the boots of
the links.

– The base -1- must be inserted such that the end of the bolt
-arrow- is centred in the hole in the base .
– Screw home the adapter -2- in the base -1-, thus locking the
base in position.

– Screw home the threaded sleeve -4- in the base -1-.

– Insert the press tool -5- in -4-.

– Screw the nut -8- onto the threaded sleeve -4- and turn as far
as it will go, thus pressing out the bolt.

Note

Either a standard wrench or an impact wrench can be used to turn

the nut -8-.

– Unscrew the nut -8- from the threaded sleeve -4-, remove the
press tool -5- and insert the press tool -6- in the threaded
sleeve -4-.
– Repeat the pressing operation.
– If the bolt can still not be removed by hand, repeat the pressing
operation using the press tool -7-.
– Unscrew the nut -8- from the threaded sleeve -4-. Remove the
press tool and the bolt.

2. Mount with transverse brace, connection of upper links to wheel bearing housing 17
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Screw the pressure screw -3- into each of the guides -A- and
press the links -B- out of the wheel bearing housing.
– Screw the pressure screw -3- out of the guide -A- and unfasten
the adapter -2-.
– Detach the base -1- from 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.

18 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

3 Suspension strut, explanatory notes

on factory codes (PR nos.)
⇒ “3.1 Removing and installing suspension strut”, page 19
⇒ “3.2 Servicing suspension strut”, page 21
⇒ “3.3 Explanatory notes on weight codes used in production (PR
numbers)”, page 25

3.1 Removing and installing suspension

strut
Special tools and workshop equipment required
♦ Ball joint puller - VAS 3287A-

Removing
– Remove the cover for the plenum chamber/battery.
– Remove wheel trim; on light-alloy wheels, pull off trim cap (use
puller in vehicle tool kit).
– Remove wheels.
– Take out rubber grommets in plenum chamber -arrows-.
For vehicles with headlight range control, pay attention to
⇒ page 69 .
So as not to damage the joints of the lower links, support must be
provided for example by way of the engine and gearbox lifter -
V.A.G 1383 A- with universal gearbox support - V.A.G 1359/2- to
prevent excessive rebound.

– Unbolt suspension strut from body. 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 - Nuts with respect to the correctness of information in this document. Copyright by AUDI AG.

– Pull ABS speed sensor wiring out of retainer on brake calliper.

Take care not to damage the surface of the brake pipes.

3. Suspension strut, explanatory notes on factory codes (PR nos.) 19

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove nut -1-.

Do not attempt to enlarge slots in wheel bearing housing using a
chisel or similar.
– Take out hexagon bolt and lift out link -2-.
– Swivel aside the wheel bearing housing in -arrow direction-.
Bolts -3- and -4- are never to be slackened off.
Otherwise the wheel alignment must be checked.
To unscrew the hexagon bolt from the suspension strut/track con‐
trol link, the guide link must first be detached from the wheel
bearing housing.
Counterhold joint pin with 4 mm Allen key if necessary.
– Heed the guide link removal and installation instructions for
vehicles with aluminium wheel bearing housing ⇒ page 79 .

– Unscrew nut from guide link joint pin and press off joint pin.
Take care not to damage boot.

– Unscrew the suspension strut/track

Protected control
by copyright. Copying for link
privatebolt -1-. purposes, in part or in whole, is not
or commercial
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove suspension strut downwards.
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

♦ Take care not to damage the boot when removing the sus‐
pension strut.
♦ Servicing suspension strut ⇒ page 21

Installing
Installation is performed in reverse sequence; note the following:
Tightening torques ⇒ page 12

20 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Insert the suspension strut such that the hole -arrow- in the
spring plate is facing the centre of the vehicle.

Note

♦ Remove any remnants of adhesive on thread of joint pin.

♦ Bonded rubber bushes can only be turned to a limited extent.
The bolt connection between the suspension strut and the
track control link should therefore only be tightened when the
vehicle is standing on the ground.
♦ When screwing on, press down the upper links as far as pos‐
sible.

Take care not to damage the surface of the brake pipes.

– Fit wheel and tighten. ⇒ Wheels and tyres; Rep. gr. 44

3.2 Servicing suspension strut

1 - Hexagon nut, 60 Nm
❑ Always renew
2 - Suspension strut mounting
3 - Washer
4 - Top spring plate
❑ Installation position
⇒ page 25
❑ Installing ⇒ page 24
5 - Coil spring
❑ Surface of spring coil
must not be damaged
❑ Note colour code
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing ⇒ page 22 , permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 23 , with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ page 23
❑ Installing ⇒ page 24
and ⇒ page 25
❑ Note different coil spring
versions; see vehicle
data sticker
⇒ page 25
❑ For correct version refer
to ⇒ Electronic parts
catalogue “ETKA”
6 - Stop buffer
❑ Insert in top spring plate
❑ For correct version refer
to ⇒ Electronic parts
catalogue “ETKA”
7 - Protective sleeve
8 - Protective cap
9 - Seat
❑ Fixed in position with recess in bead at spring plate

3. Suspension strut, explanatory notes on factory codes (PR nos.) 21

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

❑ Not fitted on all vehicles ⇒ Electronic parts catalogue “ETKA”

10 - Bottom spring plate
❑ Installation position ⇒ page 24
❑ Heed the different versions ⇒ Electronic parts catalogue “ETKA”
11 - Shock absorber
❑ Renewing ⇒ page 23
❑ Heed the different damper versions; refer to vehicle data sticker ⇒ page 25
❑ For correct version refer to ⇒ Electronic parts catalogue “ETKA”
❑ Disposal ⇒ page 2

Special tools and work‐

shop equipment re‐
quired
♦ Spring compressor -
V.A.G 1752/1-

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.

♦ -V.A.G 1752/2-
♦ -V.A.G 1752/7-
♦ -V.A.G 1752/8-
♦ Socket attachment -
3353-

Removing coil spring

– Clamp the strut hold‐
er - V.A.G 1752/2- in
a vice.

22 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Removing coil spring

– Clamp forked head of suspension strut in suspension strut
holder.
– Pre-tension the coil spring with the tensioning device -
V.A.G 1752/1- until the spring plate is free at the top.
– Make sure the coil spring is positioned correctly in the adapter
- V.A.G 1752/7- -arrow-.

Removing coil spring

– Unscrew hexagon nut from piston rod. In doing so, provide
support with an Allen key.
– Detach the components of the suspension strut and coil spring
with the spring compressor - V.A.G 1752/1- .

Renewing shock absorber

Additional operations are required if shock absorber is to be re‐
placed.
– Take off protective cap -1- and bottom spring seat -2-.
– Loosen spring plate -3- using plastic-headed hammer and de‐
tach.
Installing

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. Suspension strut, explanatory notes on factory codes (PR nos.) 23

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Installation position of bottom spring plate

Before inserting the coil spring, ensure that the lower spring plate
is in the correct position.
The hole -arrow- in spring plate -1- should be offset 90° to shock
absorber -2- bolt axis -A-.
Permissible tolerance for position of spring plate in relation to
shock absorber bolt axis: ± 2°.

Installing coil spring

– Spring seat is fixed in position at spring plate by means of a
recess. Fit protective cap and buffer stop.
– Fit the coil spring with the spring compressor - V.A.G 1752/1-
on the spring seat.
End of spring coil must make contact with stop -arrow-.

Installing upper spring plate

– Set the angle scale -arrow- of the spring compressor -
V.A.G 1752/2- to 0°.
– Fit upper spring plate, shim and shock absorber mounting.
– Use the adjustment gauge - V.A.G 1752/8- to set the upper
spring plate to the 11° position.
On the adjustment gauge - V.A.G 1752/8- , the 11° setting is
shown by “front left” or “front right”.
It should be noted that the 11° positions of the spring plates on
the left and right are in mirror image arrangement.

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 A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Installation position of top spring plate

– Studs on upper spring plate are offset 11° to shock absorber
forked head bolt axis -1-.
F = Direction of travel
R = Spring plate, right side
L = Spring plate, left side
A = 11° ± 2°
– Lower spring plate holes - B - face centre of vehicle.

Installing coil spring

– The end of the spring should contact the stop on the bottom
spring seat -arrow-.
– Tighten the hexagon nut using the socket attachment - 3353- :
60 Nm.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Slacken off coil spring. 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 adjustment gauge - V.A.G 1752/8- .
– The upper and lower spring plate will be in parallel if fitting has
been performed correctly.

3.3 Explanatory notes on weight codes

used in production (PR numbers)
The spring/shock absorber combination installed in the vehicle is
indicated by the corresponding PR number on the vehicle data
sticker.
Vehicle data sticker (example)
-A- indicates the front axle PR number.
-B- indicates the rear axle PR number.
The -arrow- indicates the running gear ⇒ page 296 .
The vehicle data sticker can be found in the spare wheel well and
in the Service Schedule.
The PR number makes it possible to identify the correct spring/
damper combination in the parts catalogue.

3. Suspension strut, explanatory notes on factory codes (PR nos.) 25

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

4 Steel wheel bearing housing

⇒ “4.1 Removing and installing wheel bearing housing”,
page 26
⇒ “4.2 Removing and installing front wheel bearing with wheel
bearing housing removed”, page 28
⇒ “4.3 Removing and installing front wheel bearing with wheel
bearing housing installed”, page 34

4.1 Removing and installing wheel bearing

housing
Removing
– Remove wheel trim; on light-alloy wheels, pull off trim cap (use
puller in vehicle tool kit).
– Remove hexagon bolt securing drive shaft ⇒ page 87 .
– Remove wheel.
– Screw all five wheel bolts in again.
– Pull ABS speed sensor wiring out of retainer on brake calliper.
– Remove bolts -1- for brake calliper and take off brake calliper.
Brake calliper HP-2: See ⇒ page 38 for procedure.
– Tie up brake calliper to body with wire.
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.

Do not suspend the brake calliper from the brake hose.

– Remove brake disc.

– Remove bolts -1- for cover plate.

– Pull ABS speed sensor out of wheel bearing housing.
– Unfasten the nuts -2- and -3-.

26 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Pull out the rubber grommet -1- and unplug the connector
-2-.
– Pull ABS speed sensor wiring from retainers -arrows-.
– Guide wiring through openings in wheel bearing housing and
remove.
Take care not to damage rubber grommet

– Remove hexagon bolt -3- and nut -4-.

– Pull out track rod ball joint.
– Unscrew nut from joint pin. If necessary, provide support at the
joint pin with a 4 mm Allen key when doing so.

– Press the joint pin of the guide link off the tapered seat.
Take care not to damage boot.
For vehicles with headlight range control, pay attention to
⇒ page 69 .

Note

♦ Use a leather cloth for example to protect the boot against

damage.
♦ For safety reasons, screw the collared nut at the joint pin of
the track control link back on again by approx. 4 turns.

– Press track control link joint pin out of tapered seat.

– Unfasten the nut -1-, take out the hexagon bolt and lift out both
links -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.

4. Steel wheel bearing housing 27

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

If hexagon bolt cannot be removed, use remover - VAS 6085-

⇒ page 15
Do not attempt to enlarge slots in wheel bearing housing using a
chisel or similar.
– Swivel aside the wheel bearing housing in -arrow direction-
and in doing so pull the drive shaft journal out of the wheel hub.
– Remove nut from joint pin of track control link.
– Take off wheel bearing housing.
Installing
Installation is performed in reverse sequence; note the following:
Tightening torques ⇒ page 12

Note

♦ Remove any remnants of adhesive on thread of joint pin.

♦ When screwing on, press down the upper links as far as pos‐
sible. 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 the headlight range control linkage ⇒ page 69 .
– Fit the brake disc. Screw on and tighten the brake calliper.
– Fit wheel and tighten. ⇒ Wheels and tyres; Rep. gr. 44
– Tighten hexagon bolt securing drive shaft ⇒ page 88 .
The front axle wheel alignment must be checked on a wheel
alignment unit recommended by VW/Audi and corrected if nec‐
essary.

4.2 Removing and installing front wheel bearing with wheel bearing housing
removed

28 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Wheel bearing housing

❑ Note the different run‐
ning gear versions
❑ For correct version refer
to ⇒ Electronic parts
catalogue “ETKA”
2 - Wheel bearing
❑ Installation position:
large internal diameter
of wheel bearing faces
wheel hub
❑ Pressing out ∅ 75
⇒ page 32
❑ Pressing out ∅ 82
⇒ page 33
❑ Pressing inner bearing
race off ⇒ Fig.
⇒ page 33 and
⇒ page 33
❑ Pressing in (75 mm ∅)
⇒ page 33
❑ Pressing in (82 mm ∅)
⇒ page 34
❑ Pressing out Protected
and in by
with
copyright. Copying for private or commercial purposes, in part or in whole, is not

wheel bearing housing

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.
fitted ⇒ page 34
3 - Wheel hub
❑ Stepped version
❑ Pressing out (75 mm ∅)
⇒ page 32
❑ Pressing out ∅ 82
⇒ page 32
❑ Pressing in (75 mm ∅)
⇒ page 34
❑ Pressing in (82 mm ∅) ⇒ page 34
❑ The contact surfaces between rim and brake disc as well as between brake disc and wheel hub must be
free from corrosion and dirt.
❑ Pressing out and in with wheel bearing housing fitted ⇒ page 34
❑ For correct version refer to ⇒ Electronic parts catalogue “ETKA”
❑ Lightweight wheel hub ⇒ page 47
4 - Hexagon bolt, 10 Nm
5 - splash plate
6 - Speed sensor
❑ Pull out to remove
❑ Fit drive shaft before installing speed sensor
❑ Push in to stop on clamping sleeve
❑ For replacement refer to ⇒ Rep. gr. 45
7 - Clamp
❑ Always renew
❑ Left and right identical
❑ Before inserting, lubricate bore in wheel bearing housing with copper paste
❑ Push into wheel bearing housing as far as it will go.

4. Steel wheel bearing housing 29

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Special tools and workshop

equipment required
♦ Thrust plate - VW 401-
♦ Thrust plate - VW 402-
♦ Press tool - VW 412-
♦ Tube - VW 416 B-
♦ Tube - VW 519-
♦ 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

30 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Press tool - VW 432-

♦ Thrust pad - VW 447 I-
♦ Assembly tool - 3291/2-
♦ Press tool - 3124-
♦ Tube - 3345-
♦ Drift sleeve - 30-100-

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. Steel wheel bearing housing 31

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Splitter 3 - Kuk‐
ko 15-2- or -Kuk‐
ko17-2-

♦ Thrust plate - 3005-

Pressing wheel hub out

of 75 mm ∅ wheel bear‐
ing

Pressing wheel hub out of 82 mm ∅ wheel bearing

Pressing wheel bearing out of 75 mm ∅ wheel bearing housing

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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 A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Pressing wheel bearing out of 82 mm ∅ wheel bearing housing

Inserting parting tool

– Insert the parting tool in the annular groove of the bearing inner
race -arrow- and pre-tension with the spindle.
Use a commercially available parting tool, e.g. -Kukko 15-2- or -
Kukko 17-2- .

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.

Pressing inner bearing race off wheel hub

Pressing wheel bearing into 75 mm ∅ wheel bearing housing

Large internal diameter of wheel bearing faces wheel hub.

4. Steel wheel bearing housing 33

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Pressing wheel bearing into 82 mm ∅ wheel bearing housing

Large internal diameter of wheel bearing faces wheel hub.

Pressing wheel hub into 75 mm ∅ wheel bearing

Make sure that the dead weight of the wheel bearing housing
does not press against the wheel hub, as this could damage the
wheel bearing.
– When pressing in, the thrust piece - VW 519- must only bear
against the inner race.
The wheel bearing housing must be kept horizontal whilst press‐
ing in as otherwise the wheel hub will be tilted in the wheel
bearing. This would result in premature bearing damage.

Pressing wheel hub into 82 mm ∅ wheel bearing

Make sure that the dead weight of the wheel bearing housing
does not press against the wheel hub, as this could damage the
wheel bearing.
– When pressing in, the thrust pad - VW 447 I- must only bear
against the inner race.
The wheel bearing housing must be kept horizontal whilst press‐
ing in as otherwise the wheel hub will be tilted in the wheel
bearing. This would result in premature bearing damage.

4.3 Removing and installing front wheel

bearing with wheel bearing housing in‐
stalled
Special tools and workshop equipment required
♦ Engine and gearbox jack - V.A.G 1383 A- with universal gear‐
box support - V.A.G 1359/2-

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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 A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Foot pump with high-pressure hose - V.A.G 1389 A/1-

♦ If there is a hand pump - V.A.G 1389/1- available in the deal‐

ership it can be converted to a foot-operated pump.
♦ To do this, use the conversion set - V.A.G 1389/3- .
♦ Hydraulic wheel bearing tool - V.A.G 1459 B-

♦ Hollow piston cylinder - HKZ-15- with thrust piece - E-0-204-

T- , hydraulic
♦ Pull rod - E-0-217+218-
♦ Special nut - E-8-214-
♦ Press tool - E-5-
♦ Press tool - E-14-1-
♦ Press tool - E-43-
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♦ Press tool - E-44-1- 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.
♦ Press tool - E-45-
♦ Support - E-40-
♦ Supplementary set - V.A.G 1459 B/2-

♦ Splitter - Kukko 15-2- or -Kukko 17-2-

4. Steel wheel bearing housing 35

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Loosen hexagon bolt for drive shaft from vehicle placed on its
wheels (otherwise danger of accident).
– Remove wheel and raise vehicle.
– Pull ABS speed sensor wiring out of retainer on brake calliper.
– Pull ABS speed sensor out of wheel bearing housing.
– Remove brake carrier with brake callipers and attach to body
with wire.
– Remove brake disc and splash plate.
– Unfasten the nut -1-, take out the hexagon bolt and lift out both
links -2-.
If hexagon bolt cannot be removed, use pusher - VAS 6085-
⇒ page 15
Do not attempt to enlarge slots in wheel bearing housing using a
chisel or similar.
– Remove hexagon bolt for drive shaft.
– Swing wheel bearing housing outwards.
– Remove drive shaft from wheel bearing housing and tie up.
– Place engine/gearbox jack - V.A.G 1383 A- underneath (dan‐
ger of accident from parts dropping out when wheel hub and
wheel bearing are pulled out).

Pulling out wheel hub

– Fit separating device -1- between wheel bearing housing and
hub and pretension.
Installation position: Flat sides of plates face towards wheel hub.
– Fit the bell -2-, the hollow piston cylinder -3- with tensioning
bolt and the special nut -4-.
– Extract the wheel hub. Hold the tool firmly whilst doing so.
1 - Splitter - Kukko 15-2- or -Kukko 17-2-
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2 - Support - E-40-
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 - Hollow piston cylinder - HKZ-15-
4 - Special nut - E-8-214- and tensioning bolt
5 - High-pressure hose with quick-release coupling

Pulling out wheel bearing

– Fit the thrust piece -1- (with collar facing bearing), the thrust
piece -2- (with the four stepped inside diameters facing wheel
bearing housing), the hollow piston cylinder -3- with tensioning
bolt and the special nut -4-.
– Pull out wheel bearing by actuating pump.
1 - Press tool - E-5-
2 - Press tool - E-44-1-
3 - Hollow piston cylinder - HKZ-15-
4 - Special nut - E-8-214- and tensioning bolt

36 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Pulling inner bearing race off hub

– Fit separating device -1- behind inner bearing race -2-.
Installation position: Chamfer on plates faces towards inner bear‐
ing race.
– Fit the bell -3- and hollow piston cylinder -4- with tensioning
bolt in position, screw on with the special nut -5- and detach
the bearing inner race.
1 - Splitter - Kukko 15-2- or -Kukko 17-2-
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3 - Support - E-40-
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 - Hollow piston cylinder - HKZ-15-

5 - Special nut - E-8-214- and tensioning bolt

Pressing in wheel bearing

Installation position: The larger internal diameter of the wheel
bearing faces outwards.
– Place the wheel bearing -1-, the thrust piece -2- (insert collar
in bearing) and the hollow piston cylinder -3- with tensioning
bolt in position at the wheel bearing housing.
– Fit the thrust piece -4- with the bevels facing the wheel bearing
housing and the special nut -5- from inside.
– Press in wheel bearing by actuating pump.
1 - Wheel bearing (observe different version: ∅ 75 mm and ∅ 82
mm)
2 - Thrust piece - E-45- for ∅ 75 mm wheel bearing or thrust piece
- E-14-1- for ∅ 82 mm wheel bearing
3 - Hollow piston cylinder - HKZ-15-
4 - Press tool - E-43-
5 - Special nut - E-8-214- and tensioning bolt

Pressing in wheel hub

– Place the wheel hub -1- and hollow piston cylinder -2- with
tensioning bolt in position at the wheel bearing.
– Fit the thrust piece -3- from inside with the collar facing the
special nut -4-.
– Press in wheel hub by actuating pump.
1 - Wheel hub
2 - Hollow piston cylinder - HKZ-15-
3 - Press tool - E-5-
4 - Special nut - E-8-214- and tensioning bolt
Perform remaining installation in reverse order of removal.

4. Steel wheel bearing housing 37

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

5 Aluminium wheel bearing housing

⇒ “5.1 Removing and installing aluminium wheel bearing hous‐
ing”, page 38
⇒ “5.2 Servicing front wheel bearing”, page 40
⇒ “5.3 Removing and installing wheel bearing unit”, page 42

5.1 Removing and installing aluminium

wheel bearing housing
Removing
– Remove wheel trim; on light-alloy wheels, pull off trim cap (use
puller in vehicle tool kit).
– Remove hexagon bolt securing drive shaft ⇒ page 87 .
– Remove wheel.
– Screw all five wheel bolts in again.
– Unscrew bolt -1- for ABS speed sensor.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove hexagon bolt -2-. 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 ABS speed sensor wiring from bracket on wheel bear‐
ing housing.

– Remove bolts -1- for brake calliper and take off brake calliper.
– Screw in the hexagon bolt -2-.
– Tie up brake calliper to body with wire.

Note

Do not suspend the brake calliper from the brake hose.

– Remove brake disc.

– Unfasten the nuts -2- and -3-.

38 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Pull out the rubber grommet -1- and unplug the connector
-2-.
– Pull ABS speed sensor wiring from retainers -arrows-.
Take care not to damage rubber grommet

– Remove hexagon bolt -3- and nut -4-.

– Pull out track rod ball joint.
– Unscrew nut from joint pin.

Note

♦ For safety reasons, screw the collared nut at the joint pin of
the guide link back on again by approx. 4 turns such that it is
flush.
♦ Make sure both lever arms are in parallel when applying max‐
imum force and adjust if necessary.

– Counterhold joint pin with 4 mm Allen key.

– Press the joint pin of the guide link off the tapered seat.
Take care not to damage boot.
For vehicles with headlight range control, pay attention to
⇒ page 69 .

Note

♦ For safety reasons, screw the collared nut at the joint pin of
the track control link back on again by approx. 4 turns such
that it is flush.
♦ Make sure both lever arms are in parallel when applying max‐
imum force and adjust if necessary.

– Press track control link joint pin out of tapered 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.

5. Aluminium wheel bearing housing 39

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unfasten the nut -1-, take out the hexagon bolt and lift out both
links -2-.
Do not attempt to enlarge slots in wheel bearing housing using a
chisel or similar.
– Swivel aside the wheel bearing housing in -arrow direction-
and in doing so pull the drive shaft journal out of the wheel hub.
– Remove nut from joint pin of track control link.
– Take off wheel bearing housing.
Installing
Installation is performed in reverse sequence; note the following:
Tightening torques ⇒ page 12

Note

♦ Remove any remaining adhesive on thread of outer joint pin.

♦ When screwing on, press down the upper links as far as pos‐
sible.

♦
– Fit the headlight range control linkage ⇒ page 69 .
– Fit the brake disc. Screw on and tighten the brake calliper.
– Fit wheel and tighten. ⇒ Wheels and tyres; Rep. gr. 44
– Tighten hexagon bolt securing drive shaft ⇒ page 88 .
The front axle wheel alignment must be checked on a wheel
alignment unit recommended by VW/Audi and corrected if nec‐
essary.
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5.2 Servicing front wheel bearing 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 A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Wheel bearing housing

❑ Note different running
gear versions
❑ For correct version refer
to ⇒ Electronic parts
catalogue “ETKA”
2 - Cap screws, 80 Nm + fur‐
ther 90° turn
3 - Bushes
4 - splash plate
5 - Hexagon bolt, 10 Nm
6 - Wheel hub
❑ Pressing out
⇒ page 166 and
⇒ page 32
❑ Pulling off inner race
⇒ page 45
❑ Stepped version
❑ The contact surface be‐
tween rim and brake
disc as well as between
brake disc and wheel
hub must be free from
corrosion and dirt.
❑ Lightweight wheel hub
⇒ page 47
7 - Angular contact ball bearing
❑ Pressing out (75 mm ∅)
⇒ page 32
❑ Pressing out ∅ 82
⇒ page 32
❑ Pressing in (75 mm ∅)
⇒ page 191
❑ Pressing in (82 mm ∅) ⇒ page 191
❑ Pressing off inner race ⇒ page 45
❑ Removing and installing with wheel bearing housing installed ⇒ page 168
❑ Installation position: large internal diameter of wheel bearing faces wheel hub
❑ Pressing out and in with wheel bearing housing fitted ⇒ page 34

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. Aluminium wheel bearing housing 41

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

5.3 Removing and installing wheel bearing unit

Special tools and workshop

equipment required
♦ Thrust plate - VW 401-
♦ Thrust plate - VW 402-
♦ Tube - VW 416 B-
♦ Press tool - VW 412-
♦ Tube - VW 519-
♦ 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Splitter 3 - Kukko 15-2- or -Kukko 17-2-

42 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

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

Removing
– Remove wheel trim; on light-alloy wheels, pull off trim cap (use
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

puller in vehicle tool kit).

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 hexagon bolt for drive shaft. (Loosen only when ve‐
hicle is standing on wheels -danger of accident-).
– Remove wheel.
– Secure brake disc with one wheel bolt.
– Remove hexagon bolt -2-.
– Detach ABS speed sensor wiring from bracket on wheel bear‐
ing housing.
– Remove bolts -1- for brake calliper and take off brake calliper.
– Re-attach brake line retainer. Screw in and tighten hexagon
bolt -2-.
– Secure the brake calliper to the body so that the weight of the
brake calliper does not bend or damage the brake line.

– Unscrew bolt -1- for ABS speed sensor.

5. Aluminium wheel bearing housing 43

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Note

♦ Tie up brake calliper to body with wire.

♦ Do not suspend the brake calliper from the brake hose.

– Remove brake disc.

– Unfasten the nut -1-, take out the hexagon bolt and lift out both
links -2-.
Do not attempt to enlarge slots in wheel bearing housing using a
chisel or similar.
– Swivel aside the wheel bearing housing in -arrow direction-
and in doing so pull the drive shaft journal out of the wheel hub.
– Take off wheel bearing housing.

– Unscrew countersunk bolts -1-.

– Take out wheel bearing unit.

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 out of 75 mm ∅ wheel bearing

44 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Pressing wheel hub out of 82 mm ∅ wheel bearing

Pressing inner bearing race off wheel hub

– Fit splitter into groove on circumference of inner bearing race
-arrow- and tighten spindle.

Note

Use commercially available splitter , e.g. -Kukko 15-2- or -Kuk‐

ko 17-2- .

– Press inner bearing race off wheel hub.

Pressing wheel hub into 75 mm ∅ 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.

5. Aluminium wheel bearing housing 45

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Pressing wheel hub into 82 mm ∅ wheel bearing

– When pressing in, the thrust piece - VW 511- must only bear
against the inner race.
Installing
Installation is performed in reverse sequence; note the following:
Tightening torques ⇒ page 12

Note

♦ Remove any remaining adhesive on thread of outer joint pin.

♦ When screwing on, press down the upper links as far as pos‐
sible.

– Fit the brake disc. Screw on and tighten the brake calliper.
– Fit wheel and tighten. ⇒ Wheels and tyres; Rep. gr. 44
– Tighten hexagon bolt for drive shaft.
Tightening torque for M14 hexagon bolt: 115 Nm + turn +180°
further.
Tightening torque for M16 hexagon bolt: 190 Nm + turn +180°
further.
Heed the sequence of operations.
– Tighten hexagon bolt securing drive shaft ⇒ page 88 .
The front axle wheel alignment must be checked on a wheel
alignment unit recommended by VW/Audi and corrected if nec‐
essary.

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.

46 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

6 Lightweight wheel hub

⇒ “6.1 Servicing lightweight wheel hub”, page 47

6.1 Servicing lightweight wheel hub

Special tools and workshop equipment required
♦ Press tool - VW 473-

♦ Assembly tool - T40089/1-

♦ Thrust plate - VW 401-

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.

Distinguishing features
The lightweight wheel hub can be distinguished from the conven‐
tional wheel hub by the deflector ring -1- and the sleeve -2-.
The lightweight wheel hub is only to be used in conjunction with
the corresponding wheel bearing, refer to ⇒ Electronic parts
catalogue “ETKA” .
The lightweight wheel hub is only to be used on vehicles fitted
with this at the factory.

6. Lightweight wheel hub 47

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Removing/fitting deflector
– Carefully prise off old deflector ring -1- using a screwdriver.
– Fit new deflector ring on wheel hub.

– Apply special tools as shown in illustration.

1- Press tool - VW 473-
2- Assembly tool - T40089/1-
3- Deflector ring
4- Wheel hub
5- Thrust plate - VW 401-
– Press on deflector ring as far as radius on wheel hub using
assembly tool - T40089/1- as illustrated.

Note

The deflector ring must be pressed on until it is seated against

the radius on the wheel 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.

48 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

7 Servicing mounting bracket (steel

wheel bearing housing)
⇒ “7.1 Removing and installing mounting bracket (steel wheel
bearing housing)”, page 49
⇒ “7.2 Replacing bush, front and rear upper link (steel wheel
bearing housing)”, page 52

7.1 Removing and installing mounting

bracket (steel wheel bearing housing)
Removing
– Remove wheel trim; on light-alloy wheels, pull off trim cap (use
puller in vehicle tool kit).
– Remove wheel.
– Remove clip -1- with a pair of pliers.
This clip does not have to be re-used.
– Unfasten the nut -2-, take out the hexagon bolt and lift out both
links.
Do not attempt to enlarge slots in wheel bearing housing using a
chisel or similar. 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.

– Protect the steering rack boot against damage.

For greater clarity, the steering rack has been removed in the il‐
lustration.
The protective sleeve -1- can be ordered under part no. -893 512
137- .
– A strip, dimension -A- 20...25 mm, must be cut out of protective
sleeve -1-.
– Carefully deburr the cut surfaces.
– Push the protective sleeve over the steering rack boot. The
open side of the sleeve must point downwards.
To unscrew the hexagon bolt from the suspension strut/track con‐
trol link, the guide link must first be detached from the wheel
bearing housing.
Counterhold joint pin with 4 mm Allen key.

7. Servicing mounting bracket (steel wheel bearing housing) 49

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unscrew nut from guide link joint pin and press off joint pin.
Take care not to damage boot.
– Remove ABS speed sensor wiring from retainer on brake cal‐
liper.
So as not to damage the joints of the lower links, support must be
provided for example by way of the engine and gearbox lifter -
V.A.G 1383 A- to prevent excessive rebound.

– Unscrew hexagon bolt -1- securing suspension strut to track

control link.
– Swing wheel bearing housing out to the side.

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 hexagon bolts -1- in plenum chamber.

– Take out suspension strut with mounting bracket.
Take care not to damage boot.

50 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Detaching upper link from mounting bracket

– Clamp suspension strut in vice (use soft jaws).
– Unscrew both links -arrows-.
– Unscrew nuts -1- and detach mounting bracket.
Installing
Installation is performed in reverse sequence; note the following:
Tightening torques ⇒ page 12 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.

– Holes in spring plate -arrows- of suspension strut -1- must face

centre of vehicle.
F = Direction of travel
R = Right mounting bracket
L = Left mounting bracket
– Tighten hexagon nuts -2- to 20 Nm.

Attaching transverse link at top to mounting bracket

– Align upper links, dimension -A- = 57 ± 2 mm.
– Renew all bolts and nuts.

Note

♦ Bonded rubber bushes can only be turned to a limited extent.

The bolt connections on the suspension links should therefore
only be tightened when the vehicle is standing on the ground.
♦ Remove any remnants of adhesive on thread of joint pin.
♦ When screwing on, press down the upper links as far as pos‐
sible.

The front axle wheel alignment must be checked on a wheel

alignment unit recommended by VW/Audi and corrected if nec‐
essary.

7. Servicing mounting bracket (steel wheel bearing housing) 51

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

7.2 Replacing bush, front and rear upper

link (steel wheel bearing housing)
Special tools and workshop equipment required
♦ Assembly tool - 3348/2-

♦ Assembly tool - 3348/3-

♦ Assembly tool - 3301-

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.

♦ Assembly tool - 3301/1-

♦ Assembly tool - 3301/3-

Note

Always use protective jaws when clamping aluminium links in a

vice.

Pulling out bush

52 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Installation position of bush

A = ≈ 90° ± 5°

Installing 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.

7. Servicing mounting bracket (steel wheel bearing housing) 53

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

8 Servicing mounting bracket (alumini‐

um wheel bearing housing)
⇒ “8.1 Removing and installing mounting bracket (aluminium
wheel bearing housing)”, page 54

8.1 Removing and installing mounting

bracket (aluminium wheel bearing hous‐
ing)
Removing
– Remove wheel trim; on light-alloy wheels, pull off trim cap (use
puller in vehicle tool kit).
– Remove wheel.
– Secure brake disc with one wheel bolt.
– Remove clip -1- with a pair of pliers.
This clip does not have to be re-used.
– Unfasten the nut -2-, take out the hexagon bolt and lift out both
links.
Do not attempt to enlarge slots in wheel bearing housing using a
chisel or similar. 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.

– Protect the steering rack boot against damage.

For greater clarity, the steering rack has been removed in the il‐
lustration.
The protective sleeve -1- can be ordered under part no. -893 512
137- .
– A strip, dimension -A- 20...25 mm, must be cut out of protective
sleeve -1-.
– Carefully deburr the cut surfaces.
– Push the protective sleeve over the steering rack boot. The
open side of the sleeve must point downwards.
To unscrew the hexagon bolt from the suspension strut/track con‐
trol link, the guide link must first be detached from the wheel
bearing housing.
– Detach brake calliper and attach to body.
– Counterhold joint pin with 4 mm Allen key if necessary.

Note

♦ For safety reasons, screw the collared nut at the joint pin of
the guide link back on again by approx. 4 turns such that it is
flush.
♦ Make sure both lever arms are in parallel when applying max‐
imum force and adjust if necessary.

54 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Press the joint pin of the guide link off the tapered seat.
Take care not to damage boot.
So as not to damage the joints of the lower links, support must be
provided for example by way of the engine and gearbox lifter -
V.A.G 1383 A- to prevent excessive rebound.

– Unscrew hexagon bolt -1- securing suspension strut to track

control link.
– Swing wheel bearing housing out to the side.

– Unscrew hexagon bolts -1- in plenum chamber.

– Take out suspension strut with mounting bracket.
Take care not to damage 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.

8. Servicing mounting bracket (aluminium wheel bearing housing) 55

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Detaching upper link from mounting bracket

– Clamp suspension strut in vice (use soft jaws).
– Unscrew both links -arrows-.
– Unscrew nuts -1- and detach mounting bracket.
Installing
Installation is performed in reverse sequence; note the following:
Tightening torques ⇒ page 12
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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.

– Holes in spring plate -arrows- of suspension strut -1- must face

centre of vehicle.
F = Direction of travel
R = Right mounting bracket
L = Left mounting bracket
– Tighten hexagon nuts -2- to 20 Nm.

56 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Attaching transverse link at top to mounting bracket

– Align upper links. Distance -A- = 57 ± 2 mm.
– Renew all bolts and nuts.

Note

♦ Bonded rubber bushes can only be turned to a limited extent.

The bolt connections on the suspension links should therefore
only be tightened when the vehicle is standing on the ground.
♦ Remove any remnants of adhesive on thread of joint pin.
♦ When screwing on, press down the upper links as far as pos‐
sible.

– Fit the brake disc. Screw on and tighten the brake calliper.
– Fit wheel.
The front axle wheel alignment must be checked on a wheel
alignment unit recommended by VW/Audi and corrected if nec‐
essary.

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. Servicing mounting bracket (aluminium wheel bearing housing) 57

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

9 Servicing subframe
⇒ “9.1 Removing and installing subframe”, page 58
⇒ “9.2 Pre-tensioned bushes (4-cyl.)”, page 61
⇒ “9.3 Renewing subframe bushes”, page 63

9.1 Removing and installing subframe

Special tools and workshop

equipment required
♦ Support bracket - 10-222/
A-
♦ Rack - 10-222A/1-
♦ Mandrels - 3393-

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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.

58 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Removing
– Support the engine with the support bar .
– Remove wheel trim; on light-alloy wheels, pull off trim cap (use
puller in vehicle tool kit).
– Remove wheels.
– Remove noise insulation tray.

– Before unfastening the subframe, use the test bars - 3393- to

check whether the holes -1- and -2- coincide.
If this is not the case, wheel alignment must be performed after
fitting the subframe.
So as not to damage the joints of the upper links, support must
be provided for example by way of the engine and gearbox lifter
- V.A.G 1383 A- to prevent excessive rebound.

– Unscrew hexagon nuts -3-.

– Slacken off hexagon bolt -1- for attaching guide link to sub‐
frame.

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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.

– Remove hexagon bolts -1-.

– Slacken off hexagon bolts -2- and lower subframe at rear.

Note

To prevent excessive bending of the joints of the track control and

guide links at the pin end, these should be attached to the body
with binding wire or similar.

– Pull out hexagon bolts for guide links.

– Pull guide links out of subframe.

9. Servicing subframe 59
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove hexagon bolt -5-.

For vehicles with headlight range control, pay attention to
⇒ page 69 .
– Unfasten hexagon nut -2- for attaching track control link to
subframe and take out hexagon bolt.
– Remove ABS speed sensor wiring from retainer on brake cal‐
liper.

– Pull the track control link out of the subframe -arrow-.

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

the gearbox.
– Remove hexagon nuts -3- and -4-.
– Unscrew hexagon bolts -5-.
– Slacken off hexagon bolts -6- until subframe can be taken out.
Installing
Installation is performed in reverse sequence; note the following:
Tightening torques ⇒ page 12
– Renew all bolts and nuts.
Before tightening, the subframe must be fixed in position with re‐
spect to the body using the test bars - 3393- .

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.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Hole -1-, hole -2- in subframe and hole -3- in aluminium brack‐
et must align on both sides.

Note

♦ This locating method avoids the need for a subsequent wheel

alignment check, provided that:
♦ Only the subframe has been removed and installed.
♦ Holes -1- and -2- were in alignment prior to repair work.
♦ Bonded rubber bushes can only be turned to a limited extent.
The bolt connections on the suspension links should therefore
only be tightened when the vehicle is standing on the ground.
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
– Protect the holes in
withthe body
respect to thefor fitting ofthe
correctness test bars
information in this -document.
3393- Copyright by AUDI AG.
against corrosion.
Thread in body can be repaired using wire thread insert according
to DIN 8140 (Helicoil). The threaded insert must be of the same
length as the thread in the body.
Pay attention to the modified connecting links and tightening tor‐
ques ⇒ page 81 .
Always use a new ribbed nut.
– Fit ABS speed sensor wiring into retainer on brake calliper.
– Fit wheels.

9.2 Pre-tensioned bushes (4-cyl.)

The aluminium shims are arranged differently on 4-cylinder petrol
engines and 4-cylinder TDI engines

9. Servicing subframe 61
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Rear left plate

❑ Thickness 1 mm
❑ only 4-cyl. petrol en‐
gines
❑ Fixed in position on 3
rubber nipples
❑ Between subframe and
body
2 - Rear right plate
❑ Thickness 4 mm
❑ only 4-cyl. petrol en‐
gines
❑ Fixed in position on 3
rubber nipples
❑ Between subframe and
body
3 - Subframe
❑ with 3 rubber nipples
4 - Rear left plate
❑ Thickness 2 mm
❑ Between subframe and
support
5 - Rear right plate
❑ Thickness 5 mm
❑ Between subframe and
support
6 - Rear left and right support

Note

If the subframes are replaced, the

shims are only to be fitted with bush‐
es with rubber nipples.

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.

62 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

9.3 Renewing subframe bushes

Special tools and workshop

equipment required
♦ Assembly tool - 3291-
♦ Puller - 3351/1-
♦ Puller - 3351/4-
♦ Removal toolProtected
- 3372- 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
♦ Removal tool -with
3372/1-
respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Removal tool - 3372/2-

♦ Thrust plate - 30-205-

Removing rear bonded rubber bush

Make sure the pressing-out tool - 3372- is correctly positioned and
cannot tip up.

9. Servicing subframe 63
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Extracting front bonded rubber bush

All bonded rubber bushes at the subframe are extracted using the
same tool.

Preparation for installing subframe bush

– Fit the Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
pressing-out tool - 3372- in position
permitted and insert
unless authorised by AUDIthe
AG. half
AUDI shells
AG does not guarantee or accept any liability
- 3372/2- . with respect to the correctness of information in this document. Copyright by AUDI AG.

Aligning bonded rubber bushes

The bonded rubber bushes must be aligned using a long rectan‐
gular tube or straightedge.
A = 90° ± 5°
Always use jaw protectors when clamping subframe in vice.

Fitting rear bonded rubber bush

– Use assembly lubricant - G 294 421 A1- when pressing in the
bonded rubber bushes.
– Insert the bush -A- until the thrust piece - 3372/1- is flush with
the top edge of the pressing-out tool - 3372- .
– Lift off the pressing-out tool - 3372- and half shells - 3372/2- .

64 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Fitting rear bonded rubber bush

– Insert the half shells - 3372/2- between the bridge - 3351/4-
and the subframe.
– Pull in bush as far as the stop.
Apply corrosion protection if paint surface on subframe is dam‐
aged.

Fitting front bonded rubber bush

– Use assembly lubricant - G 294 421 A1- when pressing in the
bonded rubber bushes.
– Insert the half shells - 3372/2- in the pressing-out tool - 3372- .
⇒ page 64
– Insert the bush -A- until the thrust piece - 3372/1- is flush with
the top edge of the pressing-out tool - 3372- .

Fitting front bonded rubber bush

– Lift the pressing-out tool - 3372- and take out the half shells -
3372/2- .
– Replace the bridge - 3351/4- with the thrust piece - 3351/1-
and then insert the bush as far as it will go.
Apply corrosion protection if paint surface on subframe is dam‐
aged.

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.

9. Servicing subframe 65
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

10 Track control link (steel wheel bear‐

ing housing), vehicle level sender
⇒ “10.1 Removing and installing track control link”, page 66
⇒ “10.2 Renewing bush for track control link”, page 67
⇒ “10.3 Vehicle level senders ”, page 69

10.1 Removing and installing track control

link
Removing
– Remove wheel trim; on light-alloy wheels, pull off trim cap (use
puller in vehicle tool kit).
– Remove wheel.

Note

Use a leather cloth for example to protect the boot against dam‐
age.

– Remove nut from joint pin of track control link, then press joint
pin out of tapered seat.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
To unscrew the hexagonpermitted
bolt from the
unless suspension
authorised strut/track
by AUDI AG. AUDI AG does con‐
not guarantee or accept any liability
trol link, the guide link must
withfirst betodetached
respect from
the correctness the wheel
of information in this document. Copyright by AUDI AG.
bearing housing.
Counterhold joint pin with 4 mm Allen key.

– Unscrew nut from guide link joint pin and press off joint pin.
Take care not to damage boot.

66 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove hexagon bolt -1-.

– Remove ribbed nuts -2- and -3-and take out coupling rod.
So as not to damage the joints of the upper links, support must
be provided for example by way of the engine and gearbox lifter
- V.A.G 1383 A- to prevent excessive rebound.
– Remove hexagon bolt -4-.
– Take out track control link.
Installing
Installation is performed in reverse sequence; note the following:
Tightening torques ⇒ page 12
– Renew all bolts and nuts.

Note

♦ Only use outer holes -arrow-.

♦ Bonded rubber bushes can only be turned to a limited extent.
The bolt connections on the suspension links should therefore
only be tightened when the vehicle is standing on the ground.

Pay attention to the modified connecting links and tightening tor‐

ques ⇒ page 81 .
– Arrow on coupling rod points in direction of travel.

10.2 Renewing bush for track control link

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.

10. Track control link (steel wheel bearing housing), vehicle level sender 67
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Special tools and workshop

equipment required
♦ Assembly tool - 3301-
♦ Assembly tool - 3301/4-
♦ Assembly tool - 3346-
♦ Assembly tool - 3346/2-
♦ Assembly tool - 3346/3-
♦ Assembly tool - 3350/1-

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

Always use protective jaws when clamping aluminium links in a

vice.

Removing inner bush

68 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Installation position of bush

– Fitting marks -A- at track control link and edge of bush in par‐
allel

Installing inner bush

– Insert the bush -A- in the 3.2 mm recess in the thrust piece -
3346/1- .
– Pull in bush as far as the stop.

Removing outer 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.

Installing outer bush

– Insert the bush -A- in the 8 mm recess in the thrust piece -
3346/1- .
– Pull in bush as far as the stop.

10.3 Vehicle level senders

10. Track control link (steel wheel bearing housing), vehicle level sender 69
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Vehicles with gas discharge lamps or air suspension have auto‐

matic headlight range control as standard equipment.
In order to function properly, the automatic headlight range control
system requires information on the bump and rebound travel at
the front and rear axle.
For this purpose, the position of the lower left link with respect to
the body is transmitted by way of a coupling rod to the front left
vehicle level sender - G78- . This relays electrical signals to the
left - J344- and right -J345- gas discharge light control unit.
At the rear axle, these signals are passed
Protected byCopying
by copyright. the rear left orvehicle
for private commercial purposes, in part or in whole, is not
level sender - G76- to the control units
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.
A total of 4 senders are required with air suspension.
These signals are required for calculating the current attitude of
the vehicle.
The automatic headlight range control reacts to changes in the
suspension height (attitude of the vehicle). Further information on
the mode of operation can be found in self-study programme 192.
The following situations may produce a change in the suspension
height:

70 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Caution

Headlight setting

The basic headlight setting must always be checked when:

Basic setting of headlights ⇒ Electrical system; Rep. gr. 01 ; Self-

diagnosis of automatic headlight range control system; basic
setting

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.

10. Track control link (steel wheel bearing housing), vehicle level sender 71
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Retainer
2 - Front left vehicle level send‐
er - G78-
❑ Is tested electrically via
self-diagnosis
❑ In the event of prob‐
lems, refer to ⇒ Electri‐
cal system; Rep. gr. 01 ;
Self-diagnosis of auto‐
matic headlight range
control system
3 - Hexagon socket head bolt,
10 Nm
4 - Rivet
5 - Self-locking nut, 10 Nm
❑ Always renew after re‐
moving
6 - Suspension strut
7 - Anti-roll bar coupling rod
8 - Coupling rod of front left ve‐
hicle level sender - G78-
❑ Do not pull coupling rod
from ball head!
❑ Coupling rods are not to
be interchanged on all‐
road vehicles
9 - Mark at link for installation
position of front left vehicle lev‐
el sender - G78-
10 - Front wishbone,Protected
bottom 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
11 - Clip with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ for example lever out

with slot screwdriver
❑ The clip must be unfastened for removing and installing the track control link

Note

So as not to damage the seal when fitting the linkage at the vehicle
level sender , use an open-ended wrench (w.a.f. 10 mm) with di‐
mension -A- 4 mm.

72 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Dimension -A- = 4 mm
– The headlight range control linkage is attached to the track
control link between the stops using pliers.
– On installation, pay attention to correct mutual positioning of
the sensor crank and linkage.

Note

♦ Connecting link must be vertical

♦ The sensor crank (arm) must face forwards and downwards.
♦ The coupling rods are not to be interchanged on allroad vehi‐
cles.

Vehicle level sender in installation position - allroad

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
The 4 vehicle level senders - G76- , -G77- , -G78-permitted
and -G289- are
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.
identical on the Audi allroad. Only the mounts and the coupling
rod kinematics vary depending on side and axle.

Note the different colour of the coupling rods at the front axle.
Basic setting must be performed if the vehicle level sender is re‐
placed or a connection unfastened.

10. Track control link (steel wheel bearing housing), vehicle level sender 73
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

11 Track control link (aluminium wheel

bearing housing)
⇒ “11.1 Removing and installing track control link (aluminium
wheel bearing housing)”, page 74

11.1 Removing and installing track control

link (aluminium wheel bearing housing)
Removing
– Remove wheel trim; on light-alloy wheels, pull off trim cap (use
puller in vehicle tool kit).
– Remove wheel.
For vehicles with headlight range control, pay attention to
⇒ page 69 .
– Secure brake disc with one wheel bolt.
– Detach brake calliper and attach to body.

Note

♦ Use a leather cloth for example to protect the boot against

damage.
♦ For safety reasons, screw the collared nut at the joint pin of
the track control link back on again by approx. 4 turns such
that it is flush.
♦ Make sure both lever arms are in parallel when applying max‐
imum force and adjust if necessary.

– Press track control link joint pin out of tapered seat.

To unscrew the hexagon bolt from the suspension strut/track con‐
trol link, the guide link must first be detached from the wheel
bearing housing.
Counterhold joint pin with 4 mm Allen key.
– Unscrew nut from joint pin of guide link.

Note

♦ For safety reasons, screw the collared nut at the joint pin of
the guide link back on again by approx. 4 turns such that it is
flush.
♦ Make sure both lever arms are in parallel when applying max‐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
permitted unless authorised
imum force and adjust if necessary. with respect to the correctness of information in this document. Copyright by AUDI AG.

74 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unscrew nut from guide link joint pin and press off joint pin.
Take care not to damage boot.

– Remove hexagon bolt -1-.

– Remove ribbed nuts -2- and -3-and take out coupling rod.
So as not to damage the joints of the upper links, support must
be provided for example by way of the engine and gearbox lifter
- V.A.G 1383 A- to prevent excessive rebound.
– Remove hexagon bolt -4-.
– Take out track control link.
Installing
Installation is performed in reverse sequence; note the following:
Tightening torques ⇒ page 12
– Renew all bolts and nuts.

Note

Bonded rubber bushes can only be turned to a limited extent. The

bolt connections on the suspension links should therefore only be
tightened when the vehicle is standing on the ground.

Pay attention to the modified connecting links and tightening tor‐

ques ⇒ page 81 .
– Arrow on coupling rod points in direction of travel.
– Fit the brake disc. Screw on and tighten the brake calliper.
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. Track control link (aluminium wheel bearing housing) 75

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

12 Guide link (steel wheel bearing hous‐

ing)
⇒ “12.1 Removing and installing guide link”, page 76
⇒ “12.2 Renewing guide link bush”, page 77

12.1 Removing and installing guide link

Removing
– Remove wheel trim; on light-alloy wheels, pull off trim cap (use
puller in vehicle tool kit).
– Remove wheel.
– Unscrew nut from guide link joint pin and press off joint pin.
Provide support at the joint pin with a 4 mm Allen key when
doing so.

– Remove hexagon bolt -1-.

Take care not to damage the underseal or the surfaces of the
brake pipes.
– If necessary, lower the subframe at the rear.
– Take out guide link.
Installing
Installation is performed in reverse sequence; note the following:
Tightening torques ⇒ page 12
– Renew all bolts and nuts.

Note

Bonded rubber bushes can only be turned to a limited extent. The

bolt connections on the suspension links should therefore only be
tightened when the vehicle is standing on the ground.

Note

Only use outer holes -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.

76 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

12.2 Renewing guide link bush

Special tools and workshop

equipment required
♦ Assembly tool - 3301-
♦ Assembly tool - 3346/2-
♦ Assembly tool - 3346/3-
♦ Assembly tool - 3347-
♦ Assembly tool - 3347/1-
♦ Assembly tool - 3347/2-

Removing hydro-bush from link

Note

Always use protective jaws when clamping aluminium links in a

vice.

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.

12. Guide link (steel wheel bearing housing) 77

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Installation position of hydro-bush

The arrows on hydro-mounting -1- and groove -2- point towards
the joint pin.
The maximum permissible misalignment is ± 5°.

Installing hydro-bush
– Insert the hydro-bush -A- in the assembly tool - 3347/2- .
– Clamp together with sleeve - 3347/1- , spindle - 3346/2- and
hexagon nut.
– Pull in hydro-bush -A- as far as 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.

78 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

13 Guide link (aluminium wheel bearing

housing)
⇒ “13.1 Removing and installing guide link (aluminium wheel
bearing housing)”, page 79

13.1 Removing and installing guide link (alu‐

minium wheel bearing housing)
Removing
– Remove wheel trim; on light-alloy wheels, pull off trim cap (use
puller in vehicle tool kit).
– Remove wheel.
– Remove hexagon bolt -2-.
– Remove bolts -1- for brake calliper and take off brake calliper.
– Screw on the hexagon bolt -2-.
– Attach the brake calliper to the body.
– Secure brake disc with one wheel bolt.

Note

Do not suspend the brake calliper from the brake hose.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Unscrew nut from joint pin of guide link. Provide permitted
support at the
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
joint pin with a 4 mm Allen key when doing so. with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

♦ For safety reasons, screw the collared nut at the joint pin of
the guide link back on again by approx. 4 turns such that it is
flush.
♦ Make sure both lever arms are in parallel when applying max‐
imum force and adjust if necessary.

– Unscrew nut from guide link joint pin and press off joint pin.
Take care not to damage boot.

13. Guide link (aluminium wheel bearing housing) 79

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove hexagon bolt -1-.

Take care not to damage the underseal or the surfaces of the
brake pipes.
– If necessary, lower the subframe at the rear.
– Unscrew the hexagon bolts -2- and -3-.
– Take out guide link.
Installing
Installation is performed in reverse sequence; note the following:
Tightening torques ⇒ page 12
– Renew all bolts and nuts.

Note

Bonded rubber bushes can only be turned to a limited extent. The

bolt connections on the suspension links should therefore only be
tightened when the vehicle is standing on the ground.

– Fit the brake disc. Screw on and tighten the brake calliper.

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.

80 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

14 Anti-roll bar, connecting link

⇒ “14.1 Removing and installing anti-roll bar”, page 81
⇒ “14.2 Coupling rod with rubber bushes in place of coupling rod
with ball joint was introduced for Model Year '99.”, page 81

14.1 Removing and installing anti-roll bar

Removing
– Remove the engine noise insulation.
– Slacken nut -1-.
– Remove coupling rod from anti-roll bar.
– Unscrew hexagon nuts -2-.
Installing
Installation is performed in reverse sequence; note the following:
Tightening torques ⇒ page 12
Tightening torques for hexagon nuts -2- : 25 +/- 4Nm
– Install mounting and anti-roll bar free of grease.
– Arrow on coupling rod points in direction of travel.

– If renewing the anti-roll bar, check the suspension version fit‐

ted on the vehicle.
Pay attention to the modified connecting links and tightening tor‐
ques ⇒ page 81 .
– Always use a new ribbed nut.

14.2 Coupling rod with rubber bushes in

place of coupling rod with ball joint was
introduced for Model Year '99.
Connecting link with ball joint
1- Connecting link with ball joint
2- Track control link
3- Self-locking hexagon nut, 40 Nm + further 90° turn
4- Clip
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5- Self-locking hexagon nut, 100 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.
6- Anti-roll bar

14. Anti-roll bar, connecting link 81

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Connecting link with bonded rubber bush

Connecting link -A- for left side of vehicle
Arrow on coupling rod points forwards.
– The permanently installed spacer -1- at the connecting link
must be fitted at the anti-roll bar.
– Connecting link -B- for right side of vehicle
Arrow on coupling rod points forwards.
-Arrow- points in direction of travel.

Bonded rubber bushes can only be turned to a limited extent. The

bolt connections on the suspension links should therefore only be
tightened when the vehicle is standing on the ground.
1- Connecting link with bonded rubber bush; bonded rubber
bush with press-fitted spacer -A- is bolted to anti-roll bar
2- Self-locking hexagon nut, 40 Nm + further 90° turn
3- Hexagon bolt
4- Track control link
5- Hexagon bolt
6- Self-locking hexagon nut, 60 Nm
7- Anti-roll bar

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.

82 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

15 Front axle (allroad)

⇒ “15.1 Exploded view of front axle (allroad)”, page 83
⇒ “15.2 Spacers”, page 85
⇒ “15.3 Transverse brace/support”, page 86

15.1 Exploded view of front axle (allroad)

Observe the general notes ⇒ page 10 .
Before performing repair work at the front axle of the Audi allroad,
the vehicle height must be deactivated at normal level
⇒ page 304 .

1 - Hexagon bolt, 45 Nm and

turn 55° further
Use new 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.
Heed the connection se‐
quence ⇒ page 260

2 - Washer (1x)
3 - Hexagon bolt M 10 x 62
❑ Always renew after re‐
moving
4 - Upper link (rear)
❑ Installation position
⇒ page 265
❑ Renewing bush
⇒ page 52
5 - Hexagon bolt, 5 Nm
❑ Always renew after re‐
moving
❑ For adjusting toe con‐
stant “S”
6 - Bolt
7 - Self-locking nut
❑ Always renew after re‐
moving
❑ 40 Nm for steel wheel
bearing housing
❑ 45 Nm for aluminium
wheel bearing housing
8 - Hexagon bolt M 10 x 100
9 - Self-locking nut, 40 Nm
❑ Always renew after re‐
moving
10 - Upper link (front)
❑ Installation position ⇒ page 265
❑ Renewing bush ⇒ page 52
11 - Suspension strut
❑ Removing and installing ⇒ page 260
❑ Servicing ⇒ page 265

15. Front axle (allroad) 83

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

12 - Hexagon bolt
❑ 70 Nm and turn 180° further
❑ Always renew after removing
13 - Guide link (bottom)
Hydro-bush must be renewed if leaking ⇒ page 77
❑ For correct version refer to ⇒ Electronic parts catalogue “ETKA”
14 - Self-locking nut, 110 Nm
❑ Always renew after removing
15 - Wheel bearing housing
❑ Removing and installing ⇒ page 26
❑ Servicing ⇒ page 28
16 - splash plate
17 - Hexagon bolt
❑ Always renew after removing
Tightening torque for M16 bolt:

Initial tightening torque: 120 Nm

Tightening torque: 200 Nm and turn 180° further

Vehicle must be standing on the ground when tightening

18 - Hexagon socket head bolt, 10 Nm

19 - Self-locking nut, 110 Nm 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
permitted unless authorised
❑ Alwayswith renew
respectafter removing
to the correctness of information in this document. Copyright by AUDI AG.

20 - Hexagon bolt M 12 x 1.5 x 85

❑ 90 Nm and turn 90° further
21 - Self-locking nut
❑ Always renew after removing
22 - Coupling rod
Arrow on coupling rod points in direction of travel

23 - Self-locking hexagon nut

❑ Always renew after removing
❑ 40 Nm and turn 90° further
❑ Underside of nut is ribbed
❑ Always use this special nut for replacement purposes.
24 - Hexagon bolt
❑ 70 Nm and turn 180° further
❑ Always renew after removing
25 - Track control link (bottom)
❑ On removal and installation, pay attention to installation position of vehicle level sender ⇒ page 260
❑ For removal and installation, refer to ⇒ page 69
❑ Servicing ⇒ page 67
26 - Hexagon bolt M 12 x 1.5 x 110, allroad M 12 x 1.5 x 140
❑ 110 Nm and turn 90° further
❑ Always renew after removing
❑ Thread in body can be repaired using wire thread insert according to DIN 8140 (Helicoil). The thread
insert must be of the same length as the thread in the body.

84 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

27 - Hexagon bolt, 75 Nm
❑ M10 × 70
❑ Always renew after removing
28 - Self-locking nut, 60 Nm
❑ Always renew after removing
29 - Clip
❑ Inserted in track control link
❑ Always renew
30 - 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
❑ toOn
with respect removalofand
the correctness installation,
information payCopyright
in this document. attention to AG.
by AUDI installation position of vehicle level sender ⇒ page 260
❑ For removal and installation, refer to ⇒ page 69
❑ Spacers for allroad only ⇒ page 85
❑ Removing and installing ⇒ page 58
❑ Servicing ⇒ page 63
31 - Hexagon bolt
❑ 30 Nm and turn 90° further
❑ Always renew after removing
32 - Subframe support
❑ Different versions ⇒ page 86
33 - Self-locking nut
❑ Always renew after removing
34 - Self-locking nut
❑ Always renew after removing
35 - Drive shaft with triple roller joint
36 - 12-point socket head bolt, 70 Nm
❑ For vehicles with triple roller joint
❑ M10 × 20
37 - Hexagon bolt M 10 x 62
❑ Always renew after removing
38 - Mounting bracket
❑ Removing and installing ⇒ page 264
39 - Self-locking nut
❑ 50 Nm and turn 90° further
❑ Always renew after removing
40 - Bolt, 23 Nm
❑ Use new bolts

15.2 Spacers
Spacers with index “B” are fitted between the subframe and body
at the front axle of the allroad.
These are eccentric and are 25 mm high.
The spacers are fitted eccentrically on the subframe bushes:
Front:
Larger projection faces in direction of travel.

15. Front axle (allroad) 85

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Rear:
Larger projection faces opposite direction of travel.
– When removing mark the installation position of the spacer
plates.

15.3 Transverse brace/support

1 - Support (left-side)
❑ For TDI
2 - Bolt with washer
❑ 30 Nm and turn 90° fur‐
ther
❑ Use new bolt
3 - Bolt with washer
❑ 40 Nm
4 - Cross piece
❑ For TDI
5 - Bolt with washer
❑ 30 Nm and turn 90° fur‐
ther
❑ Use new bolt
6 - Support (right-side)
❑ For TDI
7 - Support (left-side)
❑ for biturbo
8 - Bolt with washer
❑ 75 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
9 - Bolt with 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.
❑ 30 Nm and turn 90° fur‐
ther
❑ Use new bolt
10 - Support (right-side)
❑ for biturbo
11 - Cross piece
❑ for biturbo

86 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

16 Drive shaft
⇒ “16.1 Removing and installing drive shaft”, page 87

16.1 Removing and installing drive shaft

Removing
– Remove wheel trim; on light-alloy wheels, pull off trim cap (use
puller in vehicle tool kit).
– With the vehicle standing on its wheels, slacken off the hexa‐
gon bolt for the outer joint of the drive shaft by max. 90°.
– Remove wheel.
– With the vehicle raised on a lifting platform, screw out the hex‐
agon bolt for the outer joint of the drive shaft (if necessary have
a second mechanic press the brake).
– Unscrew the drive shaft from the flange shaft/gearbox -1-.
– Pull the wire of the ABS speed sensor out of the holder at the
brake calliper -arrow-.
– Pull ABS speed sender out of wheel bearing housing slightly.

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.

16. Drive shaft 87

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unfasten the nut -1-, take out the hexagon bolt and lift out both
links -2-.
Do not attempt to enlarge slots in wheel bearing housing using a
chisel or similar.

Note

Do not loosen bolts -3- and -4- as this would change the front axle
alignment.

– Swivel aside the wheel bearing housing in -arrow direction-.

– Take out drive shaft.
Installing
Installation is performed in reverse sequence; note the following:
Tightening torques ⇒ page 12

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
with respect to the correctness of information in this document. Copyright by AUDI AG.
When screwing on, press down the upper links as far as possible.

– Bolt drive shaft to gearbox.

Tightening torques:
M8 = 40 Nm
M10 = 70 Nm
– Push ABS speed sensor into wheel bearing housing onto stop
and insert cable in retainer on brake calliper.
– Screw on the outer joint of the drive shaft.

Note

Vehicle must not be in contact with ground when tightening outer

joint of drive shaft.

A second mechanic is required for the next operation.

– 1. Mechanic: Gets into vehicle and presses foot brake
– 2. Mechanic: Tightens hexagon bolt for drive shaft
M14 hexagon bolt: 115 Nm
M16 hexagon bolt: 190 Nm
– Fit wheel.
– Tighten hexagon bolt for drive shaft. Only tighten when vehicle
is standing on wheels -danger of accident-.
– Turn hexagon bolt +180° further.

88 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

17 Servicing drive shaft with inner con‐

stant velocity joint
⇒ “17.1 Exploded view”, page 89
⇒ “18 Servicing drive shafts with triple roller joint AAR 2900”, page
96

17.1 Exploded view

Quantities and type of grease:
Constant velocity joints are filled with grease - G 000 603- .
Regrease joint when renewing boot.
Grease of which in:
Outer joint Total quantity Joint Boot
∅ mm [g] [g] [g]
88 90 40 50
98 120 80 40
Inner joint
∅ mm
100 80 30 50
108 120 35 85

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.

17. Servicing drive shaft with inner constant velocity joint 89

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Circlip
❑ Renew
❑ Remove and install us‐
ing circlip pliers -
VW 161 A-
2 - Gasket
❑ Replace; detach back‐
ing and bond into joint
3 - Inner constant velocity joint
❑ Outside diameter 100 or
108 mm depending on
engine/gearbox combi‐
nation
❑ Renew only as com‐
plete unit
❑ Pressing off
⇒ page 94
❑ Pressing on Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ page 94 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

❑ Greasing ⇒ page 89
with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Grease splines on drive

shaft lightly with grease
used in joint when fitting
joint onto drive shaft
4 - Drive shaft (tubular shaft)
❑ Grease must be applied
to the splines on the
shaft when fitting the
outer or inner joint
5 - Hose clip
❑ Renew
6 - Boot
❑ Check for splits and
chafing
❑ Before tensioning hose clip, briefly lift boot to equalise pressure ⇒ page 95
❑ Greasing ⇒ page 89
7 - Hose clip
❑ Renew
❑ Tension ⇒ page 93 and ⇒ page 95
8 - Dished spring
❑ Large ∅ (concave side) makes contact with thrust washer
❑ Installation position ⇒ page 95
9 - Thrust washer
❑ Installation position ⇒ page 95
10 - Circlip
❑ Renew
❑ Insert in groove on shaft
11 - Outer constant velocity joint
❑ Renew only as complete unit
❑ Removing ⇒ page 94
❑ Installing: Drive onto shaft using plastic-headed hammer until circlip engages in annular groove of con‐
stant velocity joint.

90 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

❑ Greasing ⇒ page 89
❑ Grease splines on drive shaft lightly with grease used in joint when fitting joint onto drive shaft
12 - Hexagon bolt
❑ Always renew after removing
Tightening torque for M14 bolt:
❑ 115 Nm and turn 180° further
Tightening torque for M16 bolt:
❑ 190 Nm and turn 180° further
Observe instructions for removal ⇒ page 87

Observe instructions for installation ⇒ page 88

13 - Multi-point socket head bolt
❑ M 8 x 48: 40 Nm
❑ M 10 x 48: 70 Nm
14 - Lock plate
15 - Boot for inner constant velocity joint
❑ Check for splits and chafing
❑ Drive off with drift
❑ Before attaching to constant velocity joint, apply sealant - D 454 300 A2- to sealing surface
❑ Greasing ⇒ page 89

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.

17. Servicing drive shaft with inner constant velocity joint 91

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Special tools and workshop

equipment required
♦ Hose clip pliers -
V.A.G 1275-
♦ Spindle - 3207-
♦ Press tool - VW 411-
♦ Circlip pliers - VW 161 A-
♦ Thrust plate - VW 401-
♦ Thrust plate - VW 402-
♦ Press tool - VW 412-

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.

92 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Support sleeve - VW 522-

♦ Clamp - 40-204 A-
♦ Hose clip pliers -
V.A.G 1682-
♦ Pliers - 3340-

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.

Boots made of rubber are secured using pliers - V.A.G 1275- .

The instructions relating to Fig. ⇒ page 93 only apply to stain‐
less steel clamps.
Tightening hose clip on outer joint
– Apply clamp tensioner - V.A.G 1682- as shown. Ensure jaws
of clamp tensioner make contact with both sides of lug
-arrows B- on hose clip.
– Tighten hose clip by turning spindle with torque wrench (take
care to keep pliers straight).
♦ Tightening torque: 20 Nm.
♦ Use torque wrench with 5…50 Nm adjustment range (e.g. -
V.A.G 1331- ).
♦ Make sure thread of spindle on clamp tensioner moves freely.
Lubricate with MoS2 grease if necessary.
♦ If the thread is stiff (e.g. due to dirt), the required clamping
force will not be attained at the hose clip when the specified
tightening torque is applied.

17. Servicing drive shaft with inner constant velocity joint 93

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Pressing off outer constant velocity joint

– Clamp drive shaft in vice using protective jaw covers.
– Detach hose clamp and push back bellows.
– Screw the pressure screw - 3207- with M 16/M14 type thread
into the joint pin until the constant velocity joint is pressed off
the drive shaft.

Pressing off inner constant velocity joint

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

♦ First drive rubber boot off with drift.

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

♦ Support ball hub.

Pressing on inner constant velocity joint

– Grease splines -A- on drive shaft lightly with grease used in
joint before fitting joint or triple roller spider onto drive shaft.

– Press on joint as far as stop.

– Engage circlip.

Note

Chamfer on internal diameter of ball hub (splines) must face con‐

tact collar of drive shaft.

94 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Installation position of spacer ring and dished spring (outboard

end)
1 - Dished spring
2 - Spacer ring (plastic)

Venting joint boot

Only applies to rubber boots.
The CV joint boot is often squashed when it is installed on the
joint body. This creates a partial vacuum inside the boot, which
draws in a fold -arrow- whilst driving. For this reason, vent the boot
to equalise pressure after installation by briefly lifting the lip at the
small-diameter end. 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.

17. Servicing drive shaft with inner constant velocity joint 95

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

18 Servicing drive shafts with triple roller

joint AAR 2900
⇒ “18.1 Exploded view”, page 96
⇒ “18.2 Servicing outer constant velocity joint”, page 98
⇒ “18.3 Dismantling and assembling triple roller joint AAR 2900”,
page 99

18.1 Exploded view

Quantities and type of grease for drive shaft with triple roller joint:
The 98 mm dia. constant velocity joint is filled with grease -
G 000 633- .
The triple roller joint is filled with grease - G 000 605- .
Regrease joint when renewing boot.
Grease of which in:
Outer joint Total quantity Joint Boot
∅ mm [g] [g] [g]
98 120 80 40
Inner joint
100 80 30 50

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.

96 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Hexagon bolt
❑ Always renew after re‐
moving
Tightening torque for M16 bolt:
❑ 190 Nm and turn 180°
further
Observe instructions for re‐
moval ⇒ page 87

Observe instructions for instal‐

lation ⇒ page 88

2 - Boot for outer constant ve‐

locity joint
❑ Check for splits and
chafing
❑ Greasing ⇒ page 96
❑ Briefly lift boot to equal‐
ise pressure before
tightening hose clips
⇒ page 99
❑ Different versions (rub‐
ber or Hytrel)
3 - Hose clip
❑ Different versions for
rubber or Hytrel boot
❑ Renew
❑ Tightening ⇒ page 99
4 - Drive shaft (tubular shaft)
❑ Grease must be applied
to the splines on the
shaft when fitting the
outer or inner joint
5 - Hose clip
❑ Renew
❑ Tightening ⇒ page 99
6 - Joint body
7 - Multi-point socket head bolt
❑ M 10 x 20: 70 Nm
8 - Triple roller spider
Chamfer -arrow- faces towards drive shaft splines
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

❑ Installation position ⇒ page 103

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.
❑ Grease splines on drive shaft lightly with grease used in joint when fitting triple roller spider onto drive
shaft.
9 - Circlip
❑ Renew
❑ Insert in groove on shaft
10 - O-ring
A new O-ring is provided in the repair kit and must be fitted

11 - Cover
❑ Always renew
Is destroyed on removal

18. Servicing drive shafts with triple roller joint AAR 2900 97
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Repair kit contains modified cover

12 - Hose clip
❑ Always renew
❑ Tightening ⇒ page 104
❑ Various types of hose clip are possible depending on version. Can also be fitted using pliers - 3340- ,
refer to ⇒ Electronic parts catalogue “ETKA”
13 - Boot for triple roller joint
❑ Greasing ⇒ page 96
14 - Hose clip
❑ Always renew
❑ Tightening ⇒ page 99
15 - Dished spring
❑ Installation position ⇒ page 99
16 - Spacer ring (plastic)
❑ Installation position ⇒ page 99
17 - Circlip
❑ Always renew
❑ Fit into annular groove on shaft before installing (no longer visible once joint is installed)
18 - Outer constant velocity joint
❑ Renew only as complete unit
❑ Pressing off ⇒ page 99
❑ Installing:
❑ Drive joint onto shaft with plastic hammer until circlip engages
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Greasing ⇒ page 96 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.
❑ Grease splines on drive shaft lightly with grease used in joint when fitting joint onto drive shaft

18.2 Servicing outer constant velocity joint

Boots made of rubber are secured using pliers - V.A.G 1275- .
Instructions apply only to stainless steel clips.

98 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Tightening hose clip on outer joint

– Apply clamp tensioner - V.A.G 1682- as shown. Ensure jaws
of clamp tensioner make contact with both sides of lug
-arrows B- on hose clip.
– Tighten hose clip by turning spindle with torque wrench (take
care to keep pliers straight).
♦ Tightening torque: 20 Nm.
♦ Use torque wrench with 5…50 Nm adjustment range (e.g. -
V.A.G 1331- ).
♦ Make sure thread of spindle on clamp tensioner moves freely.
Lubricate with MoS2 grease if necessary.
♦ If the thread is stiff (e.g. due to dirt), the required clamping
force will not be attained at the hose clip when the specified
tightening torque is applied.

Pressing off outer constant velocity joint

– Clamp drive shaft in vice using protective jaw covers.
– Remove the large hose clip and pull back the rubber boot.
– Screw the spindle - 3207- into the joint pin until the constant
velocity joint can be detached.

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.

Venting joint boot

Only applies to boots made of rubber:
A partial vacuum is sometimes created in the rubber boot during
installation.
This vacuum produces a fold -arrow- when driving.
For this reason, please note the following:
– Before tightening the hose clips, vent the boot to equalise
pressure by briefly lifting the lip.

Installation position of spacer ring and dished spring (outboard

end)
1 - Dished spring
2 - Spacer ring (plastic)

18.3 Dismantling and assembling triple roller joint AAR 2900

18. Servicing drive shafts with triple roller joint AAR 2900 99
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Special tools and workshop

equipment required
♦ Tube - VW 416 B-
♦ Press tool - VW 412-
♦ Tube - VW 426-
♦ Tube - 3110-
♦ Puller - Kukko 12/1-
♦ Press tool - 2050-

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.

100 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Pliers - V.A.G 1275-

♦ Circlip pliers - VW 161 A-
♦ Spindle - 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.

Dismantling
– Knock out cover.

Note

♦ Use the old bolt when knocking out.

♦ When doing so hold the shaft at an angle of approx. 20°.

Use a plastic-headed hammer and tube - 3110- .

18. Servicing drive shafts with triple roller joint AAR 2900 101
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove any swarf in area around cover.

– Release the large hose clip.
– Release small hose clip on shaft and push back boot.

– Mark installation position of components -1- to -3-.

The joint may be noisy if these parts are not
Protected marked
by copyright. andforrein‐
Copying private or commercial purposes, in part or in whole, is not
stalled in their original positions. 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 a waterproof felt-tip pen for marking.
– Take O-ring -arrow- out of groove.
1 - Joint body
2 - Triple roller spider
3 - Drive shaft

– Remove circlip.
1 - Pliers (commercial type)

– Detach triple roller spider from drive shaft. To do so, use puller
- Kukko 12/1- (commercially available).
– Remove grease from groove for O-ring.
– Check rolling element and track for wear.
– Clean shaft and housing.
Assembling
– Push small hose clip for boot onto shaft.
– Slip new boot onto shaft.
– Push joint body onto shaft.
– Push boot onto joint body.

102 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Fitting triple roller spider

– Grease splines -A- on drive shaft lightly with grease used in
joint before fitting joint or triple roller spider onto drive shaft.

The chamfer -arrow- on the spider faces the shaft and facilitates
assembly.
– Fit triple roller spider onto shaft according to markings and
drive home onto stop.
– Install circlip (ensure proper seating).
– Press 70 g of grease - G 000 605- from repair kit into triple
roller joint.
– Push joint body over rollers.

Note

Take care not to twist the boot when doing so.

– Press 70 g of grease - G 000 605- from repair kit into back of

triple roller joint.

– Carefully clean groove -4- for O-ring.

– Insert O-ring -3- in groove -4-.
For ease of illustration, components are shown removed.
1 - Circlip
2 - Cover from repair kit
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - O-ring 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 - Groove in triple roller joint

18. Servicing drive shafts with triple roller joint AAR 2900 103
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Insert drive shaft in press.

– Lightly press on cover -1- from repair kit so you can then fit
circlip from repair kit.
– Insert circlip from repair kit so it fits all round under retaining
lip.

Note

Make sure that circlip engages audibly.

– Position joint body in central position. The correct position is

between “min” and “max” in the illustration.

Note

When setting the joint body to the central position, use a screw‐
driver -arrow- or similar to let air into the boot.

– Fit the hose clip -2-.

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
To facilitate fitting of multi-point socket head bolts when installing
with respect to the correctness of information in this document. Copyright by AUDI AG.
drive shaft, fastener lug -2- on hose clip must be positioned be‐
tween mounting flanges -1- on joint body.

Tightening hose clip on inner joint

104 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Use pliers - V.A.G 1275- to tighten small hose 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

18. Servicing drive shafts with triple roller joint AAR 2900 105
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

19 Servicing drive shafts with triple roller

joint AAR 3300 i
⇒ “19.1 Exploded view”, page 106
⇒ “19.2 Servicing outer constant velocity joint”, page 108
⇒ “19.3 Dismantling and assembling triple roller joint AAR 3300
i”, page 109

19.1 Exploded view

Quantities and type of grease for drive shaft with triple roller joint:
The 98 mm dia. constant velocity joint is filled with grease -
G 000 633- .
The triple roller joint is filled with grease - G 000 605- .
Regrease joint when renewing boot.
Grease of which in:
Outer joint Total quantity Joint Boot
∅ mm [g] [g] [g]
98 120 80 40
Inner joint
130 70 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

106 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Hose clip
❑ Always renew
❑ Tightening ⇒ page 108
❑ Various types of hose
clip are possible de‐
pending on version. Fit‐
ting can also be per‐
formed using the pliers -
3340- , refer to ⇒
Electronic parts cata‐
logue “ETKA” .
2 - Boot for triple roller joint
❑ Greasing ⇒ page 106
3 - Hose clip
❑ Always renew
❑ Tightening ⇒ page 108
4 - Circlip
❑ Refer to ⇒ Electronic
parts catalogue “ETKA”
5 - Dished spring
❑ Installation position
⇒ page 109
6 - Spacer ring (plastic)
❑ Installation position
⇒ page 109
7 - Circlip
❑ Always renew
❑ Fit into annular groove
on shaft before installing
(no longer visible once
jointCopying
Protected by copyright. is installed)
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
8 - Outer
with respect to the constant
correctness ofvelocity
informationjoint
in this document. Copyright by AUDI AG.
❑ Renew only as complete unit
❑ Pressing off ⇒ page 109
❑ Installing:
❑ Drive joint onto shaft with plastic hammer until circlip engages
❑ Greasing ⇒ page 106
❑ Grease splines on drive shaft lightly with grease used in joint when fitting joint onto drive shaft
9 - Hexagon bolt
❑ Always renew after removing
Tightening torques for M16 bolt:
❑ 190 Nm and turn 180° further
Observe instructions for removal ⇒ page 87
Observe instructions for installation ⇒ page 88

10 - Hose clip
❑ Different versions for rubber or Hytrel boot
❑ Renew
❑ Tightening ⇒ page 108
11 - Boot for outer constant velocity joint
❑ Check for splits and chafing

19. Servicing drive shafts with triple roller joint AAR 3300 i 107
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

❑ Greasing ⇒ page 106

❑ Briefly lift boot to equalise pressure before tightening hose clips ⇒ page 109
❑ Different versions (rubber or Hytrel)
12 - Hose clip
❑ Renew
❑ Tightening ⇒ page 108
13 - Drive shaft
❑ Different versions available
❑ Grease must be applied to the splines on the shaft when fitting the outer or inner joint
14 - Circlip
❑ Refer to ⇒ Electronic parts catalogue “ETKA”
15 - Triple roller spider
Chamfer -arrow- faces towards drive shaft splines
❑ Grease splines on drive shaft lightly with grease used in joint when fitting triple roller spider onto drive
shaft.
16 - Circlip
❑ Renew
❑ Insert in groove on shaft
17 - Multi-point socket head bolt
❑ M 10 x 20: 70 Nm
18 - Joint body

19.2 Servicing outer constant velocity joint

Boots made ofbyrubber
Protected copyright.are secured
Copying using
for private plierspurposes,
or commercial - V.A.G 1275-
in part . is not
or in whole,
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Instructions
withapply only
respect to to stainless
the correctness steel inclips.
of information this document. Copyright by AUDI AG.

Tightening hose clip on outer joint

– Apply clamp tensioner - V.A.G 1682- as shown. Ensure jaws
of clamp tensioner make contact with both sides of lug
-arrows B- on hose clip.
– Tighten hose clip by turning spindle with torque wrench (take
care to keep pliers straight).
♦ Tightening torque: 20 Nm.
♦ Use torque wrench with 5...50 Nm range (e.g. -V.A.G 1331- ).
♦ Make sure thread of spindle on clamp tensioner moves freely.
Lubricate with MoS2 grease if necessary.
♦ If the thread is stiff (e.g. due to dirt), the required clamping
force will not be attained at the hose clip when the specified
tightening torque is applied.

108 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Removing outer constant velocity joint from drive shaft

– Clamp drive shaft in vice using protective jaw covers.
– Remove the large hose clip and pull back the rubber boot.
– Apply a copper or brass drift to the inner ring of the constant
velocity joint, and drive off using a hammer.

Venting joint boot

Only applies to boots made of rubber:
A partial vacuum is sometimes created in the rubber boot during
installation.
This vacuum produces a fold -arrow- when driving.
For this reason, please note the following:
– Before tightening the hose clips, vent the boot to equalise
pressure by briefly lifting the lip.

Installation position of spacer ring and dished spring (outboard

end)
1 - Circlip
2 - Dished spring
3 - Spacer ring (plastic)

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.

19.3 Dismantling and assembling triple roller joint AAR 3300 i

19. Servicing drive shafts with triple roller joint AAR 3300 i 109
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Special tools and workshop

equipment required
♦ Thrust plate - VW 401-
♦ Thrust plate - VW 402-
♦ Assembly tool - T10065-
♦ Tube - VW 416 B-
♦ Press tool - VW 411-
♦ Press tool - VW 447 H-

♦ 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.

110 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Disassembly and assembly tool - T40018-

Dismantling
– Clamp the drive shaft horizontally in a vice.

Note

♦ Use protective jaw covers

♦ Take care not to damage drive shaft.

– Mark position of joint body relative to drive shaft.

If the position of the components is not marked and these are not
installed in their previous position on assembly, noise may sub‐
sequently occur whilst driving.
Use a waterproof felt-tip pen for marking.
– Open hose clips -arrows-.
– Push back 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
– Insert the disassembly and assembly
with respect tool - T40018-
to the correctness behind
of information in this document. Copyright by AUDI AG.
the joint body.

Locating pin -1- must lie against outside of joint body.

– Bring the disassembly and assembly tool - T40018- into con‐
tact with the joint element by turning the knurled screw -2-.

Note

♦ The joint body must be fixed in position in the disassembly and

assembly tool - T40018- such that there is no play.
♦ Only hand-tighten the bolts -2-.

19. Servicing drive shafts with triple roller joint AAR 3300 i 111
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Screw the multi-purpose tool - VW 771- into the disassembly

and assembly tool - T40018- .
– Detach the joint element horizontally with the multi-purpose
tool .
Leave the joint element in the disassembly and assembly tool -
T40018- .

– Mark installation position of components -1- and -2- as shown.

The joint may be noisy if these parts are not marked and rein‐
stalled in their original positions.
Use a waterproof felt-tip pen for marking.
1 - Drive shaft
2 - Triple roller spider
– Remove grease with a lint-free cloth.

– Remove circlip.
1 - Pliers (commercial type)

– Press the triple roller star and circlip off the drive shaft.
The assembly tool - T10065/4- must not rest on the rolling ele‐
ment.
– Detach the boot for the triple roller star.
– Check rolling element
Protected and
by copyright. track
Copying for wear.
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
– Clean shaft and housing.
with respect to the correctness of information in this document. Copyright by AUDI AG.

Assembling
– Push small hose clip for boot onto shaft.
– Slip new boot onto shaft.

112 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Press on circlip -1- as far as centre of splines.

– Use the special tools shown in the illustration.

Instead of -T10065/2- for drive shaft with tapered end, use -
T10065/3- for drive shaft with cylindrical (straight) end
⇒ page 113 .

Pressing triple roller star onto drive shaft

– Grease splines -A- on drive shaft lightly with grease used in
joint before fitting joint or triple roller spider onto 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
This description only applies to drive shafts with tapered end
with respect to the correctness of information in this document. Copyright by AUDI AG.

-arrow-.
Chamfer on spider faces towards drive shaft and is used as an
assembly aid.
– Use the special tools shown in the illustration.
Special tool -T10065/2- must not rest on rollers.
– Fit triple roller spider onto shaft according to markings and
drive home onto stop.
– Circlip must engage audibly. Triple roller spider must lie di‐
rectly against circlip (zero gap).

19. Servicing drive shafts with triple roller joint AAR 3300 i 113
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

This description only applies to drive shafts with cylindrical end

-arrow-.
Chamfer on spider faces towards drive shaft and is used as an
assembly aid.
– Use the special tools shown in the illustration.
Special tool -T10065/3- must not rest on rollers.
– Fit triple roller spider onto shaft according to markings and
drive home onto stop.
– Circlip must engage audibly. Triple roller spider must lie di‐
rectly against circlip (zero gap).
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 circlip.
1 - Pliers (commercial type)
– Press 70 g of grease - G 000 605- from the repair set into the
back of the triple roller joint.
– Lightly grease the rollers.
Take care to keep the rolling elements straight.

– Use plastic-headed hammer to drive joint body over triple roller

spider.
– Pack remaining quantity of grease into boot.
– Make sure boot is properly seated on joint body.
– Boot must engage in groove and make contact with contour of
joint body.

– Position joint body in central position. The correct position is

between “min” and “max” in the illustration.

Note

When setting the joint body to the central position, use a screw‐
driver -arrow- or similar to let air into the boot.

114 Rep. gr.40 - Front suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Fit the hose clip -2-.

Note

To facilitate fitting of multi-point socket head bolts when installing

drive shaft, fastener lug -2- on hose clip must be positioned be‐
tween mounting flanges -1- on joint body.

– Use pliers - V.A.G 1275- to tighten small hose 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

19. Servicing drive shafts with triple roller joint AAR 3300 i 115
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

42 – Rear suspension
1 General notes
⇒ “1.1 General information”, page 116
⇒ “1.2 Contact corrosion”, page 116
⇒ “1.3 Repairing threads in longitudinal member”, page 117

1.1 General information

All contact surfaces must be cleaned when installing wax-coated
components. The contact surfaces must be free of wax and
grease.
Tightening torques refer to unoiled bolts and nuts.
Load-bearing components and other suspension parts must not
be welded or straightened.
Do not subject coil springs to hammer blows or weld splashes and
do not make any new paint markings.
Do not perform welding or cutting operations (using power grind‐
ers) near the coil springs or suspension struts. Cover up coil
springs or suspension struts if necessary.
Do not attempt to move the vehicle without the drive shafts fitted;
this would result in wheel bearing damage. If the vehicle does
have to be moved, always note the following points:
– Fit an outer joint in place of the drive shaft.
– Tighten the outer joint to 115 Nm (M14 bolt) or 190 Nm (M16
bolt).
Bonded rubber bushes can only be turned to a limited extent. The
suspension must therefore always be in the unladen position or
the reference position when the suspension link attachments are
tightened.
If the wheel alignment has to be checked and adjusted at a later
stage, all bolts and nuts which need to be slackened to make ad‐
justments should initially only be tightened to the specified torque
figure. After wheel alignment has been checked and adjusted,
bolts and nuts must then be fully tightened by turning them
through the specified angle.

WARNING

All bolts and nuts must be fully tightened according to specifi‐

cations before the vehicle is driven on public roads.

1.2 Contact corrosion

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Contact corrosion can occur if unsuitable
permittedfasteners (bolts,
unless authorised nuts,
by AUDI AG. AUDI AG does not guarantee or accept any liability
washers ...) are used. with respect to the correctness of information in this document. Copyright by AUDI AG.

For this reason, all the fastening components have received a

special surface treatment (Dacromet). These elements can be
recognised by their greenish colour.
In addition, rubber parts, plastic parts and adhesives are made of
non-conductive material.
Always fit new components if you are not sure that the old com‐
ponents can be safely re-installed.

116 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Please note:
Always use genuine parts. These have been tested and are com‐
patible with aluminium.
All accessories must be approved by AUDI AG.
Damage caused by contact corrosion is not covered by the war‐
ranty.

1.3 Repairing threads in longitudinal mem‐

ber
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Under certain circumstances it is possible to repair the unless
permitted threads in by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
the captive nuts in the longitudinal member. with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Each thread can only be repaired once.

♦ If a second repair is needed, the captive nut must be renewed.

WARNING

Always wear safety goggles when drilling.

♦ Have all thread repairs checked by foreman or supervisor.

♦ The thread insert must be of the same length as the thread in
the body.
♦ Repair any damage to the underseal; for the appropriate in‐
formation, refer to the booklet ⇒ Body repairs; Corrosion
protection measures .

1. General notes 117

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

2 Rear axle, mounting bracket, vehicle

level sender (front-wheel drive vehi‐
cles)
⇒ “2.1 Exploded view of rear axle, mounting bracket, vehicle level
sender (front-wheel drive vehicles)”, page 118
⇒ “2.2 Removing and installing rear axle with mounting bracket”,
page 120
⇒ “2.3 Removing and installing mounting bracket”, page 123
⇒ “2.4 Vehicle level sender in vehicles with automatic headlight
range control, front-wheel drive vehicles”, page 127

2.1 Exploded view of rear axle, mounting bracket, vehicle level sender (front-
wheel drive 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.

Note

♦ The subframe is not to be welded and straightened.

♦ Always renew self-locking nuts.
♦ When using a pneumatic/electric screwdriver or similar, bolted connections must only be hand-tightened.

118 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Spring seat
2 - Holder for speed sensor
3 - Speed sensor
❑ Removing and installing
⇒ Rep. gr. 45
❑ Must be renewed if the
wheel bearing unit is re‐
placed
4 - Coil spring
❑ Removing: ⇒ page 131
❑ Surface of spring coil
must not be damaged
❑ Note different spring
versions; see vehicle
data sticker
⇒ page 296
❑ For assignment, refer to
⇒ Electronic parts cata‐
logue “ETKA”
❑ After installation, lower
ends of springs on left
and right should be in
marked area as shown.
❑ -Arrow A- points in the
direction of travel.
❑ -Arrow B- points to the
right.
❑ The lower spring wind‐
ings are gradually being
provided with marks
which must face to the
rear on installation.
5 - Wheel bearing
❑ Servicing ⇒ page 128
❑ The ABS speed sensor must be renewed on replacing the wheel bearing unit ⇒ Rep. gr. 45
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

6 with
- Mounting
respect to thebracket
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
correctness of information in this document. Copyright by AUDI AG.
❑ Following installation, check and if necessary adjust the settings
❑ Take particular care when fitting the bolts
❑ Different versions available
❑ For assignment, refer to ⇒ Electronic parts catalogue “ETKA”
❑ Removing and installing ⇒ page 123
❑ The combined fitting of cast and forged mounting brackets is not permitted.
7 - Hexagon nut
❑ Always renew after removing
8 - Hexagon bolt M 12 x 1.5 x 90
❑ Always renew after removing
❑ 110 Nm and turn 90° further
❑ Thread in body can be repaired using wire thread insert according to DIN 8140 (Helicoil). The thread
insert must be of the same length as the thread in the body.
9 - Stone deflector for mounting bracket
❑ With heavy duty running gear only

2. Rear axle, mounting bracket, vehicle level sender (front-wheel drive vehicles) 119
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

10 - Hexagon bolt, 10 Nm
11 - Hexagon bolt M 12 x 1.5 x 60
❑ Always renew after removing
❑ Take particular care when fitting the bolts
❑ 110 Nm and turn 90° further
❑ Thread in body can be repaired using wire thread insert according to DIN 8140 (Helicoil). The thread
insert must be of the same length as the thread in the body.
12 - Subframe
❑ Wheel bearing/wheel hub contact surfaces and threaded holes must be free of paint and dirt.
❑ Heed the removal and installation instructions for vehicles with automatic headlight range control
⇒ page 127
❑ Following installation, check and if necessary adjust the settings
13 - Hexagon bolt M 14 x 1.5 x 190
❑ 120 Nm and turn 90° further
❑ Always renew after removing
14 - Strap
❑ Installing ⇒ page 126
15 - Thread in longitudinal member
❑ Take particular care when fitting the bolts
❑ Thread in body can be repaired using wire thread insert according to DIN 8140 (Helicoil). The thread
insert must be of the same length as the thread in the body.

Tightening torques:
Shock absorber to rear axle 50 Nm + 90°
Mounting bracket at rear axle 120 Nm + 90°
Mounting bracket to body 110 Nm + 90°

2.2 Removing and installing rear axle with

mounting bracket
Special tools and workshop equipment required
♦ Engine and gearbox jack - V.A.G 1383 A- with universal gear‐
box support - V.A.G 1359/2-

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.

Removing
– The vehicle must be standing on its wheels over a lifting plat‐
form.
– Remove wheel trims, or remove trim caps from wheels (vehi‐
cles with light-alloy wheels).
– Raise the vehicle.
– Remove wheels.

120 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove cover -arrows-.

– Detach the stone deflector for the mounting bracket (heavy
duty running gear only).

Note

Use the engine and gearbox lifter - V.A.G 1383 A- with universal
gearbox support - V.A.G 1359/2- for removing and installing the
subframe.

– Remove bolt -2- (one on the left, one on the right) and lower
the gearbox jack.
– If necessary, have a second mechanic pull the rear axle down‐
wards and remove the coil spring.

– Remove retainer -arrows- for hand brake 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
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove retainer -arrow- for hand brake cable.
– Remove the holder for the speed sensor.

2. Rear axle, mounting bracket, vehicle level sender (front-wheel drive vehicles) 121
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Pull out ABS speed sensor.

– Unclip speed sensor wire from bracket.

– Unclip brake pipe.

Note

For ease of illustration, the picture shows the rear axle without the
wheel bearing unit.

– Remove securing bolts -arrows- for brake calliper housing.

– Remove brake pads.
– Suspend brake calliper from bodywork.
– Remove brake disc.
– Use felt-tip pen to visibly mark contours of mounting bracket
on left and right at longitudinal member.

Note

Use the engine and gearbox lifter - V.A.G 1383 A- with universal
gearbox support - V.A.G 1359/2- for removing and installing the
subframe.

– Remove mounting bracket bolts -arrows- on both sides and

take out rear axle.
Installing
Installation is performed in reverse sequence; note the following:
Tightening torques ⇒ page 118
– Install rear axle in vehicle.
– Align mounting brackets in accordance with felt-tip marks on
longitudinal member.
– Renew all bolts and nuts.
– Tack the bolts. Check and if necessary adjust the vehicle set‐
tings. 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.

122 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Tighten the mounting bracket bolts -arrows-.

– If necessary, have a second mechanic pull the rear axle down‐
wards and install the coil spring. Note installation position
⇒ Item 4 (page 119) .

– Fit bolt attaching damper to rear axle at bottom.

1 - Self-locking nut
2 - Hexagon bolt
3 - Shock absorber
The bolted joint between the damper and rear axle must be tight‐
ened with the vehicle standing on its wheels.
– Tighten the damper at the rear axle.
– Clip brake pipes and ABS wiring back in place again.

– Fit ABS speed sensor -1- (with a new rubber seal) and
Protected push Copying for private or commercial purposes, in part or in whole, is not
by copyright.
in onto stop. 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.
– Locating lug -A- points towards the front on the left-hand side
of the vehicle and towards the rear on the right-hand side.
– Install holder for speed sensor.
– Tighten handbrake cable holders to 10 Nm.
– Fit the brake disc with brake linings and tighten the brake cal‐
liper.
– Fit wheels. ⇒ Wheels and tyres; Rep. gr. 44

2.3 Removing and installing mounting

bracket
Special tools and workshop equipment required

2. Rear axle, mounting bracket, vehicle level sender (front-wheel drive vehicles) 123
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Engine and gearbox jack - V.A.G 1383 A- with universal gear‐

box support - V.A.G 1359/2-

Removing
– The vehicle must be standing on its wheels over a lifting plat‐
form.
– Raise the vehicle.
– Remove cover -arrows-.
– Remove stone deflector for mounting bracket (heavy duty run‐
ning gear only).

Note

Use the engine and gearbox lifter - V.A.G 1383 A- with universal
gearbox support - V.A.G 1359/2- for removing and installing the
mounting bracket.

– Remove bolt -2- (one on the left, one on the right) and lower
the gearbox jack.
– If necessary, have a second mechanic pull the rear axle down‐
wards and remove the coil spring.
– Use felt-tip pen to visibly mark contours of mounting bracket
on left and right at longitudinal member.

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.

124 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– On one side only, remove bolt -arrows- securing mounting

bracket to rear axle.
– Support rear axle.

– Slacken bolts -arrows- for mounting bracket and remove.

Installing
Installation is performed in reverse sequence; note the following:
Tightening torques ⇒ page 118

– Renew all bolts and nuts. Make sure the locating element of
the rubber bush -arrow A- is positioned in the hole of the sub‐
frame -arrow B-.
– Insert bolt for mounting bracket and rear axle and tighten nut
until mounting bracket makes contact with rear axle.
– Position the mounting bracket at the old mark.
– Tack the bolts. Check and if necessary adjust the vehicle set‐
tings.

– Tighten the mounting bracket bolts -arrows-.

– Slacken off the bolt for the mounting bracket and rear axle until
the nutby and
Protected boltCopying
copyright. can be turned
for private by hand.
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 with
bolted joint
respect between
to the correctness the mounting
of information in thisbracket
document. and rear
Copyright by axle must
AUDI AG.
be tightened with the vehicle standing on its wheels.
Otherwise, the bush would be subject to torsion loading and its
service life shortened.
– If necessary, have a second mechanic pull the rear axle down‐
wards and install the coil spring. Note installation position
⇒ Item 4 (page 119) .

2. Rear axle, mounting bracket, vehicle level sender (front-wheel drive vehicles) 125
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Fit bolt attaching damper to rear axle at bottom.

1 - Self-locking nut
2 - Hexagon bolt
3 - Shock absorber
– Fit the retaining strap for the anti-roll bar
.

– Guide in the retaining strap -1- behind the holder at the sub‐
frame -2-.
– Place the retaining strap around the anti-roll bar -3- and fasten
it such that the anti-roll bar shackle makes contact with the
anti-roll bar and holder.

– Press the anti-roll bar approx. 6 mm towards the subframe

-a- and compress the retaining strap as far as possible in the
lock.
– Relieve load on anti-roll bar.
The bolted joint between the damper and rear axle must be tight‐
ened with the vehicle standing on its wheels.

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.

126 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

2.4 Vehicle level sender in vehicles with au‐

tomatic headlight range control, front-
wheel drive vehicles
For the mode of operation and additional repair instructions, refer
to ⇒ page 69 .
1 - Hexagon bolt
2 - Rear left vehicle level sender - G76-
- Is tested electrically via self-diagnosis
- In the case of complaints ⇒ Electrical system; Rep. gr. 01 ; Self-
diagnosis of automatic headlight range control
- Do not pull coupling rod from ball head!
3 - Self-locking nut, 10 Nm
- Always renew after removing
4 - Rear 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.

2. Rear axle, mounting bracket, vehicle level sender (front-wheel drive vehicles) 127
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

3 Wheel bearing (front-wheel drive)

⇒ “3.1 Exploded view of wheel bearing (front-wheel drive)”, page
128
⇒ “3.2 Removing and installing wheel bearing/wheel hub unit”,
page 128

3.1 Exploded view of wheel bearing (front-

wheel drive)
Wheel bearing and wheel hub are combined in one housing.
This wheel bearing/hub unit is maintenance-free and has zero
play. There is no provision for adjustment or repair.

1 - Self-locking bolt, 35 Nm
❑ Renew
❑ Counter-hold guide pin
when loosening and
tightening
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Brake calliper 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 - Hexagon socket head bolt
❑ 60 Nm
4 - Brake disc
5 - Hexagon socket head bolt
❑ 60 Nm
6 - Wheel bearing/wheel hub
unit
❑ The ABS speed sensor
must be renewed on re‐
placing the wheel bear‐
ing unit ⇒ Rep. gr. 45
7 - splash plate
8 - Subframe
9 - Speed sensor
❑ Removing and installing
⇒ Rep. gr. 45
❑ Must be renewed if the
wheel bearing unit is re‐
placed.
❑ Always replace the O-
ring and coat with lubri‐
cating paste -
G 000 650-
10 - Holder for speed sensor

3.2 Removing and installing wheel bearing/

wheel hub unit
Special tools and workshop equipment required

128 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Removal lever - 80-200-

Removing
– The vehicle must be standing on its wheels over a lifting plat‐
form.
– Remove wheel trims, or remove trim caps from wheels (vehi‐
cles with light-alloy wheels).
– Raise the vehicle.
– Remove wheels.
– Remove securing bolts -arrows- for brake calliper housing.
– Remove brake pads.
– Suspend brake calliper from bodywork.
– Remove brake disc.
– Remove the holder for the speed sensor.

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.

– Pull out ABS speed sensor.

3. Wheel bearing (front-wheel drive) 129

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Screw out the bolts -arrows- for the wheel bearing/wheel hub
unit.
– Remove wheel bearing/wheel hub unit with cover plate for
brake disc.
Installing
Installation is performed in reverse sequence; note the following:
Tightening torques ⇒ page 128
– Wheel bearing/wheel hub contact surfaces and threaded
holes must be free of paint and dirt.
– Tighten the wheel hub unit and splash plate at the rear axle.
– Replace thebyABS
Protected speed
copyright. sensor
Copying ⇒or Rep.
for private gr. purposes,
commercial 45 . 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.
– Insert new ABS speed sensor -1- as far as it will go.
– Locating lug -A- points towards the front on the left-hand side
of the vehicle and towards the rear on the right-hand side.
– Install holder for speed sensor.
– Fit brake disc with brake pads and tighten brake calliper to 35
Nm.
– Fit wheel and tighten. ⇒ Wheels and tyres; Rep. gr. 44

130 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

4 Shock absorber/spring (front-wheel

drive vehicles)
⇒ “4.1 Removing and installing shock absorber/spring”,
page 131
⇒ “4.2 Servicing shock absorber (front-wheel drive vehicles)”,
page 132

4.1 Removing and installing shock absorb‐

er/spring
Special tools and workshop equipment required
♦ Engine and gearbox jack - V.A.G 1383 A- with universal gear‐
box support - V.A.G 1359/2-

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.
Removing

Note

Use the engine and gearbox lifter - V.A.G 1383 A- with universal
gearbox support - V.A.G 1359/2- for removing and installing the
springs and shock absorbers.

– Remove wheel.
– Raise vehicle to installation height, thus relieving the load on
the coil spring.
– Remove bolt -2- (one on the left, one on the right) and lower
the gearbox jack.
– If necessary, have a second mechanic pull the rear axle down‐
wards and remove the coil spring.
– Remove bolts -1- and take out shock absorber.
Installing
Installation is performed in reverse sequence; note the following:
– Renew all bolts and nuts.
– Insert the shock absorber in the body and secure in position
⇒ Item 7 (page 132) .
– If necessary, have a second mechanic pull the rear axle down‐
wards and install the coil spring. Note correct installation po‐
sition ⇒ Item 4 (page 119)

4. Shock absorber/spring (front-wheel drive vehicles) 131

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Fit bolt attaching damper to rear axle at bottom.

1 - Self-locking nut
2 - Hexagon bolt
3 - Shock absorber
The bolted joint between the damper and rear axle must be tight‐
ened with the vehicle standing on its wheels.
– Tighten the shock absorber at the rear axle
⇒ Item 3 (page 132) .

4.2 Servicing shock absorber (front-wheel drive vehicles)

1 - Gas-filled shock absorber

❑ Can be replaced individ‐
ually
❑ Heed the different shock
absorber versions; refer
to vehicle data sticker
⇒ page 296
❑ For correct version refer
to ⇒ Electronic parts
catalogue “ETKA”
❑ Disposal ⇒ Special In‐
formation Running gear
No. 2
❑ Checking shock absorb‐
er for leakage and noise
⇒ Special information,
Running gear no. 17
❑ Defective shock absorb‐
ers must always be dis‐
posed of properly
2 - Hexagon nut
❑ Always renew after re‐
moving
3 - Hexagon bolt M 10 x by
Protected 90copyright. 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 renewwith after re‐to the correctness of information in this document. Copyright by AUDI AG.
respect
moving
❑ Only tighten with vehicle
standing on its wheels
❑ 50 Nm and turn 90° fur‐
ther
4 - Protective cap
❑ Press to stop
5 - Protective tube
6 - Stop buffer
7 - Hexagon bolt, 45 Nm
8 - Shock absorber mounting
9 - Self-locking hexagon nut, 25 Nm
❑ Loosening and tightening ⇒ page 133
❑ Always renew after removing

132 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

10 - Assembly cap
❑ For factory assembly only; not required when performing repairs
11 - Threads in wheel housing

Special tools and work‐

shop equipment re‐
quired
♦ Counterhold tool -
3079-

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
Loosening and tighten‐ with respect to the correctness of information in this document. Copyright by AUDI AG.

ing nut on shock absorb‐

er mounting
– Unscrew the assem‐
bly cap
⇒ Item 10
(page 133) .

4. Shock absorber/spring (front-wheel drive vehicles) 133

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

5 Rear axle (four-wheel drive vehicles)

⇒ “5.1 Exploded view of rear axle (four-wheel drive vehicles)”,
page 134
⇒ “5.2 Removing and installing subframe”, page 136
⇒ “5.3 Aligning subframe with vehicle”, page 140
⇒ “5.4 Replacing bonded rubber bushes for subframe (steel)”,
page 140
⇒ “5.5 Replacing bonded rubber bushes for subframe (alumini‐
um)”, page 144

5.1 Exploded view of rear axle (four-wheel drive vehicles)

Before performing repair work at the rear axle of the Audi allroad,
the vehicle height must be deactivated at normal level
⇒ page 304 .

Note

Always renew self-locking bolts/nuts.

1 - Hexagon bolt M 8 x 22
2 - Anti-roll bar
3 - Hose clip
4 - Self-locking nut
❑ 25 Nm
❑ Always renew after re‐
moving
5 - Hexagon bolt M 10 x 50
6 - Coupling rod
❑ Installation position:
Bend faces outwards
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
7 - Self-locking nut 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.
❑ 50 Nm
❑ Always renew after re‐
moving
8 - Threads in wheel housing
❑ Servicing ⇒ page 11
9 - Hexagon bolt
❑ 45 Nm
10 - Suspension strut
❑ Note different spring
versions; see vehicle
data sticker
⇒ page 296
❑ Dismantling and assem‐
bling ⇒ page 155
11 - Self-locking nut
❑ 70 Nm + turn +90° fur‐
ther

134 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

❑ Always renew after re‐

moving
12 - Washer
13 - Upper link
14 - Washer
15 - Self-locking nut
❑ Always renew after removing
16 - Hexagon bolt M 12 x 1.5 x 95
❑ Always renew after removing
17 - Hexagon bolt M 12 x 1.5 x 95
❑ 70 Nm + turn +90° further
❑ Always renew after removing
18 - Hexagon bolt
❑ 55 Nm
19 - Self-locking nut
❑ 100 Nm
❑ Always renew after removing
20 - Eccentric washer
21 - Wheel bearing housing
❑ Steel version ⇒ page 160
❑ Aluminium version ⇒ page 182
❑ The aluminium version is fitted with a packing plate between the wheel bearing housing and coupling
rod
22 - Eccentric bolt
23 - Lower wishbone
❑ Heed the removal and installation instructions for vehicles with automatic headlight range control
⇒ page 179
24 - Eccentric 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
25 - Track rod with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ The bonded rubber bushes are not available as replacement parts

❑ Different versions possible. Refer to ⇒ Electronic parts catalogue “ETKA”
26 - Hexagon bolt
❑ Heed the different tightening torques:
❑ For steel wheel bearing housing and RS 6: 90 Nm
❑ For aluminium wheel bearing housing: 110 Nm
27 - Washer
28 - Self-locking nut
❑ Always renew after removing
❑ The aluminium wheel bearing housing is fitted with a threaded plate
29 - Self-locking nut
❑ 100 Nm
❑ Always renew after removing
30 - Eccentric washer
31 - Hexagon bolt M 12 x 1.5 x 100
❑ 70 Nm + turn +90° further
❑ Always renew after removing

5. Rear axle (four-wheel drive vehicles) 135

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

32 - Self-locking nut
❑ 70 Nm + turn +90° further
❑ Always renew after removing
33 - Self-locking nut
❑ Always renew after removing
34 - Self-locking nut
❑ 95 Nm
❑ Always renew after removing
35 - Hexagon bolt M 12 x 1.5 x 80
❑ 95 Nm
36 - Subframe
❑ Replacing bonded rubber bush with steel subframe ⇒ page 140
❑ Replacing bonded rubber bush with aluminium subframe ⇒ page 144
❑ Heed the removal and installation instructions for vehicles with automatic headlight range control
⇒ page 179
❑ Pay attention to the spacers for the allroad ⇒ page 197
37 - Hexagon 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
❑ Always renew after toremoving
with respect the correctness of information in this document. Copyright by AUDI AG.

38 - Hexagon bolt
❑ Always renew after removing

Tightening torques:
Subframe to body 110 Nm + 90°
Use new bolts
Damper to link 70 Nm + 90°
Use new bolts
Brake calliper to holder 30 Nm
Use new bolts
Propshaft to final drive 55 Nm
Use new bolts
Use thread cutter to re-cut thread in final drive
flange

5.2 Removing and installing subframe

Removing
– Remove wheels.
– Unplug connector behind catalytic converter and remove rear
part of exhaust system.
– To avoid subsequent damage to the constant velocity joint,
always tie the propshaft in position with binding wire -arrows-
or similar.

136 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Mark installation position before removing propshaft -arrows-. If

installation is not correct the imbalance becomes too great.

– Detach handbrake cables from brake calliper.

– Loosen bolt -A- on both sides.

– Unhook handbrake cables -B- out of retainer -C-.

– Press locking lugs -A- together and push handbrake cables

-2- out of wishbone -1-.

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 axle (four-wheel drive vehicles) 137

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Whilst providing support at the guide pin, unscrew the bolts

-arrows- from the brake calliper housing.

– Unbolt speed sensor wiring -2-.

1 - Securing pin
3 - Attachment point at subframe
– Unclip the speed sensor wire at the subframe.
– Pull the ABS speed sensor out of the wheel bearing housing.
– Heed the removal and installation instructions for vehicles with
automatic headlight range control ⇒ page 179 .

– Remove transverse link from damper.

1 - Suspension link
2 - Handbrake cable
3 - Shock absorber bolt
A - Handbrake cable retaining 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

138 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Position engine and gearbox jack - V.A.G 1383 A- with uni‐

versal gearbox support - V.A.G 1359/2- under final drive.
– Remove bolts for subframe.
– Slowly lower the subframe with the engine and gearbox lifter
- V.A.G 1383 A- .
Installing
Installation is performed in reverse sequence; note the following:

Note

♦ Thread in body can be repaired using wire thread insert ac‐

cording to DIN 8140 (Helicoil). The thread insert must be of
the same length as the thread in the body.
♦ Bonded rubber bushes can only be turned to a limited extent.
The bolt connection should therefore only be tightened when
the vehicle is standing
Protected on theforground.
by copyright. 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.
– Align the subframe with the vehicle ⇒ page 140 .
Otherwise, the bush would be subject to torsion loading and its
service life shortened.
– Tighten the subframe bolts -1-.

All versions except Allroad

The arrows on the aluminium shims of the bonded rubber bushes
must face opposite the direction of travel as illustrated.

5. Rear axle (four-wheel drive vehicles) 139

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Allroad
The arrows on the aluminium shim -3- of the front bonded rubber
bush must face in the direction of travel as illustrated. The arrows
on the aluminium shim -4- of the rear bonded rubber bush must
face opposite the direction of travel as illustrated.
Pay attention to the spacers for the allroad ⇒ page 197

5.3 Aligning subframe with vehicle

Lateral alignment of subframe
– Determine the distance between the subframe and longitudi‐
nal member. The gap -a- should be equal on the right and left.

Longitudinal alignment of subframe

– Measure the dimension -a-.
Dimension -a-: 504 ± 2 mm
– Tighten theby subframe
Protected bolts
copyright. Copying ⇒ page
for private 12 . purposes, in part or in whole, is not
or commercial
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
After installation, check
with respect to position
the correctness of steering
of information wheel by
in this document. test-driving
Copyright by AUDI AG.
vehicle.
Wheel alignment must be checked and adjusted if steering wheel
is not in central position.

5.4 Replacing bonded rubber bushes for subframe (steel)

140 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Special tools and workshop

equipment required
♦ Thrust plate - VW 402-
♦ Assembly tool - 3291-
♦ Assembly tool - 3346-
♦ Removal tool - 3372-
♦ Press tool - 3354/1-

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.

The bonded rubber bushes can only be removed and installed

with the subframe lowered.
Removing and installing subframe ⇒ page 136
Other than the anti-roll bar, no components need be detached
from the subframe.
Mark the installation position of the bonded rubber bushes on the
subframe.
To enable the new bonded rubber bushes and aluminium shims
to be re-installed in the correct position, the installation position
must be marked before extracting the defective bonded rubber
bushes.
– Use a felt-tip pen for example to mark the installation position
of the aluminium shim.
– Use a screwdriver to prise the aluminium shim off the bonded
rubber bush.
– Use a felt-tip pen for example to mark the semi-circular recess
-arrow- on the subframe.

5. Rear axle (four-wheel drive vehicles) 141

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Extracting bonded rubber bush

– Attach tools as shown in illustration.
– Pull out bonded rubber bush by turning spindle.

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.

Installing bonded rubber bush

The front and rear bonded rubber bushes are not identical. Pay
attention to the correct assignment on installation ⇒ Electronic
parts catalogue “ETKA”

Note

Attention must therefore be paid to the correct assignment and

installation position when fitting.

– The bonded rubber bush must be inserted such that the recess
-arrow- is facing the mark previously made at the subframe.

– Then fit the bonded rubber bush and the special tools in posi‐
tion.
Use lubricant - G 294 421 A1- for example when pressing in the
bonded rubber bushes.
When fitting, take care to keep the bonded rubber bush straight
as otherwise the outer race could be damaged.

142 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Insert the bonded rubber bush until the chamfer -arrows- is

located in front of the subframe mounting hole.
– Now check that the chamfer of the outer ring is positioned
evenly. Correct installation position again if necessary.
– Then slowly finish fitting the bonded rubber bush. A second
mechanic is required to guide the tools and the bonded rubber
bush during the fitting process.

All versions except Allroad

The arrows on the aluminium shims -2- and -3- of the bonded
rubber bushes must face opposite the direction of travel as illus‐
trated.

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.

Allroad
The arrows on the aluminium shim -3- of the front bonded rubber
bush must face in the direction of travel as illustrated. The arrows
on the aluminium shim -4- of the rear bonded rubber bush must
face opposite the direction of travel as illustrated.
Pay attention to the spacers for the allroad ⇒ page 197

5. Rear axle (four-wheel drive vehicles) 143

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

5.5 Replacing bonded rubber bushes for

subframe (aluminium)
Special tools and workshop equipment required
♦ Engine and gearbox jack - V.A.G 1383 A- with universal gear‐
box support - V.A.G 1359/2-

♦ 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.

♦ Torque wrench - V.A.G 1332-

♦ Foot pump with high-pressure hose - V.A.G 1389 A/1-

144 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ If there is a hand pump - V.A.G 1389/1- available in the deal‐

ership it can be converted to a foot-operated pump. To do this,
use the conversion set - V.A.G 1389/4- .
♦ Hydraulic wheel bearing tool - V.A.G 1459 B-

♦ Hollow piston
Protected cylinder
by copyright. - HKZ-15-
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 with
toolrespect
- E-0-204-T-
to the correctness of information in this document. Copyright by AUDI AG.

♦ Press tool - E-5-

♦ Drift sleeve - 40-21-
♦ -T40033/1- from assembly tool
♦ -T40033/3- from assembly tool
♦ -T40033/4- from assembly tool
♦ -T40033/7- from assembly tool
♦ -T40033/8- from assembly tool
♦ Spindle - VAS 6031-
♦ Nut - VAS 6033-
♦ Nut - VAS 6034-

Note

♦ The bonded rubber bushes can only be removed and installed

with the subframe lowered.
♦ If a front bonded rubber bush is to be replaced, only slacken
off the front subframe bolts.
♦ If a rear bonded rubber bush is to be replaced, only slacken
off the rear subframe bolts.
♦ If a further subframe bolt is loosened (front or rear), wheel
alignment must be performed following installation.
♦ Mark the installation position of the bonded rubber bushes and
the aluminium shims on the subframe.

– Loosen front or rear subframe bolts.

– Only remove those subframe bolts where the hydro-bush is to
be renewed.

5. Rear axle (four-wheel drive vehicles) 145

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Carefully lower the subframe by approx. 5 cm using the engine

and gearbox lifter - V.A.G 1383 A- .
– Use a felt-tip pen for example to mark the installation position
of the aluminium shim.
– Use a screwdriver to prise the aluminium shim off the bonded
rubber bush.

– Use a felt-tip pen for example to mark the semi-circular recess

-arrow- on the subframe.

Extracting front bonded rubber bush

– Apply special tools as shown in illustration.
1 - Nut - VAS 6033-
2 - Support ring - T40033/8-
3 - Tube - T40033/3-
4 - Mounting - T40033/4-
5 - Hollow piston cylinder - HKZ-15-
6 - Press tool - T40033/1-
7 - Nut - VAS 6034-
8 - Spindle - VAS 6031-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
9 - Subframe 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.
– Take up play in special tools.
– Extract bonded rubber bush by actuating pump.

Note

The tool has to be re-applied when extracting the bonded rubber

bush with the hydraulic wheel bearing removal and installation
tool - V.A.G 1459 B- .

Fitting front bonded rubber bush

The front and rear bonded rubber bushes are not identical. Pay
attention to the correct assignment on installation ⇒ Electronic
parts catalogue “ETKA” .
The bonded rubber bush and the aluminium shim must be fitted
in the correct direction ⇒ page 149 or ⇒ page 150 .

146 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Using the special tools, align the bonded rubber bush with the
mark previously made as shown and insert in the subframe.
1 - Nut - VAS 6033-
2 - Press tool - T40033/7-
3 - Bonded rubber bush
4 - Press tool - T40033/1-
5 - Hollow piston cylinder - HKZ-15-
6 - Press tool - E-5-
7 - Nut - VAS 6034-
8 - Spindle - VAS 6031-
9 - Subframe
– Take up play in special tools.
– Then check whether the bonded rubber bush makes uniform
contact. Correct installation position again if necessary.
– The tools and the bonded rubber bush must be guided during
the fitting process.
– Completely
Protected byfit the bonded
copyright. Copying forrubber
private orbush by means
commercial ofpart
purposes, in pump ac‐ is not
or in whole,
tion.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

♦ At the start of the fitting process, take care to keep the bonded
rubber bush straight as otherwise the outer race could be
damaged.
♦ The tool has to be re-applied when fitting the bonded rubber
bush with the hydraulic wheel bearing removal and installation
tool - V.A.G 1459 B- .

– Lift subframe with engine and gearbox jack - V.A.G 1383 A- .

– Tighten the subframe bolts. ⇒ page 134
Use new bolts.
Removing rear bonded rubber bush
– Unplug the connector from the vehicle level sender (left side
only).

5. Rear axle (four-wheel drive vehicles) 147

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Apply special tools as shown in illustration.

1 - Nut - VAS 6033-
2 - Support ring - T40033/8-
3 - Tube - T40033/3-
4 - Mounting - T40033/4-
5 - Press tool - E-5-
6 - Drift sleeve - 40-21-
7 - Hollow piston cylinder - HKZ-15-
8 - Nut - VAS 6034-
9 - Spindle - VAS 6031-
10 - Subframe
– Take up play in special tools.
– Extract bonded rubber bush by actuating pump.

Note

The tool has to be re-applied when extracting the bonded rubber

bush with the hydraulic wheel bearing removal and installation
tool - V.A.G 1459 B- .

Fitting rear bonded rubber bush

The front and rear bonded rubber bushes are not identical. Pay
attention to the correct assignment on installation ⇒ Electronic
parts catalogue “ETKA” .
The bonded rubber bush and the aluminium shim must be fitted
in the correct direction ⇒ page 149 or ⇒ page 150 .

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.

148 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Using the special tools, align the bonded rubber bush with the
mark previously made as shown and insert in the subframe.
1 - Nut - VAS 6033-
2 - Press tool - T40033/7-
3 - Bonded rubber bush
4 - Press tool - E-5-
5 - Drift sleeve - 40-21-
6 - Hollow piston cylinder - HKZ-15-
7 - Nut - VAS 6034-
8 - Spindle - VAS 6031-
9 - Subframe
– Take up play in special tools.
– Then check whether the bonded rubber bush makes uniform
contact. Correct installation position again if necessary.
– The tools and the bonded rubber bush must be guided during
the fitting process.
– Install bonded rubber bush as far as stop by actuating pump.

Note

♦ At the start of the fitting process, take care to keep the bonded
rubber bush straight as otherwise the outer race could be
damaged.
♦ The tool has to be re-applied when fitting the bonded rubber
bush with the hydraulic wheel bearing removal and installation
tool - V.A.G 1459 B- . 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

♦ Plug in the connector of the vehicle level sender .

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

♦ Lift subframe with engine and gearbox jack - V.A.G 1383 A- .

♦ Tighten the subframe bolts. ⇒ page 134
♦ Use new bolts.

All versions except Allroad

The arrows on the aluminium shims of the bonded rubber bushes
must face opposite the direction of travel as illustrated.

5. Rear axle (four-wheel drive vehicles) 149

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Allroad
The arrows on the aluminium shim -3- of the front bonded rubber
bush must face in the direction of travel as illustrated. The arrows
on the aluminium shim -4- of the rear bonded rubber bush must
face opposite the direction of travel as illustrated.
Pay attention to the spacers for the allroad ⇒ page 197

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.

150 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

6 Subframe, final drive (four-wheel

drive vehicles)
⇒ “6.1 Exploded view of subframe, final drive (four-wheel drive
vehicles)”, page 151
⇒ “6.2 Pressing out/pressing in bonded rubber bush for cross
member”, page 152
⇒ “6.3 Pressing out/pressing in bonded rubber bush for gearbox
support”, page 153

6.1 Exploded view of subframe, final drive (four-wheel drive vehicles)

1 - Subframe
❑ Aligning subframe with
vehicle ⇒ page 140
2 - Bonded rubber bush
❑ Replacing bonded rub‐
ber bush with steel sub‐
frame ⇒ page 140
❑ Replacing bonded rub‐
ber bush with aluminium
subframe ⇒ page 144
3 - Hexagon bolt M 10 x 75
4 - Hexagon socket head bolt
M10 x 45, 55 Nm
5 - Nut, 40 Nm
6 - Washer
7 - Hexagon socket head bolt
M10 x 25, 40 Nm
8 - Gearbox support
❑ Replacing bonded rub‐
ber bush ⇒ page 153
9 - Final drive
❑ Servicing ⇒ 5-speed
manual gearbox 01A;
Rep. gr. 39 ; Servicing
rear final drive
10 - Cross member
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
❑ Marking bonded rubber
with respect to the correctness of information in this document. Copyright by AUDI AG.
bush ⇒ page 152
❑ Pressing out bonded
rubber bush
⇒ page 152
❑ Pressing in bonded rub‐
ber bush ⇒ page 152

6. Subframe, final drive (four-wheel drive vehicles) 151

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

6.2 Pressing out/pressing in bonded rubber

bush for cross member
Marking installation position of bonded rubber bush in cross mem‐
ber
– Mark installation position -arrows- with for example a felt tip
pen.

Pressing bonded rubber bush out of cross member

Pressing bonded rubber bush into cross member

– Position the bonded rubber bush such that one of the rubber
studs -1- is opposite the mark -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.

152 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

6.3 Pressing out/pressing in bonded rubber

bush for gearbox support
Marking installation position of bonded rubber bush in gearbox
support
– Use a felt-tip pen for example to mark the installation position
on the gearbox support -arrow A-.

Pressing bonded rubber bush out of gearbox 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.

Pressing bonded rubber bush into gearbox support

– Position the bonded rubber bush such that one of the rubber
studs -arrow B- is opposite the mark -arrow A-.

6. Subframe, final drive (four-wheel drive vehicles) 153

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

7 Shock absorber/spring (four-wheel

drive vehicles)
⇒ “7.1 Removing and installing shock absorber/spring”,
page 154
⇒ “7.2 Dismantling and assembling suspension strut”,
page 155
⇒ “7.3 Retrofitting dust sleeve for shock absorber piston rod.”,
page 158

7.1 Removing and installing shock absorb‐

er/spring
Removing
– Remove wheel.
– Unscrew bolts from brake calliper housing. Provide support at
the guide pin whilst doing so.

– Remove clamp -3- for anti-roll bar -2-.

1 - Subframe
4 - Eccentric bolt

– Remove coupling rod -1- from anti-roll bar.

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.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove bolt -2- for wishbone -1-.

– Unscrew hexagon bolts -arrows- for shock absorber to body.

– Unscrew bolt -3- for shock absorber to wishbone -1- and re‐
move shock absorber.
– Pull wheel bearing housing down slightly to remove shock ab‐
sorber.
Installing
Install in reverse order of removal.
– Bonded rubber bushes can only be turned to a limited extent.
The bolt connection should therefore only be tightened when
the vehicle is standing on the ground.
Otherwise, the bush would be subject to torsion loading
Protected andCopying
by copyright. its for private or commercial purposes, in part or in whole, is not
service life shortened. 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.
Tightening torques:
Anti-roll bar clamp to subframe 25 Nm
Coupling rod to anti-roll bar 50 Nm
Transverse link to wheel bearing housing 70 Nm + 90°
Shock absorber to body 45 Nm
Damper to link 70 Nm + 90°
Use new bolts
Brake calliper to holder 30 Nm
Use new bolts

7.2 Dismantling and assembling suspension strut

7. Shock absorber/spring (four-wheel drive vehicles) 155

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Protective cap
Pre-assembled on shock ab‐
sorber

2 - Rubber insert
Pre-assembled on shock ab‐
sorber

3 - Spring seat
4 - Spacer ring
The spacer is only fitted on
shock absorbers from the
manufacturer “Bilstein”.
It must not be attached to the
shock absorbers of other man‐
ufacturers. 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 - Gas-filled shock absorber
with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Can be replaced individ‐

ually
❑ For correct version refer
to ⇒ Electronic parts
catalogue “ETKA”
❑ Disposal ⇒ Special In‐
formation Running gear
No. 2
❑ Checking shock absorb‐
er for leakage and noise
⇒ Special information,
Running gear no. 17
Functional check

– Compress shock ab‐

sorber by hand. It
should be possible to
press in the piston rod smoothly and with uniform force over the full travel.

If there is sufficient shock absorber gas pressure, the piston rod returns to its initial position.

If the piston rod does not return to its initial position, the shock absorber may still be OK provided that there is
no loss of oil.

6 - Coil spring
❑ Note different coil spring versions; see vehicle data sticker ⇒ page 296
❑ Check for paint damage, repair paint damage if necessary
❑ For correct version refer to ⇒ Electronic parts catalogue “ETKA”
❑ After installation, the ends of the spring should lie against the stops of the rubber inserts.
7 - Spring pad with protective tube.
Made up of two sections

8 - Stop buffer
9 - Shock absorber mounting
10 - Self-locking hexagon nut, 27 Nm
❑ Always renew after removing

Special tools and workshop equipment required

156 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Tensioning device - V.A.G 1752-

♦ Shock absorber wrench - 3017 A-

Dismantling
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Insert -V.A.G
permitted 1752/1-byinto
unless authorised AUDIcoil spring.
AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

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

- V.A.G 1752/7- -arrow-.
– Pre-tension the coil spring with the tensioning device -
V.A.G 1752/1- until the shock absorber mount is free at the
top.
– Use the shock absorber wrench - 3017 A- to unscrew the hex‐
agon nut from the piston rod.
– Detach the coil spring and individual components from the
shock absorber.

7. Shock absorber/spring (four-wheel drive vehicles) 157

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Assembling
Installation is carried out in reverse sequence.
The start of the spring at the top and bottom must make contact
with the stop of the spring seat -arrow-.
The illustration shows the lower end of the spring. This must face
the centre of the vehicle.

Fitting location of shock absorber mounting

The axis of the mounting pins -1- must be aligned with the axis
-2- of the shock absorber bush -4- at the bottom.
The mounting pins -1- face the outside of the vehicle.
3 - Shock absorber mounting

7.3 Retrofitting dust sleeve for shock ab‐

sorber piston rod.
– Remove the shock absorber/spring ⇒ page 154 .
– Dismantle the suspension strut ⇒ page 155 .
– Detach upper spring plate with spring seat and protective tube
from shock absorber.
– Separate spring seat with protective tube -1- from upper spring
plate -2-.
– Shorten removed spring seat -1- at bottom by dimension -A-
using a knife, as shown in illustration.

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
Dimension -A- approx. 50 millimetres. with respect to the correctness of information in this document. Copyright by AUDI AG.

Shortened spring seat -2-

158 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Route piston rod sleeve -1- from below through shortened

spring seat -2-.

– Align piston rod sleeve -1- symmetrical to spring seat -2- by

rotating it.
In the correct position the embossed arrow -1- on the piston rod
sleeve points to the notch -2- in the spring 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
– Insert
withspring
respect toseat together
the correctness with piston
of information in thisrod sleeve
document. -1- into
Copyright spring
by AUDI AG.
plate -2-.
– Mount spring seat on spring, inserting piston rod sleeve into
spring when doing so.
– Mount spring with spring plate on shock absorber and piston
rod.
– Assemble suspension strut. ⇒ page 155
– Install shock absorber/spring. ⇒ page 154

7. Shock absorber/spring (four-wheel drive vehicles) 159

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

8 Wheel bearing housing (steel), upper

link, lower link, vehicle level sender ,
coupling rod for anti-roll bar (four-
wheel drive vehicles)
⇒ “8.1 Exploded view of wheel bearing housing (steel), upper link,
lower link, vehicle level sender , coupling rod for anti-roll bar (four-
wheel drive vehicles)”, page 160
⇒ “8.2 Removing and installing wheel bearing housing”,
page 162
⇒ “8.3 Pressing rear wheel bearing out and in with wheel bearing
housing removed”, page 164
⇒ “8.4 Pressing rear wheel bearing out and in with wheel bearing
housing fitted”, page 168
⇒ “8.5 Removing and installing bonded rubber bush for wheel
bearing housing”, page 171
⇒ “8.6 Removing and installing upper suspension link”,
page 173
⇒ “8.7 Renewing bonded rubber bush for upper link”, page 174
⇒ “8.8 Removing and installing lower wishbone”, page 175
⇒ “8.9 Servicing lower link”, page 177
⇒ “8.10 Vehicle level sender
Protected in vehicles
by copyright. Copyingwith automatic
for private headlight
or commercial purposes, in part or in whole, is not
range control”, pagepermitted
179 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.
⇒ “8.11 Removing and installing coupling rod for anti-roll bar”,
page 180

8.1 Exploded view of wheel bearing housing (steel), upper link, lower link, ve‐
hicle level sender , coupling rod for anti-roll bar (four-wheel drive vehicles)

Note

If vehicles on which the drive shaft has been removed need to be moved, an outer joint must first be fitted in
place of the drive shaft and tightened to 115 Nm (M14 bolt) or 190 Nm (M16 bolt) so as not to damage the
wheel bearing.

160 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Brake calliper
❑ Servicing ⇒ Rep. gr. 47
2 - Bonded rubber bush
❑ Removing and installing
⇒ page 171
3 - Wheel bearing
❑ ∅ 75 mm
❑ ∅ 82 mm
❑ Pressing out
⇒ page 167
❑ Pressing in
⇒ page 167
❑ Removing and installing
with wheel bearing
housing installed Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ page 168 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 - Wheel bearing housing
5 - Brake disc
❑ Repair instructions ⇒
Rep. gr. 46
6 - Hexagon bolt
❑ Always renew after re‐
moving
Vehicle must be standing on
the ground when tightening

Tightening torque for M14 bolt:

❑ 115 Nm and turn 180°
further
Tightening torque for M16 bolt:
❑ 190 Nm and turn 180°
further
7 - Hexagon bolt, 10 Nm
8 - Wheel hub
❑ Pressing out ⇒ page 166
❑ Pulling off inner race ⇒ page 167
❑ Pressing in ⇒ page 168
❑ Removing and installing with wheel bearing housing installed ⇒ page 168
9 - Eccentric bolt
10 - Eccentric washer
11 - Self-locking nut
❑ Tightening torque: 100 Nm
❑ Always renew after removing
12 - Hexagon bolt, 55 Nm
13 - Coupling rod
Installation position: Bend faces outwards

14 - Hexagon bolt M 12 x 1.5 x 95

❑ 70 Nm + turn +90° further
❑ Always renew after removing

8. Wheel bearing housing (steel), upper link, lower link, vehicle level sender , coupling rod for anti-roll bar (four-wheel drive

vehicles) 161
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

15 - Lower wishbone
❑ Removing and installing ⇒ page 175
16 - Front bonded rubber bush for lower link
Pressing out is extremely difficult, and in some cases not possible at all.

It is therefore advisable to replace the entire link if the bonded rubber bush is defective.

17 - Rear bonded rubber bush for lower link

❑ Removing and installing ⇒ page 179
18 - Drive shaft
❑ Removing and installing ⇒ page 198
❑ Servicing drive shaft with constant velocity joint ⇒ page 200
❑ Servicing allroad drive shaft ⇒ page 206
19 - Front bonded rubber bush for upper link
❑ Removing and installing ⇒ page 174
❑ New bearing without kidney
❑ Refer to information on ⇒ page 175
20 - Multi-point socket head bolt
Tightening torques:

Bolt M8×48: 40 Nm

Bolt M10×48: 70 Nm

21 - Lock plate
22 - Upper link
23 - Washer
24 - Self-locking nut
❑ Always renew after removing
25 - Rear bonded rubber bush for upper link
❑ Pressing out and in ⇒ page 174
❑ New bearing without kidney
❑ Refer to information on ⇒ page 175
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
26 - Hexagon socket head bolt permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

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

❑ Underside of bolt is ribbed

❑ Always use this special bolt for replacement purposes.

8.2 Removing and installing wheel bearing

housing
Removing
– Screw out the drive shaft hexagon bolt ⇒ page 198 .
– Remove wheels.

162 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove securing bolts -1- from brake calliper.

– Take off brake calliper and tie up on body.
– Remove brake disc.
– Remove cover plate bolts.
– Detach splash plate.
– Pull the ABS speed sensor out of the wheel bearing housing.

– Remove bolt -1- for coupling rod.

– Remove bolt -A- for track rod.

– Mark installation position of eccentric washer for bolt -B-.
– Remove bolt -B-.

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. Wheel bearing housing (steel), upper link, lower link, vehicle level sender , coupling rod for anti-roll bar (four-wheel drive

vehicles) 163
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove bolt -2- for suspension link -1-.

– Pull wheel bearing housing off drive shaft.
Installing
Installation is carried out in reverse sequence.
– Bonded rubber bushes can only be turned to a limited extent.
The bolt connection should therefore only be tightened when
the vehicle is standing on the ground.
Otherwise, the bush would be subject to torsion loading and its
service life shortened.
– When fitting the drive shaft pay attention to the instructions
⇒ page 199 .
After installation, check position of steering wheel by test-driving
vehicle.
Wheel alignment must be checked and adjusted if steering wheel
is not in central position.
Tightening torques:
Drive shaft to wheel hub ⇒ page 199
Use new bolt
Track rod to wheel bearing 95 Nm
housing
Transverse link to wheel 70 Nm + 90°
bearing housing
Wheel bearing housing to 95 Nm
lower link
Coupling rod to wheel bear‐ 55 Nm
ing housing
Cover plate to transverse 10 Nm
link
Brake calliper to wheel 95 Nm
bearing housing
Damper to link 70 Nm + 90°
Use new bolts

8.3 Pressing rear wheel bearing out and in with wheel bearing housing removed

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.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Special tools and workshop

equipment required
♦ Thrust plate - VW 401-
♦ Thrust plate - VW 402-
♦ Press tool - VW 412-
♦ Tube - VW 416 B-
♦ Assembly tool - 3253/1-
♦ Splitter 3 - Kukko 15-2- or -
Kukko 17-2-

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.

8. Wheel bearing housing (steel), upper link, lower link, vehicle level sender , coupling rod for anti-roll bar (four-wheel drive

vehicles) 165
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Press tool - VW 407-

♦ Thrust plate - 3005-
♦ Wheel bearing tube - 3345-

Press out wheel 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.

166 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Press out wheel bearing

Inserting parting tool

– Insert the parting tool in the annular groove of the bearing inner
race -arrow- and pre-tension with the spindle.
Use commercially available puller, e.g. splitter - Kukko 15-2- or -
Kukko 17-2- .

Pressing inner bearing race off wheel 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 wheel bearing into wheel bearing housing

– If necessary, remove corrosion and dirt from bore in wheel
bearing housing.
– Press in wheel bearing as far as stop.

8. Wheel bearing housing (steel), upper link, lower link, vehicle level sender , coupling rod for anti-roll bar (four-wheel drive

vehicles) 167
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Pressing in wheel hub

– Press in wheel hub as far as stop.

8.4 Pressing rear wheel bearing out and in

with wheel bearing housing fitted
Special tools and workshop equipment required
♦ Engine and gearbox jack - V.A.G 1383 A- with universal gear‐
box support - V.A.G 1359/2-

♦ Foot pump with high-pressure hose - V.A.G 1389 A/1-

♦ If there is a hand pump - V.A.G 1389/1- available in the deal‐

ership it can be converted to a foot-operated pump.
♦ To do this, use the conversion set - V.A.G 1389/3- 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.

168 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Hydraulic wheel bearing tool - V.A.G 1459 B-

♦ Hollow piston cylinder - HKZ-15-

♦ Press tool - E-0-204-T-
♦ Pull rod - E-0-217-
♦ Pull rod - E-0-218-
♦ Special nut - E-8-214-
♦ Press tool - E-5-
♦ Supplementary set - V.A.G 1459 B/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.

♦ Splitter - Kukko 15-2- or -Kukko 17-2-

♦ Support - E-40-
♦ Press tool - E-43-
♦ Thrust sleeve - E-44-1-
♦ Press tool - E-45-
– Screw out the drive shaft hexagon bolt ⇒ page 198 .
– Remove wheel and raise vehicle.
– Pull out retaining clip -1- and unhook handbrake cables at
brake calliper.
Do not damage rubber boot for handbrake cable when removing
and installing.
– Remove brake carrier with brake callipers and attach to body
with wire.
– Remove brake disc and splash plate.
– Pull the ABS speed sensor out of the wheel bearing housing.

8. Wheel bearing housing (steel), upper link, lower link, vehicle level sender , coupling rod for anti-roll bar (four-wheel drive

vehicles) 169
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove bolt -2- for suspension link -1-.

– Pull wheel bearing housing from drive shaft and swivel out‐
wards.
Place engine/gearbox jack - V.A.G 1383 A- underneath (danger
of accident from parts dropping out when wheel hub and wheel
bearing are pulled out).

Pulling out wheel hub

– Fit separating device -1- between wheel bearing housing and
hub and pretension.
Installation position: Flat sides of plates face to wheel hub.
– Fit the bell -2-, the hollow piston cylinder -3- with tensioning
bolt and the special nut -4-.
– Hold appliance firmly and pull out wheel hub.
1 - Splitter - Kukko 15-2- or Kukko 17-2
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Bell E-40
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 - Hollow piston cylinder - HKZ-15-
4 - Special nut - E-8-214- and tensioning bolt

Pulling out wheel bearing

– Fit the thrust piece -1- (with collar facing bearing), the thrust
sleeve -2- (with the four stepped inside diameters facing wheel
bearing housing), the hollow piston cylinder -3- with tensioning
bolt and the special nut -4-.
– Pull out wheel bearing by actuating pump.
1 - Press tool - E-5-
2 - Thrust sleeve - E-44-1-
3 - Hollow piston cylinder - HKZ-15-
4 - Special nut - E-8-214- and tensioning bolt

Pulling inner bearing race off hub

– Fit separating device -1- behind inner bearing race -2-.
Installation position: Chamfer on plates faces to inner bearing
race.
– Fit the bell -3- and hollow piston cylinder -4- with tensioning
bolt in position, screw on with the special nut -5- and detach
the bearing inner race.
1 - Splitter - Kukko 15-2- or -Kukko 17-2-
2 - Inner bearing race
3 - Support - E-40-
4 - Hollow piston cylinder - HKZ-15-
5 - Special nut - E-8-214- and tensioning bolt

170 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Pressing in wheel bearing

Installation position: The larger internal diameter of the wheel
bearing faces outwards.
– Place the wheel bearing -1-, the thrust piece -2- (insert collar
in bearing) and the hollow piston cylinder -3- with tensioning
bolt in position at the wheel bearing housing.
– Fit the thrust piece -4- with the bevels facing the wheel bearing
housing and the special nut -5- from inside.
– Press in wheel bearing by actuating pump.
1 - Wheel bearing
2 - Thrust piece - E-45- for ∅ 75 mm wheel bearing or thrust piece
- E-14-1- for ∅ 82 mm wheel bearing
3 - Hollow piston cylinder - HKZ-15-
4 - Press tool - E-43-
5 - Special nut - E-8-214- and tensioning bolt

Pressing in wheel hub

– Place the wheel hub -1- and hollow piston cylinder -2- with
tensioning bolt in position at the wheel bearing.
– Fit the thrust piece -3- from inside with the collar facing the
special nut -4-.
– Press in wheel hub by actuating pump.
1 - Wheel hub
2 - Hollow piston cylinder - HKZ-15-
3 - Press tool - E-5-
4 - Special nut - E-8-214- and tensioning bolt
Perform remaining installation in reverse order of removal.

8.5 Removing and installing bonded rubber bush for 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.

8. Wheel bearing housing (steel), upper link, lower link, vehicle level sender , coupling rod for anti-roll bar (four-wheel drive

vehicles) 171
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Special tools and workshop

equipment required
♦ Press tool - VW 412-
♦ Tube - VW 519-
♦ Thrust plate - VW 401-
♦ Press tool - 3292/3-
♦ Press tool - 3292/4-
♦ Assembly tool - 3292-
♦ Puller - 3349-
♦ Assembly tool - 3293-

Removing
The bonded rubber bush in the wheel bearing housing is of 2-part
design. Removing and installing is therefore undertaken in two
operations.
Pressing out first section of bonded rubber bush
– Fold over the metal collar of the bonded rubber bush slightly.
– Apply the parting tool - 3292- and tighten with the spindle. In
doing so, the edges of the tool must be applied exactly be‐
tween the collar of the bonded rubber bush and the wheel
bearing housing.
– Insert the pin - 3293/1- .

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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.

172 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Then apply the extractor - 3349- such that the edges are posi‐
tioned exactly between the bonded rubber bush and the wheel
bearing housing.
– Turn the spindle -2- until the bonded rubber bush is lifted
slightly off the wheel bearing housing.
– Now tighten bolts -1-.

– Fit the bridge - 3292/2- in position.

– Press out one of the two bonded rubber bushes by turning the
hexagon bolt -1-.

Pressing out second section of bonded rubber bush

– Insert the thrust piece - 3349/1- and the spindle from -3292- .
– Pull out bonded rubber bush by turning spindle.
During extraction make sure the edges of the tool make full con‐
tact with the collar of the 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.

Installing bonded rubber bush in wheel bearing housing

The bonded rubber bushes are installed in one operation.
– Fit the two bonded rubber bushes in position together with the
thrust piece - 3292/3- .
– Fit the bonded rubber bushes by turning the spindle.

8.6 Removing and installing upper suspen‐

sion link
Removing
– Remove wheel.
– Screw out the hexagon bolts for the link at the subframe.

8. Wheel bearing housing (steel), upper link, lower link, vehicle level sender , coupling rod for anti-roll bar (four-wheel drive

vehicles) 173
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove hexagon bolt -2- and take out wishbone-1-.

Installing
Installation is carried out in reverse sequence.
– Bonded rubber bushes can only be turned to a limited extent.
The bolt connection should therefore only be tightened when
the vehicle is standing on the ground.
Otherwise, the bush would be subject to torsion loading and its
service life shortened.
Tightening torques:
Wishbone to subframe 95 Nm
Transverse link to wheel bearing housing 70 Nm + 90°

8.7 Renewing bonded rubber bush for upper link

Special tools and workshop

equipment required
♦ Press tool - VW 412-
♦ Tube - VW 415 A-
♦ Press tool - 3292/4-
♦ Tube - VW 418 A-
♦ Mounting rails - VW 457-

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.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Pressing out bonded rubber bush

The bonded rubber bushes supplied as replacement parts have
no kidney-shaped recess.
For this reason, the bonded rubber bushes must always be re‐
placed in pairs on both sides.

Pressing in bonded rubber bush

8.8 Removing and installing lower wishbone

Removing
– Remove wheel.
– Unbolt speed sensor wiring -2-.
1 - Securing pin
3 - Attachment point at 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.

8. Wheel bearing housing (steel), upper link, lower link, vehicle level sender , coupling rod for anti-roll bar (four-wheel drive

vehicles) 175
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove hexagon bolt -E-.

A - Hexagon bolt
B - Handbrake cable
C - Bracket for handbrake cable
D - Suspension link
– Heed the removal and installation instructions for vehicles with
automatic headlight range control ⇒ page 179 .

– Squeeze the retainer tabs -A- in -arrow direction- and slide the
handbrake cables -2- out of the link -1-.
1 - Suspension link
2 - Handbrake cable
3 - Shock absorber bolt
A - Handbrake cable retaining clip

– Remove bolt -A- for track rod.

– Mark installation position of eccentric washer for bolt -B-.
– Remove bolt -B-.
Installing
Installation is carried out in reverse sequence.
– Bonded rubber bushes can only be turned to a limited extent.
The bolt connection should therefore only be tightened when
the vehicle is standing on the ground.
Otherwise, the bush would be subject to torsion loading and its
service life shortened.
After installation, check position of steering
Protected bywheel by
copyright. test-driving
Copying for private or commercial purposes, in part or in whole, is not
vehicle. 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.
Wheel alignment must be checked and adjusted if steering wheel
is not in central position.
– Adjust handbrake ⇒ Rep. gr. 46 .
Tightening torques:
Link to subframe 70 Nm + 90°
Use new bolts
Transverse link to wheel bearing housing 95 Nm
Damper to link 70 Nm + 90°
Use new bolts

176 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

8.9 Servicing lower link

Note

♦ Load-bearing components or parts of the suspension must not be welded or straightened.

♦ Always renew self-locking nuts.
♦ Always renew corroded nuts/bolts.

1 - Rear bonded rubber bush

❑ Pressing out
⇒ page 178
❑ Pressing in
⇒ page 179
2 - Suspension link
3 - Bonded rubber bush
Pressing out is extremely diffi‐
cult, and in some cases not
possible at all.

It is therefore advisable to re‐

place the entire link if the bon‐
ded rubber bush is defective.

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. Wheel bearing housing (steel), upper link, lower link, vehicle level sender , coupling rod for anti-roll bar (four-wheel drive

vehicles) 177
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Special tools and workshop

equipment required
♦ Thrust plate - VW 401-
♦ Thrust plate - VW 402-
♦ Press tool - VW 412-
♦ Tube - 3296-
♦ Assembly tool - 3253/1-
♦ Assembly tool - VW 284-

Pressing out bonded rubber bush

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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.

178 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Pressing in bonded rubber bush

8.10 Vehicle level sender in vehicles with automatic headlight range control
For vehicles with four-wheel drive
For the mode of operation and additional repair instructions on
this subject, refer to ⇒ page 69 .

1 - Vehicle level senders - G76-

❑ Is tested electrically via
self-diagnosis
❑ In the event of prob‐
lems, refer to ⇒ Electri‐
cal system; Rep. gr. 01 ;
Self-diagnosis of auto‐
matic headlight range
control system
2 - Coupling rod of rear left ve‐
hicle level senderProtected
- G76- by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Do not pullpermitted
coupling rod
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
from ball head!
with respect to the correctness of information in this document. Copyright by AUDI AG.

3 - Retainer
4 - Self-locking nut, 10 Nm
❑ Always renew after re‐
moving
5 - Subframe
6 - Retainer

8. Wheel bearing housing (steel), upper link, lower link, vehicle level sender , coupling rod for anti-roll bar (four-wheel drive

vehicles) 179
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

8.11 Removing and installing coupling rod for

anti-roll bar
Removing
– Remove wheel.
– Remove securing bolts -1- from brake calliper.

– Detach coupling rod from anti-roll bar.

1 - Coupling rod

– Remove clamp -3- for anti-roll bar -2-.

1 - Subframe
4 - Eccentric bolt

– Screw out the shock absorber bolt -3- at the lower link.
1 - Suspension link
2 - Handbrake cable
3 - Shock absorber bolt
A - Handbrake cable retaining clip
– Pull wheel bearing housing with lower transverse link down‐
wards.

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.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Now insert a punch -1- or similar through the hole for the shock
absorber bush.
– Remove lower hexagon bolt for coupling rod.
Installing
Installation is carried out in reverse sequence.
Tightening torques:
Damper to link 70 Nm + 90°
Use new bolts
Coupling rod to wheel bearing housing 55 Nm
Coupling rod to anti-roll bar 50 Nm
Anti-roll bar clamp to subframe 25byNm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised AUDI AG. AUDI AG does not guarantee or accept any liability
Brake calliper to wheel bearing housing 95 Nm
with respect to the correctness of information in this document. Copyright by AUDI AG.

8. Wheel bearing housing (steel), upper link, lower link, vehicle level sender , coupling rod for anti-roll bar (four-wheel drive

vehicles) 181
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

9 Servicing wheel bearing housing

(aluminium), wheel bearing unit, cou‐
pling rod and link (four-wheel drive
vehicles)
⇒ “9.1 Exploded view of wheel bearing housing (aluminium),
wheel bearing unit, coupling rod and link (four-wheel drive vehi‐
cles)”, page 182
⇒ “9.2 Removing and installing bonded rubber bush for wheel
bearing housing (aluminium)”, page 185
⇒ “9.3 Removing and installing wheel bearing unit”, page 187
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “9.4 Removing and installing wheel
permitted bearingbyhousing”,
unless authorised AUDI AG. AUDI AG does not guarantee or accept any liability
page 191 with respect to the correctness of information in this document. Copyright by AUDI AG.

⇒ “9.5 Removing and installing coupling rod (plastic) for anti-roll

bar”, page 193

9.1 Exploded view of wheel bearing housing (aluminium), wheel bearing unit,
coupling rod and link (four-wheel drive vehicles)

Note

If vehicles on which the drive shaft has been removed need to be moved, an outer joint must first be fitted in
place of the drive shaft and tightened to 115 Nm (M14 bolt) or 190 Nm (M16 bolt) so as not to damage the
wheel bearing.

182 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Brake calliper
❑ Servicing ⇒ Rep. gr. 47
2 - Bonded rubber bush
❑ Removing and installing
⇒ page 185
3 - Wheel bearing housing
4 - Countersunk bolts (4x), 80
Nm and turn 90° further
❑ Always replace screws
5 - 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
6 - Self-locking nut, 95
with respect to theNm
correctness of information in this document. Copyright by AUDI AG.
❑ Always renew after re‐
moving
7 - Eccentric washer
8 - Eccentric bolt
9 - Brake disc
❑ Repair instructions ⇒
Rep. gr. 47
10 - Hexagon bolt
❑ Always renew after re‐
moving
The vehicle must be standing
on the ground when tightening

Tightening torque for M14 bolt:

❑ 115 Nm and turn 180°
further
Tightening torque for M16 bolt:
❑ 190 Nm and turn 180°
further
11 - Wheel hub
12 - Angular contact ball bearing
❑ Pressing out (75 mm ∅) ⇒ page 32
❑ Pressing out ∅ 82 ⇒ page 32
❑ Pressing in (75 mm ∅) ⇒ page 191
❑ Pressing in (82 mm ∅) ⇒ page 191
❑ Pressing off inner race ⇒ page 190
❑ Removing and installing with wheel bearing housing installed ⇒ page 168
13 - Heat shield
14 - Lower wishbone
15 - Front bonded rubber bush for lower link
Pressing out is extremely difficult, and in some cases not possible at all.

It is therefore advisable to replace the entire link if the bonded rubber bush is defective.

16 - Rear bonded rubber bush for lower link

❑ Removing and installing ⇒ page 179

9. Servicing wheel bearing housing (aluminium), wheel bearing unit, coupling rod and link (four-wheel drive vehicles) 183
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

17 - Hexagon bolt, 55 Nm
18 - Drive shaft
❑ Removing and installing ⇒ page 198
❑ Servicing drive shaft with constant velocity joint ⇒ page 200
❑ Servicing allroad drive shaft ⇒ page 206
19 - Front bonded rubber bush for upper link
❑ Removing and installing ⇒ page 174
❑ New bearing without kidney
❑ Refer to information on ⇒ page 175
20 - Lock plate
21 - Multi-point socket head bolt
Tightening torques:

Bolt M8×48: 40 Nm

Bolt M10×48: 70 Nm

22 - Upper link
23 - Rear bonded rubber bush for upper link
❑ Pressing out and in ⇒ page 174
❑ New bearing without kidney
❑ Refer to information on ⇒ page 175
24 - Hexagon bolt M 12 x 1.5 x 95
❑ 70 Nm + turn +90° further
❑ Always renew after removing
25 - Washer
26 - Self-locking nut
❑ Always renew after removing
27 - Coupling rod
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
28 - Combi bolt with ribbed
permitted unless washer
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ 70 Nm + turn +90° further
with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Always use this special bolt for replacement purposes.

184 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

9.2 Removing and installing bonded rubber bush for wheel bearing housing
(aluminium)

Special tools and workshop

equipment required
♦ Puller 2 - Kukko 18/0-
♦ Splitter 3 - Kukko 15/1-
♦ Splitter 3 - Kukko 17/1-
♦ Puller - 3349-
♦ Assembly tool - 3292-
♦ Assembly tool - 3292/3-
♦ Assembly tool - 3293/1-
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
The bonded rubber bush in the wheel bearing housing is of 2-part
design. Removing and installing is therefore undertaken in two
operations.
Pressing out first section of bonded rubber bush
– Fold over the metal collar of the bonded rubber bush slightly.

9. Servicing wheel bearing housing (aluminium), wheel bearing unit, coupling rod and link (four-wheel drive vehicles) 185
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Apply the assembly tool - 3292- and tighten with the spindle.
In doing so, the edges of the tool must be applied exactly be‐
tween the collar of the bonded rubber bush and the wheel
bearing housing.
– Insert the pin - 3293/1- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Then apply the extractor - 3349-
permittedsuch that thebyedges
unless authorised AUDI AG. are
AUDIposi‐
AG does not guarantee or accept any liability
tioned exactly between the bonded rubber
with respect bush and
to the correctness the wheel
of information in this document. Copyright by AUDI AG.
bearing housing.
– Turn the spindle -2- until the bonded rubber bush is lifted
slightly off the wheel bearing housing.
– Now tighten bolts -1-.

– Fit the bridge - 3292/2- in position.

– Press out one of the two bonded rubber bushes by turning the
hexagon bolt -1-.
Pressing out second section of bonded rubber bush

– Insert the thrust piece - 3349/1- and the spindle from -3292- .
– Pull out bonded rubber bush by turning spindle.
During extraction make sure the edges of the tool make full con‐
tact with the collar of the bonded rubber bush.
Installing bonded rubber bush in wheel bearing housing
The bonded rubber bushes are installed in one operation.

186 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Fit the two bonded rubber bushes in position together with the
assembly tool - 3292/3- .
– Fit the bonded rubber bushes by turning the spindle.

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.

9.3 Removing and installing wheel bearing unit

Special tools and workshop

equipment required
♦ Thrust plate - VW 401-
♦ Thrust plate - VW 402-
♦ Tube - VW 416 B-
♦ Press tool - VW 412-
♦ Tube - VW 519-
♦ Press tool - VW 407-

9. Servicing wheel bearing housing (aluminium), wheel bearing unit, coupling rod and link (four-wheel drive vehicles) 187
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Splitter 3 - Kukko 15-2- or -Kukko 17-2-

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

Removing
– Screw out the drive shaft hexagon bolt ⇒ page 198 .
– Remove wheels.
The drive shaft must be removed on vehicles with outer joint di‐
ameter ∅ 98 mm.
– Remove heat shield for drive shaft -arrows-.
– Unbolt drive shaft from drive flange.

– Unscrew the hexagon socket head bolt -1-.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
– Pull ABS speed sensor -2- out of wheel bearing housing.
with respect to the correctness of information in this document. Copyright by AUDI AG.

188 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unfasten the exhaust system at the rear and attach it to the

body ⇒ Rep. gr. 26 .
– Compress the wheel bearing housing with the engine and
gearbox lifter - V.A.G 1383 A- .
– Knock drive shaft out of hub using a plastic hammer if neces‐
sary.
– Take out drive shaft.

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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.
– Remove securing bolts -1- from brake calliper.
– Take off brake calliper and tie up on body.
– Remove brake disc.

– Unscrew the cap screws -1- and -2-.

– Detach the wheel bearing unit outwards.

– Detach splash plate.

9. Servicing wheel bearing housing (aluminium), wheel bearing unit, coupling rod and link (four-wheel drive vehicles) 189
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Pressing wheel hub out of 75 mm ∅ wheel bearing

Pressing wheel hub out of 82 mm ∅ wheel bearing

Pressing inner bearing race off wheel hub

– Insert the splitter in the annular groove of the bearing inner
race -arrow- and pre-tension with the spindle.

Note

Use commercially available splitter , e.g. -Kukko 15-2- or -Kuk‐

ko 17-2- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Press inner bearing race off wheel hub. 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.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Pressing wheel hub into 75 mm ∅ wheel bearing

Pressing wheel hub into 82 mm ∅ wheel bearing

– When pressing in, the thrust piece - VW 511- must only bear
against the inner race.
Installing
Install in reverse order of removal.
– When fitting the drive shaft pay attention to the instructions
⇒ page 199 .
Tightening torques:
Drive shaft to wheel hub M14 115 Nm +180°
Use new bolt
Drive shaft to wheel hub M16 190 Nm +180°
Use new bolt
Drive shaft to drive flange M8 40 Nm
Drive shaft to drive flange M10 70 Nm
Bolts for heat shield 25 Nm
Brake calliper to hub carrier 70 Nm + 90°
Wheel bearing unit to hub carrier 80 Nm + 90°

9.4 Removing and installing wheel bearing

housing
Removing
– Screw out the drive shaft hexagon bolt ⇒ page 198 .
– Remove wheels.
– Remove securing bolts -1- from brake calliper.
– Take off brake calliper and tie up on body.
– Remove brake disc.

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.

9. Servicing wheel bearing housing (aluminium), wheel bearing unit, coupling rod and link (four-wheel drive vehicles) 191
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unscrew the hexagon socket head bolt -1-.

– Pull ABS speed sensor -2- out of wheel bearing housing.

– Remove bolt -1- for coupling rod.

– Remove bolt -A- for track rod.

– Mark installation position of eccentric washer for bolt -B-.
– Remove bolt -B-.

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.

192 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove bolt -2- for suspension link -1-.

– Pull wheel bearing housing off drive shaft.
Installing
Installation is carried out in reverse sequence.
– Bonded rubber bushes can only be turned to a limited extent.
The bolt connection should therefore only be tightened when
the vehicle is standing on the ground.
Otherwise, the bush would be subject to torsion loading and its
service life shortened.
– When fitting the drive shaft pay attention to the instructions
⇒ page 199 .
After installation, check position of steering wheel by test-driving
vehicle.
Wheel alignment must be checked and adjusted if steering wheel
is not in central position.
Tightening torques:
Drive shaft to wheel hub M14 115 Nm +180°
Use new 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
Drive shaft to wheel hub M16 190with
Nm +180°
respect to the correctness of information in this document. Copyright by AUDI AG.

Use new bolt

Track rod to wheel bearing housing 110 Nm
Upper transverse link to wheel bearing 70 Nm + 90°
housing
Wheel bearing housing to lower link 95 Nm
Coupling rod to wheel bearing housing 55 Nm
Coupling rod to anti-roll bar 50 Nm
Brake calliper to wheel bearing hous‐ 70 Nm + 90°
ing
Damper to link 70 Nm + 90
Use new bolts

9.5 Removing and installing coupling rod

(plastic) for anti-roll bar
Removing
– Remove wheel.
– Remove securing bolts -1- from brake calliper.

9. Servicing wheel bearing housing (aluminium), wheel bearing unit, coupling rod and link (four-wheel drive vehicles) 193
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Detach coupling rod from anti-roll bar.

1 - Coupling rod

– Remove clamp -3- for anti-roll bar -2-.

1 - Subframe
4 - Eccentric bolt

– Screw out the shock absorber bolt -3- at the lower link.
1 - Suspension link
2 - Handbrake cable
3 - Shock absorber bolt
A - Handbrake cable retaining clip
– Pull wheel bearing housing with lower transverse link down‐
wards.

– Now insert a punch -1- or similar through the hole for the shock
absorber bush.
– Remove lower hexagon bolt for coupling rod.
Installing
Installation is carried out in reverse sequence.
Tightening torques:
Damper to link 70 Nm + 90°
Use new bolts
Coupling rod to wheel bearing housing 55 Nm
Coupling rod to anti-roll bar 50 Nm
Anti-roll bar clamp to subframe 25 Nm
Brake calliper to wheel bearing housing 70 Nm + 90°

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.

194 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

10 Lightweight wheel hub

⇒ “10.1 Servicing lightweight wheel hub”, page 195

10.1 Servicing lightweight wheel hub

Special tools and workshop equipment required
♦ Press tool - VW 473-

♦ Assembly tool - T40089/1-

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.

♦ Thrust plate - VW 401-

Distinguishing features
The lightweight wheel hub can be distinguished from the conven‐
tional wheel hub by the deflector ring -1- and the sleeve -2-.
The lightweight wheel hub is only to be used in conjunction with
the corresponding wheel bearing, refer to ⇒ Electronic parts
catalogue “ETKA” .
The lightweight wheel hub is only to be used on vehicles fitted
with this at the factory.

10. Lightweight wheel hub 195

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Removing/fitting deflector
– Carefully prise off old deflector ring -1- using a screwdriver.
– Fit new deflector ring on wheel hub.

– Apply special tools as shown in illustration.

1- Press tool - VW 473-
2- Assembly tool - T40089/1-
3 -Protected
Deflector ring
by copyright. Copying for private or commercial purposes, in part or in whole, is not
4 -permitted
Wheel hub
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- Thrust plate - VW 401-
– Press on deflector ring as far as radius on wheel hub using
assembly tool - T40089/1- as illustrated.

Note

The deflector ring must be pressed on until it is seated against

the radius on the wheel hub.

196 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

11 Stone deflector, spacers

⇒ “11.1 Removing and installing stone deflector”, page 197
⇒ “11.2 Spacers - allroad”, page 197

11.1 Removing and installing stone deflector

Removing
The stone deflector is fitted on the Audi allroad and where appli‐
cable on the Audi A6 with heavy duty running gear as of Model
Year 2002.
– Remove bolts -2-.
Tightening torque: 10 Nm
Installing
Install in reverse order of removal.

11.2 Spacers - allroad

Spacers are fitted between the subframe and body at the rear axle
of the allroad.
With a height of 23.5 mm at the front in the direction of travel
-1-.
With a height of 25 mm at the rear in the direction of travel -2-.
They are eccentric.
– When removing mark the installation position of the spacer
plates.
When fitting the spacer -2-, take care to cover the rubber bead of
the subframe bush. The longer projection is opposite the direction
of travel.
Note the different bolt types!
The arrows at the front bush -3- face in the direction of travel.
The arrows at the rear bush -4- face opposite the direction of
travel.
Tightening torque of bolt with washer -5-: 110 Nm and turn 90°
further.
Use a new 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.

11. Stone deflector, spacers 197

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

12 Drive shaft
⇒ “12.1 Removing and installing drive shafts”, page 198

12.1 Removing and installing drive shafts

Special tools and workshop equipment required
♦ Engine and gearbox jack - V.A.G 1383 A-

Do not attempt to move the vehicle without the drive shafts fitted;
this would result in wheel bearing damage. If the vehicle does
have to be moved, always note the following points:
– Fit an outer joint in place of the drive shaft.
– Tighten the outer joint to 115 Nm (M14 bolt) or 190 Nm (M16
bolt).
Removing
– Loosen the flange bolt -arrow- only 90°, otherwise the wheel
bearing will be damaged.

WARNING

The vehicle must be standing on its wheels when loosening

and tightening the flange bolt.
-Accident risk-

– Remove 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
– Use all wheel bolts to secure the brake disc. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unscrew flange bolt.

– Remove heat shield for drive shaft -arrows-.
– Unbolt drive shaft from drive flange.

198 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unscrew the hexagon socket head bolt -1-.

– Pull ABS speed sensor -2- out of wheel bearing housing.
– Detach the exhaust system at the rear ⇒ Rep. gr. 26 .

– Compress the wheel bearing housing with the engine and

gearbox lifter - V.A.G 1383 A- .
– Unfasten the rear final drive / cross member bolted joint and
turn the final drive slightly ⇒ Rep. gr. 39 .
– Knock drive shaft out of hub using a plastic hammer if neces‐
sary.
– Take out drive shaft.
Installing
Install in reverse order of removal.
Notes on assembly
The vehicle must not be in contact with the ground when tighten‐
ing the outer joint of the drive shaft.
A second mechanic is required for the next operation.
– 1. Mechanic: Gets into vehicle and presses foot brake
– 2. Mechanic: Tightens hexagon bolt for drive shaft
M14 hexagon bolt: 115 Nm
M16 hexagon bolt: 190 Nm
– Fit wheel. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Tighten hexagon bolttofor
the drive shaft.
correctness Only tighten
of information when Copyright
in this document. vehicleby AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect
is standing on wheels -danger of accident-.
– Turn hexagon bolt +180° further.
Tightening torques:
Drive shaft to wheel hub M14 115 Nm +180°
Use new bolt
Drive shaft to wheel hub M16 190 Nm +180°
Use new bolt
Drive shaft to drive flange M 8 40 Nm
Drive shaft to drive flange M10 70 Nm
Bolts for heat shield 25 Nm

12. Drive shaft 199

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

13 Servicing drive shaft with constant

velocity joint
⇒ “13.1 Exploded view of drive shaft with constant velocity joint”,
page 200
⇒ “13.2 Servicing drive shaft with constant velocity joint”,
page 203

13.1 Exploded view of drive shaft with con‐

stant velocity joint
Quantities and type of grease:
Constant velocity joints are filled with grease - G 000 603- .
Regrease joint when renewing boot.
Grease of which in:
Outer joint Total quantity Joint Boot
∅ mm [g] [g] [g]
89 90 40 50
Inner joint
100 80 Apply grease through ball
108 120 tracks

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.

200 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Outer constant velocity joint

❑ Renew only as com‐
plete unit
❑ Removing ⇒ page 204
❑ Installing: Drive home
on the shaft with a plas‐
tic-headed hammer until
the circlip engages in
the annular groove of
the constant velocity
joint.
❑ Heed different version
of thrust washer
⇒ Item 15 (page 202) ⇒
Electronic parts cata‐
logue “ETKA”
❑ Greasing ⇒ page 200
❑ Grease splines on drive
shaft lightly with grease
used in joint when fitting
joint onto drive shaft
2 - Hexagon bolt
❑ Always renew after re‐
moving
Tightening torques for M14
bolt:
❑ 115 Nm and turn 180°
further
Tightening torques for M16
bolt:
❑ 190 Nm and turn 180°
further
❑ Removing ⇒ page 198
❑ Installing ⇒ page 199
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Boot permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Check for splits and chafing with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Greasing ⇒ page 200

4 - Hose clip
❑ Renew
5 - Multi-point socket head bolt
❑ M 8 x 48: 40 Nm
❑ M 10 x 48: 70 Nm
6 - Lock plate
7 - Boot for inner constant velocity joint
❑ Check for splits and chafing
❑ Drive off with drift
❑ Before attaching to constant velocity joint, apply sealant - D 454 300 A2- to sealing surface
❑ Greasing ⇒ page 200
8 - Circlip
❑ Only fitted on vehicles with one-piece tubular shafts (V8 engine)
❑ Renew
❑ Remove and install using circlip pliers - VW 161 A-

13. Servicing drive shaft with constant velocity joint 201

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

9 - Inner constant velocity joint

❑ Renew only as complete unit
❑ Pressing off ⇒ page 204
❑ Pressing on ⇒ page 204
❑ Greasing ⇒ page 200
❑ Grease splines on drive shaft lightly with grease used in joint when fitting joint onto drive shaft
10 - Gasket
❑ Replace; detach backing and bond into joint
11 - Circlip
❑ Renew
❑ Remove and install using circlip pliers - VW 161 A-
12 - Drive shaft
❑ Heed the different versions ⇒ Electronic parts catalogue “ETKA”
❑ Grease must be applied to the splines on the shaft when fitting the outer or inner joint
13 - Circlip
❑ Only fitted on vehicles with one-piece tubular shafts (V8 engine)
❑ Renew
❑ Remove and install using circlip pliers - VW 161 A-
14 - Dished spring
❑ Large ∅ (concave side) makes contact with thrust washer
15 - Thrust washer
❑ Heed the different versions ⇒ Electronic parts catalogue “ETKA”
16 - Drive shaft
❑ Heed the different versions ⇒ Electronic parts catalogue “ETKA”
17 - Circlip
❑ Renew
❑ Insert in groove on 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.

202 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

13.2 Servicing drive shaft with constant velocity joint

Special tools and workshop

equipment required
♦ Thrust plate - VW 401-
♦ Thrust plate - VW 402-
♦ Spindle - 3207-
♦ Press tool - VW 408 A-
♦ Support sleeve - VW 522-
♦ Clamp - 40-204 A-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Pliers - 3340- 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.

– Clamp drive shaft in vice using protective jaw covers.

– Remove hose clip and push back boot.

13. Servicing drive shaft with constant velocity joint 203

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Screw the spindle - 3207- with M14 type thread into the joint
pin until the constant velocity joint is pressed off the drive shaft.
Pressing off outer constant velocity joint

Pressing off inner constant velocity joint

Note

♦ First drive rubber boot off with drift.

♦ Support ball hub.

Pressing on inner constant velocity joint

– Grease splines -A- on drive shaft lightly with grease used in
joint before fitting joint or triple roller spider onto 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.

– Press on joint as far as stop.

– Engage circlip.

Note

Chamfer on internal diameter of ball hub (splines) must face con‐

tact collar of drive shaft.

– Install joint boot.

204 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

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

13. Servicing drive shaft with constant velocity joint 205

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

14 Servicing rear drive shaft - allroad

⇒ “14.1 Exploded view”, page 206
⇒ “14.2 Servicing inner constant velocity joint”, page 209
⇒ “14.3 Servicing outer constant velocity joint”, page 213
⇒ “14.4 Checking outer constant velocity joint”, page 215
⇒ “14.5 Checking inner constant velocity joint”, page 216

14.1 Exploded view

Quantities and type of grease:
Constant velocity joints are filled with grease - G 000 603- .
Regrease joint when renewing boot.
Outer side Grease quan‐ of which in:
tity
Outer joint Total quantity Joint Boot
[mm] [g] [g] [g]
98 120 80 Protected 40
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
Inner joint Put in grease through
with respect to theball
correctness of information in this document. Copyright by AUDI AG.

bearing races
108 120 40 80

206 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Hexagon bolt
❑ Always renew after re‐
moving
❑ Tightening torque for
M16 bolt:
❑ 190 Nm and turn 180°
further
❑ Removing ⇒ page 198
❑ Installing ⇒ page 199
2 - Outer constant velocity joint
❑ Renew only as com‐
plete unit
❑ Removing ⇒ page 213
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Installing ⇒ page
permitted unless 214 by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Greasing ⇒ page 206
❑ Checking ⇒ page 215
❑ Grease splines on drive
shaft lightly with grease
used in joint when fitting
joint onto drive shaft
3 - Circlip
❑ Always renew
❑ Before fitting the con‐
stant velocity joint, cen‐
trally align the circlip
with the opening facing
upwards.
❑ Fit into annular groove
on shaft before installing
(no longer visible once
joint is installed)
4 - Thrust washer (plastic)
❑ Installation position
⇒ page 214
5 - Dished spring
❑ Installation position ⇒ page 214
6 - Circlip
❑ Always renew
❑ Installation position ⇒ page 214
❑ Remove and install using circlip pliers - VW 161 A-
7 - Hose clip
❑ Tightening ⇒ page 215
❑ Unfastening ⇒ page 213
8 - Boot for outer constant velocity joint
❑ Check for splits and chafing
❑ Briefly lift boot to equalise pressure before tightening hose clips ⇒ page 99
9 - Drive shaft
❑ Different versions available
❑ Refer to ⇒ Electronic parts catalogue “ETKA”
❑ Grease must be applied to the splines on the shaft when fitting the outer or inner joint
10 - Cover
❑ Always renew

14. Servicing rear drive shaft - allroad 207

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

11 - Gasket
❑ Always renew
12 - Circlip
❑ Renew
❑ Insert in groove on shaft
13 - Inner constant velocity joint
❑ Renew only as complete unit
❑ Removing ⇒ page 210
❑ Installing ⇒ page 212
❑ Grease splines on drive shaft lightly with grease used in joint when fitting joint onto drive shaft
14 - Lock plate
15 - Multi-point socket head bolt
❑ M 10: 70 Nm
16 - CV joint boot with cap
❑ Check for splits and chafing
❑ Renew only as complete unit
❑ Removing ⇒ page 210
❑ Installing ⇒ page 212

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.

208 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

14.2 Servicing inner constant velocity joint

Special tools and workshop

equipment required
♦ Thrust plate - VW 401-
♦ Thrust plate - VW 402-
♦ Press tool - VW 411-
♦ Press tool - VW 434-
♦ Sleeve - 3144-
♦ Pliers - 3340-

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. Servicing rear drive shaft - allroad 209

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Support sleeve - VW 522-

♦ Clamp - 40-204 A-
♦ Circlip pliers - VW 161 A-
♦ Press tool - VW 412-

Removing inner constant velocity joint

– Clamp drive shaft in vice.
Use jaw protectors.
– Pry off cover using a screwdriver or similar.

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.

210 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove seal -arrow-.

– Use brass or copper mandrel to drive off cap of boot.

Do not open hose clip.

– Remove 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.

– Use the special tools shown to press the inner constant ve‐
locity joint off the shaft.
– Detach the inner constant velocity joint boot from the shaft.

14. Servicing rear drive shaft - allroad 211

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Fitting inner constant velocity joint

– Apply sealant (hatched area) to clean surface on inside of boot
cover. Route continuous bead of sealant, (∅ 2..3 mm) around
inside of holes -arrow-.
– Use sealant - D 454 300 A2- .
– Slide the boot onto the shaft.
Shaft, boot and contact surface of cover must be free of grease.

– Grease splines -A- on drive shaft lightly with grease used in

joint before fitting joint or triple roller spider onto 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.

– Press on joint as far as stop.

Chamfer on internal diameter of ball hub (splines) must face con‐
tact collar of drive shaft.
Use the special tools shown in the illustration.
Tensioner - 40-204 A- and clamping surface on drive shaft must
be free of grease.

– Fit circlip.
– Always renew circlip.
– Check that circlip is properly seated.
– Fill the boot with 80 g of drive shaft grease.
Take care not to damage sealant bead.

212 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Align cover and bolts -arrows- with bolt holes.

The alignment must be very accurate, because no further align‐
ment is possible once the part has been hammered on.
– Drive on cover using a plastic hammer.
– Wipe off surplus sealant.
– Pack 40 grams of drive shaft grease into joint through ball
races.
– Degrease contact surface for seal.

– Remove the adhesive backing from the seal -arrow- and bond
into the constant velocity joint.

– Use special tools shown to press on cover -A-.

Instead of the special tool -2036/1- , use can be made for example
of a flat steel bar of appropriate size.

– Position boot between -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
14.3 Servicing outer constant velocity joint with respect to the correctness of information in this document. Copyright by AUDI AG.

Removing outer constant velocity joint

– Clamp drive shaft in vice.
Use jaw protectors.

14. Servicing rear drive shaft - allroad 213

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Use pliers - 3340- to unfasten the hose clamp.

The pliers - 3340- must be applied as shown to the back of the
hose clamp.
– Push back boot.

– Apply copper or brass drift to inner race of constant velocity

joint, and drive off using a hammer.
– Detach the joint.
Installing outer constant velocity joint
– Slide boot onto 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.

– Position boot between -arrows-.

1 - Always renew circlip.
2 - Thrust washer (plastic)
3 - Dished spring
4 - Circlip, always replace
– Apply 80 g of drive shaft grease to the inside of the joint ele‐
ment.

– Grease splines -A- on drive shaft lightly with grease used in

joint before fitting joint or triple roller spider onto drive shaft.
– Press on the joint as far as the circlip.

214 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Screw old drive shaft bolt into joint body as shown.

– Use plastic-headed hammer to drive joint onto shaft until circlip
engages.
– Apply 40 g of drive shaft grease to the joint on the boot end.
Fastening clamp
– Grease outer constant velocity joint ⇒ page 206 .
– Vent air from boot.

– Engage hose clip by hand at first lug.

– Use pliers - 3340- to fasten the hose clamp.

The pliers - 3340- must be applied as shown to the front of the
hose clamp.

14.4 Checking outer constant velocity joint

The joint should be dismantled to renew dirty grease or for check‐
ing the balls and ball races for wear and damage.
Removing
– Before dismantling, mark position of ball hub in relation to ball
cage and joint body with an electric scriber or oil stone.
– Swivel ball hub and ball cage.
–Protected
Takebyout ballsCopying
copyright. one for
after the
private other. purposes, in part or in whole, is not
or commercial
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. Servicing rear drive shaft - allroad 215

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Turn the cage until the two rectangular openings -arrow- are
level with the joint body.
– Lift out cage together with hub.

– Swivel one segment of hub into rectangular opening of cage.

– Pivot hub out of cage.
The 6 balls in each joint belong to one tolerance group. Check
stub axle, hub, cage and balls for pitting and signs of seizure.
Excessive backlash in the joint will cause knocking
Protectedor
byjolts under
copyright. Copying for private or commercial purposes, in part or in whole, is not
load change. In such cases the joint must be renewed. Smooth
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.
areas and ball running marks do not constitute grounds for joint
replacement.
Installing
– Fit cage with hub into joint body.
– Consecutively press in opposite balls. In doing so, take care
to re-establish the original position of the ball hub relative to
the cage and the joint body.

14.5 Checking inner constant velocity joint

The joint should be dismantled to renew dirty grease or for check‐
ing the balls and ball races for wear and damage.
Removing
– Swivel ball hub and ball cage.
– Press out joint body in direction of -arrow-.
– Push balls out of cage.

Note

Ball hub and joint body are paired. Do not interchange.

– Align ball hub with cage as shown -arrows- and pivot hub out
of cage.
– Check joint, ball hub, ball cage and balls for pitting and signs
of seizure.
Excessive backlash in the joint will cause knocking or jolts under
load change. In such cases the joint must be renewed. Polished
areas and visible tracks in the ball races are not a reason for re‐
newing the joint.

216 Rep. gr.42 - Rear suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Installing
– Insert hub into cage via the two chamfers. No specific instal‐
lation position is required. Push balls into cage.
– Insert hub with cage and balls at a right angle to the joint body.

– When inserting, ensure that the wide spacing -a- on the joint
body is aligned with the narrow spacing -b- on the hub after
swivelling in.
Chamfer on internal diameter of ball hub (splines) must face large
diameter of joint body.

– Swivel the hub into the joint body; at the same time the hub
must be swivelled out of the cage -arrows- far enough to allow
the balls to fit into the ball races.

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.

– Swivel in the hub with balls by applying firm pressure on the

cage -arrow-.
Check function of constant velocity joint.
The constant velocity joint has been correctly assembled if the
ball hub can be moved by hand backwards and forwards over its
entire axial range of movement.

14. Servicing rear drive shaft - allroad 217

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

43 – Self-levelling suspension
1 Pneumatic adaptive rear suspension
⇒ “1.1 Electrical/electronic components and fitting locations”,
page 218
⇒ “1.2 Air supply unit”, page 219
⇒ “1.3 Fault indication by way of adaptive suspension warning
lamp K134 ”, page 219
⇒ “1.4 Layout of sound insulation box”, page 219

1.1 Electrical/electronic components and fitting locations

1 - Air supply unit

The air supply unit consists of
the following components:
❑ Adaptive suspension
control unit - J197-
❑ Adaptive suspension
compressor relay -
J403-
❑ Adaptive suspension
compressor motor -
V66-
❑ Adaptive suspension
drain valve - N111-
❑ Rear left suspension
strut valve - N150-
❑ Rear right suspension
strut valve - N151-
❑ Multiple connectors with
contact assignment
❑ When renewing the con‐
trol unit, select the func‐
tion “Replace” for the
relevant control unit in
the “Guided Fault Find‐
ing”.
Use vehicle diagnostic, testing
and information system -
VAS 5051- .

2 - Air spring (rear 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
3 - Adaptive suspension send‐
with respect to the correctness of information in this document. Copyright by AUDI AG.

er - G84-
❑ Checked by self-diag‐
nosis
4 - Air spring (rear right)

218 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1.2 Air supply unit

1 - VOSS connections (air connection)
2 - Multi-pin connector
- In the event of malfunctions, check connector for corrosion.
- Push 20-pin connector of wiring loom onto control unit in air
supply unit plug is felt to engage.
3 - Noise insulation box
4 - Two-pin connector (power supply for adaptive
Protected suspension
by copyright. Copying for private or commercial purposes, in part or in whole, is not
compressor motor - V66- ) 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.
- Press on 2-pin round plug for compressor supply until plug is felt
to engage.

1.3 Fault indication by way of adaptive sus‐

pension warning lamp - K134-
Possible causes of trouble if the adaptive suspension warning
lamp - K134- does not go out after switching on the ignition and
following completion of the test sequence (approx. 2 s):
♦ Voltage less than 10 V
♦ Fault in adaptive suspension system, interrogate fault memory
⇒ Running gear, self-diagnosis; Rep. gr. 01
♦ Dash panel insert defective

1.4 Layout of sound insulation box

1 - Adaptive suspension control unit - J197-
2 - Adaptive suspension compressor motor - V66- and compres‐
sor
3 - Two-pin connector
4 - Adaptive suspension compressor relay - J403-
5 - Multi-pin connector at adaptive suspension control unit - J197-
(on back)
6 - Twelve-pin connector at adaptive suspension control unit -
J197-
The valves are located underneath the grey foam.

1. Pneumatic adaptive rear suspension 219

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

2 Servicing self-levelling suspension

⇒ “2.1 Exploded view: Air supply unit”, page 220
⇒ “2.2 Performing basic setting”, page 221
⇒ “2.3 Assignment of ground clearances (setting dimensions) for
adaptive suspension”, page 222
⇒ “2.4 Charging system - 2-wheel air suspension”, page 225
⇒ “2.5 Functional check”, page 226
⇒ “2.6 Exploded view: Unit retainer”, page 226
⇒ “2.7 Exploded view: Front-wheel drive wire routing”,
page 229
⇒ “2.8 Exploded view: Air spring damper (front-wheel drive)”,
page 231
⇒ “2.9 Removing and installing air spring”, page 233
⇒ “2.10 Removing and installing shock absorber/spring”,
page 233
⇒ “2.11 Exploded view of vehicle level sender (front-wheel drive)”,
page 234
⇒ “2.12 Removing and installing vehicle level sender (front-wheel
drive)”, page 235
⇒ “2.13 Exploded view: All-wheel drive wire routing”, page 236
⇒ “2.14 Exploded view: All-wheel drive air spring damper”,
page 237
⇒ “2.15 Removing and installing shock absorber/spring”,
page 238
⇒ “2.16 Exploded view of vehicle level sender (four-wheel drive)”,
page 240
⇒ “2.17 Removing and installing vehicle level sender (four-wheel
drive)”, page 241

2.1 Exploded view: Air supply unit

The tightening torque for all air pipes on the Audi A6 is 2 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

220 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Clip
2 - Air pipe
Heed the note ⇒ page 231

3 - Connection piece
4 - Hexagon nut M6
5 - Self-tapping screw
6 - Metal washer
❑ For centring valve unit
7 - Rubber seal
8 - Housing cover
9 - Top part of foam element
10 - Valve unit
11 - Air compressor
12 - Gasket
❑ Always renew
13 - Bottom part of foam ele‐
ment
14 - Unit housing
15 - Hexagon bolt, 10 Nm
❑ If re-used, apply locking
compound - D 000 600
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
A2- 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.
16 - Fleece mat
❑ A6 Avant only
❑ Formed fleece mat bon‐
ded onto lower shell of
unit
17 - Air pipe
❑ Between compressor
and solenoid valve
Heed the note ⇒ page 231

2.2 Performing basic setting

Heed the test requirements for wheel alignment on vehicles with
adaptive suspension (1BG) ⇒ page 221 .
Test requirements:
♦ Vehicle kerb weight
♦ For inflation pressure, refer to inflation pressure label or ⇒
Wheels/tyres catalogue; Section 2 for summer tyres and Sec‐
tion 4 for winter tyres .
♦ Correct tread depth (set 1 mm less for each 1 mm of wear).
♦ Wait for completion of the adaption process (observe com‐
pressor operation).
♦ Measure the vehicle level relative to the ground at the appro‐
priate points (specified jacking points).
Basic setting must be performed if the control unit, the turn angle
sensor or the entire unit is replaced.

2. Servicing self-levelling suspension 221

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Set the special tool to the appropriate length (refer to assign‐

ment of ground clearances ⇒ page 222 ).

2.3 Assignment of ground clearances (setting dimensions) for adaptive sus‐

pension 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.
Valid for tyres: 195/65 R15 215/55 R16 Valid for all engines
205/60 R15 235/45 R17
205/55 R16
FWD 324,52)1 3332)1 -
Saloon/Avant
4WD 324,52)1 3332)1 -
Saloon/Avant
FWD/4WD - - 3332)1
Saloon/Avant V8

2) 1/ Test dimension ± 8 mm

Special tools and workshop equipment required

♦ Gap setting gauge - T40002-

– Raise the vehicle (rear suspension fully extended).

222 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Insert the spacer gauge - T40002- in the specified jacking

points -arrows- at the rear.

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. Servicing self-levelling suspension 223

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Turn the two knurled screws so that the rubber bead at the
specified jacking point is compressed and the spacer gauge
is held in position.
– Lower vehicle.

Note

The vehicle must be standing on a flat surface.

Only on 4WD models

– Move the vehicle approx. 1 m forwards and backwards and
bounce at the rear. This eliminates the torsion of the rear tyres.
– Refer to the table to check the clearance dimension (specified
jacking points/workshop floor) and repeat basic setting if nec‐
essary in the event of deviation. Allowance is to be made for
the deviation determined at the spacer gauge - T40002- . If the
vehicle is too low, this amount is to be added to the setting
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dimension (see table). 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.
Basic setting must be performed if the control unit, the turn angle
sensor or the entire unit is replaced.
The drive position is set.
Test requirements:
♦ Power supply and fuses for corresponding system OK ⇒ Cur‐
rent flow diagrams, Electrical fault finding and Fitting locations
♦ Connect up vehicle diagnostic, testing and information system
- VAS 5051- or fault reader - V.A.G 1551- and select functions
⇒ Running gear, self-diagnosis; Rep. gr. 01 .
♦ Use the spacer gauge - T40002- (blocks).
Procedure
– Basic setting is implemented by way of function 11 “Login”.
– Insert the spacer gauge - T40002-
Implementing function 11 “Login”
Indicated on display:
Rapid data transfer HELP
Select function XX

– Press keys 1 and 1 .

Indicated on display:
Rapid data transfer Q
11 - Login procedure

– Confirm entry with Q key.

Indicated on display:
Log-in procedure
Enter code number XXXXX

– Press keys 3 , 1 , 5 , 6 and 4 .

Indicated on display:
Login procedure Q
Code 31564

– Confirm entry with Q key.

224 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Indicated on display:
Rapid data transfer HELP
Select function XX

– Press keys 0 and 4 .

Indicated on display:
Rapid data transfer Q
04 - Basic setting

– Confirm entry with Q key.

Indicated on display:
Basic setting
Enter display group number XXX

– Press keys 0 , 0 and 1 .

Indicated on display:
Basic setting Q
Enter display group number 001

– Confirm entry with Q key.

Indicated on display: 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
System in basic setting with respect to the correctness of information in this document. Copyright by AUDI AG.
->
Wait

– Press → key.
The system discharges air and lowers the rear end of the vehicle
as far as the spacer gauge - T40002- .
At the same time, the old reference position is cancelled in the
control unit. There is an entry into the fault memory (fault 01437).
The following appears on the display on completion of “basic set‐
ting 1”:
System in basic setting ->
further with basic setting 2

– Now press key 3 .

Indicated on display:
System in basic setting ->
Drive position learnt

– Press → key.
– This completes the basic setting procedure.
– Then erase the fault memory ⇒ Running gear, self-diagnosis;
Rep. gr. 01 .

2.4 Charging system - 2-wheel air suspen‐

sion
The system must be re-charged if the shock absorber, the air
spring or the air pipe is replaced (or air pressure dissipated).
Before charging the system, the vehicle must not be standing on
its wheels (if suspension system repairs have been performed
beforehand), as otherwise the air spring will be damaged.
– Raise vehicle (full rear axle rebound).
– Make sure there are no folds in the air springs.

2. Servicing self-levelling suspension 225

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Charge the air springs by way of the final control diagnosis

function ⇒ Running gear, self-diagnosis for adaptive suspen‐
sion, TPM; Rep. gr. 01 ; Self-diagnosis, electrical checks; Self-
diagnosis of 2-wheel adaptive suspension system; Final
control diagnosis .
– Check the system for leaks.
– Check correct positioning of installed air springs/struts.
– Lower vehicle.
– Check the level and set if necessary ⇒ page 221 .

2.5 Functional check

Switch on the ignition, interrogate the fault memory and erase it
if necessary ⇒ Running gear, self-diagnosis; Rep. gr. 01 .
System faults are indicated by continuous lighting of the yellow
warning lamp in the rev counter.
Then check operation by subjecting the rear axle to load (e.g. by
opening the rear lid and sitting in the luggage compartment).
After max. 10 seconds, the system must start to provide lifting/
pumping action as compensation for the load-induced rear axle
compression.
Max. pumping time: 30 seconds
If the clearance dimension decreases by more than 6 mm within
24 hours, the system is leaking and must be checked.
The self-levelling suspension system monitors the switch-on time
of the compressor so as to prevent possible overheating or ex‐
cessive battery discharge. Proceed as follows if lifting action does
not take place despite being necessary:
– Wait approx. 6 minutes. After this time at the latest, lifting ac‐
tion is possible for approx.15 s in the event of overheating.
– Starting the engine makes it possible to implement normal
raising again irrespective of the condition of the battery.

2.6 Exploded view: Unit retainer

The tightening torque for all air pipes on the Audi A6 is 2 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

226 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Air supply unit

2 - Rubber mounting
❑ Kidney-shaped recess
faces upwards
3 - Bracket for air supply unit
❑ Installing ⇒ page 228
4 - Self-locking hexagon nut
5 - Rubber grommet
6 - Hexagon bolt, 25 Nm
7 - Holder, support section 1 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
8 - Hexagon nut, 25 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.

9 - Speed nut M 8 x 25 x 17
10 - Holder, support section 2
A - Black connector
B - Red connector
C - Air connections

Removing
– Switch off ignition.
– Disconnect the earth strap from the battery.
Before removing the air supply unit with mount, take out the tool
kit (tool box) and the navigation unit or CD changer ⇒ Radio,
telephone, navigation; Rep. gr. 91 .
– Unplug the black connector -A-.
– Unplug the red connector -B-.
– Unscrew the air connections -C-.
– Unscrew hexagon nuts -8-.

2. Servicing self-levelling suspension 227

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Installing
– Instead of the bonded joint, additional attachment points are
required on installing the holder -3-.
– Remove dirt (wax etc.) from inside in bodywork area around
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
bracket
permittedmount.
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.
– Remove the grommet in the bottom section of the unit mount.
– Insert the unit mount in the body and screw to the wheel hous‐
ing flange and longitudinal member.
– Make three ∅ 8.5 mm holes in the unit mount and body at the
marked locations (mount).
– Remove the unit mount and deburr the holes.
– Remove corrosion protection (PVC) on outside of bodywork in
area of nut contact surface.

228 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Insert the unit mount and screw on as follows.

Tightening sequence:
– Mount to longitudinal member -A-
– Mount to wheel housing flange -B-
– -1- Hexagon bolt 25 Nm
– -2- Hexagon flange nut
– -3- Speed nut
– Insert the rubber grommet.
– Seal the bolting points on the outside of the body (black Ter‐
olan).

– Insert the unit with support section in the unit mount and screw
on -1- and -2-.
– Pay attention to the installation position of the rubber bushes
⇒ Item 2 (page 227) .
– The connectors must be heard to engage fully.
– When inserting the valves, take care not to alter the position
of the cutting rings on the compressed air pipes, as otherwise
the screw connection may leak.
Perform the remaining installation operations in reverse order.

2.7 Exploded view: Front-wheel drive wire routing

The tightening torque for all air pipes on the Audi A6 is 2 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Servicing self-levelling suspension 229

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Clip
2 - Air pipe
❑ Between air supply unit
and air spring
❑ Clip in air pipes at marks
provided
❑ Heed the note
⇒ page 231
3 - Air supply unit
❑ Removing and installing
⇒ page 226
4 - Shock absorber
5 - Connection piece
❑ Heed the note
⇒ page 231
6 - Clip
❑ Clip onto damper
7 - Air pipe
❑ Between air supply unit
and air spring
❑ Heed the note
⇒ page 231
8 - Clip
❑ Clip onto handbrake ca‐
ble
9 - Air pipe
❑ Between air spring and
damper
❑ Heed the note
⇒ page 231
10 - Stone deflector
11 - Cable tie
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12 - Connection piece permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Refer to note ⇒ page 231
with respect to the correctness of information in this document. Copyright by AUDI AG.

230 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Marks
Pay attention to the assignment of the correct coloured marks
-A- to the corresponding position marks of the clips/grommets
-B-.

Plug-in system
– Pipes have been properly connected if only one mark
-arrow- is visible.

Note

♦ Pipes must not be shortened.

♦ Pipe removal involves unfastening the union.
♦ Route air pipes before removing protective transportation caps
(detach immediately prior to making connection).

2.8 Exploded view: Air spring damper (front-wheel drive)

The tightening torque for all air pipes on the Audi A6 is 2 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Servicing self-levelling suspension 231

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - O-ring
2 - Air spring
❑ Removing and installing
⇒ page 233
3 - Connection piece
❑ Refer to note
⇒ page 231
4 - Bolt with washer, 5 Nm
5 - Stone deflector 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 - Spring seat with respect to the correctness of information in this document. Copyright by AUDI AG.

7 - Protective sleeve
8 - Stop buffer
9 - Clip
10 - Air pipe
❑ Clip in the air pipes at
the marked locations
❑ Heed the note
⇒ page 231
11 - Connection piece
❑ Heed the note
⇒ page 231
12 - Shock absorber
13 - Hexagon bolt, 45 Nm
14 - Assembly cap
❑ For factory assembly
only; not required when
performing repairs
15 - Self-locking hexagon nut,
25 Nm
❑ Loosening and tightening ⇒ page 133
❑ Always renew after removing
16 - Upper damper mount

Loosening and tightening nut on shock absorber mounting

– Unscrew the assembly cap ⇒ Item 14 (page 232) .

232 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

2.9 Removing and installing air spring

Removing
– Unscrew the bolts with washers -1- and carefully fold down the
stone deflector.
– Carefully open and unscrew the air connections -3-.
– Take out the air spring.
Installing

Note

♦ The system must be charged before standing the vehicle on

its wheels again ⇒ page 225 .
♦ The vehicle suspension must be extended when charging.
♦ Pay attention to the position of the air spring on charging.

Perform the remaining installation operations in reverse order.

2.10 Removing and installing shock absorb‐

er/spring
Special tools and workshop equipment required
♦ Engine and gearbox jack - V.A.G 1383 A- with universal gear‐
box support - V.A.G 1359/2-

Removing
– Carefully open and unscrew the air connections -4-.
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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.

Use the engine and gearbox lifter - V.A.G 1383 A- with universal
gearbox support - V.A.G 1359/2- for removing and installing the
spring cylinders.

2. Servicing self-levelling suspension 233

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Slacken off the bolt -2- on the left and lower the gearbox lifter.
– Remove bolts -1- and take out shock absorber.
– If necessary, have a second mechanic pull the rear axle down‐
wards and remove the damper.
Installing
Install in reverse order of removal.
– Renew all bolts and nuts.
– Insert damper in bodywork and tighten to 45 Nm.

– Fit bolt attaching damper to rear axle at bottom.

1 - Self-locking nut
2 - Hexagon bolt
3 - Shock absorber
The system must be charged after installing the air spring or
damper.
Charging system ⇒ page 225

Note

The vehicle must not be standing on its wheels before charging

has been performed.

The bolted joint between the damper and rear axle must be tight‐
ened with the vehicle standing on its wheels.
– Tighten the damper at the rear axle to 50 Nm + 90°.

2.11 Exploded view of vehicle level sender (front-wheel drive)

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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.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Hexagon nut, 3 Nm
❑ Refer to information on
⇒ page 235
2 - Vehicle level senders
3 - Coupling rod
4 - Holder for vehicle level
sender
5 - Double hexagon bolt, 25
Nm
6 - Hexagon nut, 10 Nm
7 - Hexagon socket head bolt,
4 Nm
8 - Hexagon nut, 5 Nm
9 - Cable tie
10 - Hexagon nut, 10 Nm

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2.12 Removing and installing vehicle level

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.

sender (front-wheel drive)

Removing
– Switch off ignition.
– Disconnect the earth strap from the battery.
– Unplug the connector -2- from the vehicle level sender .
– Release cable ties.
– Unfasten the hexagon nuts -1-, -4- and -5-.
– Take out the vehicle level sender .
Make sure the sensor crank does not turn through 180°. Other‐
wise, basic setting must be performed again ⇒ Running gear,
self-diagnosis; Rep. gr. 01 .
Dimension -A-: 4 mm.

2. Servicing self-levelling suspension 235

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Note

So as not to damage the seal when fitting the linkage -1- at the
vehicle level sender , use an open-ended wrench (w.a.f. 8 mm)
with dimension -A-.

Installing
On installing the vehicle level sender , pay attention to correct
mutual positioning of the sensor crank and linkage.

Note

♦ The linkage must be vertical.

♦ The sensor crank (arm) must face to the rear and downwards.

Perform remaining installation in reverse order of removal.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2.13 Exploded view: All-wheel drive wire routing
with respect to the correctness of information in this document. Copyright by AUDI AG.

The tightening torque for all air pipes on the Audi A6 is 2 Nm.

1 - Clip
2 - Air pipe
❑ Clip in the air pipes at
the marked locations
❑ Heed the note
⇒ page 231
3 - Connection piece
❑ Heed the note
⇒ page 231
4 - Hexagon nut M6
5 - Air supply unit
❑ Removing and installing
⇒ page 226
6 - Hexagon bolt, 10 Nm
7 - Air spring
8 - Shock absorber
9 - Clip
10 - Left sensor holder
❑ Removing and installing
⇒ page 237
11 - Hexagon nut, 10 Nm
12 - Retainer
❑ Removing and installing
⇒ page 237
13 - Hexagon nut, 10 Nm
14 - Socket
15 - Cable tie
❑ 1x left

236 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

❑ 3x right

Air pipe from sensor to air spring damper

1 - Left sensor holder
2 - Retainer
3 - Hexagon nut, 10 Nm

Note

♦ The air pipes are colour-coded:

♦ Black on left side
♦ Blue on right side

2.14 Exploded view: All-wheel drive air spring damper

The tightening torque for all air pipes on the Audi A6 is 2 Nm.

1 - Self-locking hexagon nut,

27 Nm
❑ Always renew after re‐
moving
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Remove air-tight seal‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
ing plug beforehand with respect to the correctness of information in this document. Copyright by AUDI AG.

2 - Air spring
❑ Fitting ⇒ page 238
3 - Shock absorber
4 - Clip
5 - Self-locking nut, 70 Nm +
turn 90° further
❑ Always renew after re‐
moving
6 - Washer
7 - Air spring strut
8 - Hexagon bolt M 12 x 1.5 x
95
❑ Always renew after re‐
moving
9 - Connection piece
❑ Heed the note
⇒ page 231
10 - Air pipe
❑ Clip in air pipes at marks
provided
❑ Heed the note
⇒ page 231
11 - Connection piece
❑ Heed the note
⇒ page 231
12 - Hexagon bolt, 45 Nm

2. Servicing self-levelling suspension 237

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Fitting air spring strut

The bayonet catch must be absolutely clean.
– Coat the rubber seals -1- and -2- with lithium grease - G 052
150 A2- .
– Fasten the bayonet catch by simultaneously pressing and
turning.

2.15 Removing and installing shock absorb‐

er/spring
Removing
– Remove wheels.
– Remove both the subframe/lower link bolts -E-.
A - Hexagon bolt
B - Handbrake cable
C - Bracket for handbrake cable
D - Suspension link
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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 handbrake cables from brake calliper.

238 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Loosen bolt -A- on both sides.

– Unhook handbrake cables -B- out of retainer -C-.

– Press locking lugs -A- together and push handbrake cables

-2- out from wishbone -1-.

– Unclip the speed sensor wire at the subframe.

3 - Attachment point at 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.

– Remove transverse link from damper.

1 - Suspension link
2 - Handbrake cable
3 - Shock absorber bolt
A - Handbrake cable retaining clip

2. Servicing self-levelling suspension 239

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unbolt shock absorber hexagon bolts -arrows- to body.

Installing
Following removal and installation of the air spring dampers, the
system must be charged again.
Charging system ⇒ page 225
– Bonded rubber bushes can only be turned to a limited extent.
The bolt connection should therefore only be tightened when
the vehicle is standing on the ground.
Otherwise, the bush would be subject to torsion loading and its
service life shortened.
– Adjust handbrake ⇒ Rep. gr. 46 .
Tightening torques:
Link to subframe 70 Nm + 90°
Use new bolts
Transverse link to wheel bearing housing 95 Nm
Damper to link 70 Nm + 90°
Use new bolts

2.16 Exploded view of vehicle level sender (four-wheel drive)

1 - Coupling rod
2 - Vehicle level senders
3 - Holder for vehicle level
sender
4 - Hexagon socket head bolt,
4 Nm
5 - Washer
6 - Self-locking hexagon nut, Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

40 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.

7 - Hexagon nut, 3 Nm
❑ Refer to information on
⇒ page 235
8 - Hexagon nut, 3 Nm
❑ Refer to information on
⇒ page 235
9 - Anti-roll bar
10 - Bolt with washer, 10 Nm
11 - Hose clip
12 - Lever

240 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

2.17 Removing and installing vehicle level

sender (four-wheel drive)
Removing
– Switch off ignition.
– Disconnect earthing strap from battery.
– Unplug the connector -1- from the vehicle level sender .
– Remove hexagon bolt -3-.
– Unfasten hexagon nut -4-.
Make sure the sensor crank does not turn through 180°, as oth‐
erwise basic setting must be performed again ⇒ Running gear,
self-diagnosis; Rep. gr. 01 .

Note

♦ So as not to damage the seal when fitting the linkage -6- at the
vehicle level sender , use an open-ended wrench (w.a.f. 8 mm)
with dimension -A-.
♦ Dimension -A-: 4 mm by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
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.
Installing

Note

♦ Make sure the lug at the holder ⇒ Item 3 (page 240) ,

-arrow-, engages in the subframe.
♦ The connecting link must be vertical.
♦ The sensor crank (arm) must face to the rear and downwards.
♦ Make sure the holder and clamp are bolted to the flat section
of the anti-roll bar.

Perform remaining installation in reverse order of removal.

2. Servicing self-levelling suspension 241

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

3 Pneumatic adaptive suspension - all‐

road
⇒ “3.1 Fitting locations”, page 242
⇒ “3.2 Exploded view: Accumulator”, page 243
⇒ “3.3 Removing and installing vehicle level sender at rear axle”,
page 243
⇒ “3.4 Basic setting procedure (allroad)”, page 244
⇒ “3.5 System charging (allroad)”, page 244
⇒ “3.6 System bleeding (allroad)”, page 249

3.1 Fitting locations

1 - Front right air spring strut

2 - Operating unit
3 - Rear Protected
right airby spring strut
copyright. Copying for private or commercial purposes, in part or in whole, is not

4 - Rear right vehicle level

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.
sender - G77-
5 - Adaptive suspension con‐
trol unit - J197-
❑ Removing ⇒ page 258
❑ Installing ⇒ page 258
6 - Accumulator
❑ Exploded view
⇒ page 243
7 - Rear left vehicle level send‐
er - G76-
8 - Rear left air spring strut
9 - Air supply unit with:
♦ Compressor
♦ Adaptive suspension drain
valve - N111-
♦ Transverse check valves
♦ Adaptive suspension sys‐
tem compressor tempera‐
ture sender - G290-
♦ Pressure sender - G291-
♦ Additional intake silencer
❑ Exploded view of com‐
ponents ⇒ page 255
10 - Wires/pneumatic pipes
11 - Front left air spring strut
12 - Front left vehicle level sender - G78-
13 - Front right vehicle level sender - G289-

242 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

3.2 Exploded view: Accumulator

1 - VOSS plug-in system

❑ Tightening torque: 2 Nm
2 - Hexagon nut
❑ Tightening torque: 23
Nm
3 - Accumulator
❑ If the pressure container
is to be removed, bleed
the pressure container
system beforehand
⇒ page 249
4 - Silencer
5 - Hexagon nut (3x)
❑ Tightening torque: 3 Nm
6 - Retainer
❑ Installing
7 - Bolt with washer
❑ Tightening torque: 23
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
with respect to the correctness of information in this document. Copyright by AUDI AG.

3.3 Removing and installing vehicle level

sender at rear axle
Removing
– Remove the nuts -5-.
Tightening torque: 10 Nm
– Remove the nut -4-.
Tightening torque: 10 Nm
Installing
Install in reverse order of removal.
Basic setting must be performed if the vehicle level sender is re‐
placed or a connection unfastened ⇒ page 244 .

3. Pneumatic adaptive suspension - allroad 243

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

3.4 Basic setting procedure (allroad)

Basic setting must be performed on replacing the vehicle level
sender , the entire unit or the adaptive suspension control unit .
– Perform basic setting ⇒ Running gear, self-diagnosis for
adaptive suspension, TPM; Rep. gr. 01 .
Determining height dimension x
The height dimension x is the value in mm between centre of
wheel and lower edge of wing.
– Measure rim diameter.
The measured value is dimension -a-.
– Measure vertical distance from top edge of rim to bottom edge
of wing.
The measured value is dimension -b-.
The height dimension x is calculated as follows:
x = a: 2 + b

– On completion of basic setting, check whether the height di‐

mension -x- = 402 mm ± 5 mm is attained. If it is, basic setting
must be repeated again.
– After performing basic setting, check whether the difference in
height between left and right side is no greater than ± 4 mm.
If it is, basic setting must be repeated again.

3.5 System charging (allroad)

When charging the system, the vehicle must not be standing on
its wheels (if suspension system repairs have been performed
beforehand), as otherwise the air spring will be damaged.
Service charging of the air spring system can be implemented
without unfastening any mechanical connections.
Filling the system using self-diagnosis may only be carried out
when the vehicle is stationary.

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.

244 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Note

♦ The air spring system (pressure container, air springs, com‐

pressed air pipes) can be charged using the fault reader -
V.A.G 1551- . The following limit pressures apply: Air spring 9
bar/pressure container 13 bar.
♦ The system is charged in stages (front air springs/rear air
springs/pressure container).
♦ Charging is only possible following manual deactivation of the
adaptive suspension. The adaptive suspension is deactivated
and activated by means of the fault reader - V.A.G 1551-
(function 10, channel 10) or using the manual up/down keys
(double press > 5 seconds).
♦ The charging time is limited to 65 seconds. The procedure can
however be implemented several times in succession to ach‐
ieve a longer overall charging time.
♦ Charging can be performed in stages using the up/down arrow
keys on the fault reader - V.A.G 1551- (on the fault reader -
V.A.G 1551- , keys 1 and 3 are also assigned as ↓ key and
↑ key).

Technical data of self-diagnosis

♦ Data are transmitted between the control unit and the vehicle
diagnostic, testing and information system - VAS 5051- or the
fault reader - V.A.G 1551- in “rapid data transfer” mode.
♦ The fault memory is designed as a non-volatile memory and
is thus independent of the power supply.
Connecting up vehicle diagnostic, testing and information system
- VAS 5051- or fault reader - V.A.G 1551- and selecting functions

Note

♦ Battery voltage min. 11 V

♦ Earth connections at engine and gearbox OK
♦ Engine off
♦ Automatic gearbox set to “P” or “N”

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. Pneumatic adaptive suspension - allroad 245

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Procedure
– With the ignition off, connect up the vehicle diagnostic, testing
and information system - VAS 5051- with the diagnostic cable
- VAS 5051/1- . Alternatively, connect up the fault reader -
V.A.G 1551- with the diagnostic wire - V.A.G 1551/3A- .

Note

The following description only applies to the self-diagnosis pro‐

cedure for the fault reader - V.A.G 1551- . Consult the operating
manual if use is being made of the vehicle diagnostic, testing and
information system - VAS 5051- .
3)
Indicated on display:
V.A.G - SELF-DIAGNOSIS HELP
1 - Rapid data transfer

3)
Indicated on display:
V.A.G - SELF-DIAGNOSIS HELP
2- Flash code output

3) alternating displays

Note

If display screen remains blank: ⇒ Operating instructions for fault

reader .

– Switch on ignition.
– Manually deactivate the adaptive suspension (double press
on key > 5 seconds on manual operating unit).
– Switch on printer of fault reader by pressing Print key. The
lamp in the key must light.
– Press key 1 for “Rapid data transfer”.
If the following is indicated on display:
Rapid data transfer HELP
Enter address word XX

Note

Address word 00 implements the automatic test sequence, i.e.

the fault memories of all vehicle systems with self-diagnosis ca‐
pability are interrogated with rapid data transfer.

– Enter 3 and 4 for the address word “Adaptive suspension”.

Indicated on display:
Rapid data transfer Q
34 - Adaptive suspension

– Confirm with Q key.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Indicated on display: 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.
Rapid data transfer Q
Tester transmits address word 34

246 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– The following display appears after approx. 5 seconds (exam‐

ple):
4Z7 907 553A - 2C1A1 X016 ->
Coding 25500 WSC XXXXX

– Press → key.
Indicated on display:
Rapid data transfer HELP
Select function XX

Note

A list of possible functions can be printed out by pressing the

HELP key.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Press keys 1 and 1 for the “Login procedure” and confirm
permitted unless with
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Q key. with respect to the correctness of information in this document. Copyright by AUDI AG.

Indicated on display:
Basic setting Q
11 - Log-in procedure

– Confirm entry with Q key.

Indicated on display:
Login procedure ->
Enter code number XXXXX

– Press keys 0 , 8 , 3 , 6 and 7 .

Indicated on display:
Login procedure ->
Enter code number 08367

– Confirm entry with Q key.

If the following is indicated on display:
Rapid data transfer HELP
Select function XX

– Press keys 0 and 4 .

If the following is indicated on display:
Rapid data transfer Q
04 - Basic setting

– Confirm entry with Q key.

If the following is indicated on display:
Basic setting
Enter display group number XXX

– Enter the display group number.

– Press keys 0 , 2 and 6 .
– Confirm entry with Q key.
If the following is indicated on display:
System in basic setting ->26
Charging FA, continue with next channel

– Press the ↑ key to continue.

3. Pneumatic adaptive suspension - allroad 247

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

If the following is indicated on display:

System in basic setting 27->
Charging front axle, function in progress

Note

Press the ↓ key to return to GE 26.

Indicated on display after 65 seconds:

System in basic setting 27-> Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Front axle charged, function completed
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 charging process can however be terminated prematurely by

exiting from the display group number.

– Press the ↑ key to continue.

If the following is indicated on display:
System in basic setting ->28
Charging RA, continue with next channel

– Press the ↑ key to continue.

If the following is indicated on display:
System in basic setting 29->
Charging rear axle, function in progress

Note

Press the ↓ key to return to GE 28.

Indicated on display after 65 seconds:

System in basic setting 29->
Charging rear axle, function completed

Note

The charging process can however be terminated prematurely by

exiting from the display group number.

– Press the ↑ key to continue.

If the following is indicated on display:
System in basic setting 30->
Ch. pr. cont., contin. with next channel

– Press the ↑ key to continue.

If the following is indicated on display:
System in basic setting 31->
Charging pressure container, function in
progress

248 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Note

Press the ↓ key to return to GE 30.

Indicated on display after 65 seconds:

System in basic setting 31->
Charging pressure container, function com
pleted

Note

The charging process can however be terminated prematurely by

exiting from the display group number.

– Remove the diagnostic cable from the diagnostic connection.

Further charging processes can then be performed in the above
manner. The sequence (charging front axle air springs, rear axle
air springs, pressure container) is arbitrary.
On exiting from charging mode, note that the adaptive suspension
remains manually deactivated until it is switched in again or until
a vehicle speed of more than 15 km/h is detected.

3.6 System bleeding (allroad)

Bleeding of the air spring system can be implemented without
unfastening any mechanical connections.
Filling the system using self-diagnosis may only be carried
Protected out Copying for private or commercial purposes, in part or in whole, is not
by copyright.
when the vehicle is stationary. 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

Bleeding of the air springs lowers the level of the self-support‐

ing vehicle.

3. Pneumatic adaptive suspension - allroad 249

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Note

♦ The air spring system (pressure container, air springs, com‐

pressed air pipes) can be bled using the fault reader down to
a residual pressure of < 3.5 bar.
♦ The pressure container can be bled without entering a login
code (display group number 20-21).
♦ The front/rear air springs are bled separately and a correct
login code must be entered beforehand (display group number
22...25).
♦ Bleeding is only possible following manual deactivation of the
adaptive suspension. The adaptive suspension is deactivated
and activated by means of the fault reader (function 10, chan‐
nel 10) or using the manual up/down keys (double press > 5
seconds).
♦ The bleeding time is limited to 65 seconds. The procedure can
however be implemented several times in succession to ach‐
ieve a longer overall bleeding time.
♦ Bleeding can be performed in stages using the up/down arrow
keys on the fault reader (on the fault reader - V.A.G 1551- ,
keys 1/3 are also assigned as ↓ key/ ↑ key).

Technical data of self-diagnosis

♦ Data are transmitted between the control unit and the vehicle
diagnostic, testing and information system - VAS 5051- or the
fault reader - V.A.G 1551- in “rapid data transfer” mode.
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 fault memory is designed as a non-volatile memory
withand
respect to the correctness of information in this document. Copyright by AUDI AG.
is thus independent of the power supply.
Connecting up vehicle diagnostic, testing and information system
- VAS 5051- or fault reader - V.A.G 1551- and selecting functions

Note

♦ Battery voltage min. 11 V

♦ Earth connections at engine and gearbox OK
♦ Engine off
♦ Automatic gearbox set to “P” or “N”

250 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Procedure
– With the ignition off, connect up the vehicle diagnostic, testing
and information system - VAS 5051- with the diagnostic cable
- VAS 5051/1- . Alternatively, connect up the fault reader -
V.A.G 1551- with the diagnostic wire - V.A.G 1551/3A- .

Note

The following description only applies to the self-diagnosis pro‐

cedure for the fault reader - V.A.G 1551- . Consult the operating
manual if use is being made of the vehicle diagnostic, testing and
information system - VAS 5051- .
4)
Indicated on display:
V.A.G - SELF-DIAGNOSIS HELP
1 - Rapid data transfer

4)
Indicated on display:
V.A.G - SELF-DIAGNOSIS HELP
2- Flash code output

4) alternating displays

Note

If display screen remains blank: ⇒ Operating instructions for fault

reader .

– Switch on ignition.
– Manually deactivate the adaptive suspension (double press
on key > 5 seconds on manual operating unit).
– Switch on printer of fault reader by pressing Print key. The
lamp in the key must light.
– Press key 1 for “Rapid data transfer”.
If the following is indicated on display:
Rapid data transfer HELP
Enter address word XX

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. Pneumatic adaptive suspension - allroad 251

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Note

♦ Address word 00 implements the automatic test sequence, i.e.

the fault memories of all vehicle systems with self-diagnosis
capability are interrogated with rapid data transfer.
♦ Enter 3 and 4 for the address word “Adaptive suspension”.
♦ Indicated on display:
Rapid data transfer Q
34 - Adaptive suspension

♦ Confirm with Q key.

♦ Indicated on display:
Rapid data transfer Q
Tester transmits address word 34

The following display appears after approx. 5 seconds (example):

4Z7 907 553A - 2C1A1 X016 ->
Coding 25500 WSC XXXXX

Press → key.

Indicated on display:
Rapid data transfer HELP
Select function XX

Note

A list of possible functions can be printed out by pressing the

HELP key.

– Press keys 1 and 1 for the “Login procedure” and confirm with
Q key.

Indicated on display: 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
Basic setting Q with respect to the correctness of information in this document. Copyright by AUDI AG.
11 - Log-in procedure

– Confirm entry with Q key.

Indicated on display:
Login procedure ->
Enter code number XXXXX

– Press keys 0 , 8 , 3 , 6 and 7 .

Indicated on display:
Login procedure ->
Enter code number 08367

– Confirm entry with Q key.

If the following is indicated on display:
Rapid data transfer HELP
Select function XX

– Press keys 0 and 4 .

If the following is indicated on display:
Rapid data transfer Q
04 - Basic setting

252 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Confirm entry with Q key.

If the following is indicated on display:
Basic setting
Enter display group number XXX

– Enter the display group number.

– Press keys 0 , 2 and 0 .
– Confirm entry with Q key.
If the following is indicated on display:
System in basic setting ->20
Bl. pr. cont., contin. with next channel

– Press the ↑ key to continue.

If the following is indicated on display:
System in basic setting ->21
Bleeding pressure container, function in
progress

Note

Press the ↓ key to return to GE 20.

Indicated on display after 65 seconds or on dropping below 3.5

bar in pressure container:
System in basic setting ->21
Bleeding pressure container, function com
pleted

Note

The bleeding process can however be terminated prematurely by

exiting from the display group number.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Press the ↑ key to continue.
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.
If the following is indicated on display:
System in basic setting ->22
Bleeding FA, continue with next channel

– Press the ↑ key to continue.

If the following is indicated on display:
System in basic setting ->23
Bleeding front axle, function in progress

Note

Press the ↓ key to return to GE 22.

Indicated on display after 65 seconds or on dropping below 3.5

bar in pressure container:
System in basic setting ->23
Bleeding front axle, function completed

3. Pneumatic adaptive suspension - allroad 253

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Note

The bleeding process can however be terminated prematurely by

exiting from the display group number.

– Press the ↑ key to continue

If the following is indicated on display:
System in basic setting ->24
Bleeding RA, continue with next channel

– Press the ↑ key to continue.

If the following is indicated on display:
System in basic setting 25->
Bleeding rear axle, function in progress

Note

Press the ↓ key to return to GE 24.

Indicated on display after 65 seconds or on dropping below 3.5

bar in pressure container:
System in basic setting 25->
Bleeding rear axle, function completed

Note

♦ The bleeding process can however be terminated prematurely

by exiting from the display group number.
♦ If the residual pressure has not dropped below 3.5 bar after
65 seconds, the display “.....bleeding function terminated” ap‐
pears instead of “...bleeding function completed”.

– Remove the diagnostic cable from the diagnostic connection.

Further bleeding processes can then be performed in the above
manner. The sequence (bleeding front axle air spring, rear axle
air springs, pressure container) is arbitrary.
On exiting from charging mode, note that the adaptive suspension
remains manually deactivated until it is switched in again or until
a vehicle speed of more than 15 km/h is detected.

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.

254 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

4 Compressor (allroad)
⇒ “4.1 Exploded view”, page 255
⇒ “4.2 Removing and installing compressor”, page 256

4.1 Exploded view

All plastic air connections are to be tightened to 2 Nm.
The plastic air connections are to be secured between the marks
on the air hose.
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 - Electrical connection for
compressor drive
2 - Intake/discharge pipe
3 - Air dryer
4 - Adaptive suspension sys‐
tem compressor temperature
sender - G290-
5 - Additional intake silencer
6 - Valve unit with adaptive
suspension pressure sender -
G291-
❑ The front left suspen‐
sion strut valve - N148- ,
the front right suspen‐
sion strut valve - N149- ,
the rear left suspension
strut valve - N150- , the
rear right suspension
strut valve - N151- and
the adaptive suspen‐
sion pressure accumu‐
lator valve - N311- are
combined in one valve
unit.
❑ Tightening torque for
bolt in centre of valve
unit between connec‐
tions: 4 Nm
❑ Attachment of valve
block to base plate: 3.5
Nm
7 - Compressor
8 - Electric motor
9 - Pneumatic drain valve
10 - Adaptive suspension drain valve - N111-
11 - Pressure pipe, 2 Nm
12 - Compressor pressure line connection
❑ Coloured mark: brown
13 - Connection/front left suspension strut
❑ Coloured mark: red
14 - Connection/pressure container
❑ Coloured mark: violet

4. Compressor (allroad) 255

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

15 - Connection/rear right suspension strut

❑ Coloured mark: blue
16 - Connection/rear left suspension strut
❑ Coloured mark: black
17 - Connection/front right suspension strut
❑ Coloured mark: green

4.2 Removing and installing compressor

Exploded view

1 - Flange nut
Tightening torque: 10 Nm

2 - Shield
3 - Mounting element
4 - Flange bolt
Tightening torque: 23 Nm

5 - Compressor unit
6 - Flange nut
Tightening torque: 23 Nm

7 - Coil spring
8 - Damping element
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
Nut tightening torque:
with respect to6theNm
correctness of information in this document. Copyright by AUDI AG.

Removing
– Bleed the system ⇒ page 249 .
– Remove the anti-roll bar.
– Unfasten the flange nuts for the shield.
– Unfasten the hose at the shield.
– Take out the shield.

256 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unfasten the hose -1- and unplug the connector -2- at the
compressor.
– Unfasten the flange nuts.

Note

The nuts at the damping element are not to be unfastened.

– Take out the compressor unit.

Installing
– Secure the compressor unit with the flange nuts.
Tightening torque: 23 Nm

– Attach the hose -1- to the compressor unit.

Tightening torque: 2 Nm
– Plug in the connector -2- at the compressor unit.
– Secure the shield.
Tightening torque: 10 Nm

Note

♦ The curved plastic discharge pipe at the compressor must not

make contact when the shield is fitted.
♦ The bottom part of the compressor and the discharge valve
must not make contact with the insulating material of the
shield.
♦ The corrugated tubing with the cables and the intake/dis‐
charge hose of the compressor must not make contact with
the insulating material of the spare wheel well.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ The cable for the discharge valve must not be taut.
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 compressor must be free to oscillate.

– Secure the hose at the shield.

– Install the anti-roll bar.

4. Compressor (allroad) 257

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

5 Adaptive suspension control unit -

J197- (allroad)
⇒ “5.1 Removing and installing adaptive suspension control unit
J197 (allroad)”, page 258

5.1 Removing and installing adaptive sus‐

pension control unit - J197- (allroad)
Removing adaptive suspension control unit (allroad)
– Remove the luggage compartment side trim on the driver's
side ⇒ General body repairs, interior; Rep. gr. 70 ; Avant trim
panels; luggage compartment side trim .
– Unplug the connector at the control unit.
– Detach the earth connection at the body -arrow-.
– Take out the control unit in the direction Protected
of travel.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
Adaptive suspension control unit (allroad) installation
with respect to the correctness of information in this document. Copyright by AUDI AG.

Vehicles as of chassis no.:

♦ 4B 1N 057 986 ( Rest of World)
♦ 4B 1N 056 142 ( USA )
– Slide the control unit onto the ribbed section of the holder and
clip in position.

– Screw the earth cable to the body.

Tightening torque: 11 Nm
– Plug in the connector at the control unit.
– Install the luggage compartment side trim on the driver's side
⇒ General body repairs, interior; Rep. gr. 70 ; Avant trim pan‐
els; luggage compartment side trim .
Vehicles prior to chassis no.:
♦ 4B 1N 057 986 ( Rest of World)
♦ 4B 1N 056 142 ( USA )
On vehicles prior to the above-mentioned chassis numbers, the
old control unit may not be fitted with an earth cable. Only new
control units with screen and earth cable are available as re‐
placement parts.

258 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– If applicable, drill a hole -b- of 4 mm diameter with the dimen‐

sion -a- = 20 mm as shown.
– Re-establish the corrosion protection.
– Slide the control unit onto the ribbed section of the holder and
clip in position.
– Screw the earth cable to the body using the bolt - N 905 567 .
01- .
Tightening torque: 3.5 Nm
– Plug in the connector at the control unit.
– Install the luggage compartment side trim on the driver's side
⇒ General body repairs, interior; Rep. gr. 70 ; Avant trim pan‐
els; luggage compartment side 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.

5. Adaptive suspension control unit J197 (allroad) 259

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

6 Front axle suspension strut (allroad)

⇒ “6.1 Removing and installing front axle suspension strut (all‐
road)”, page 260
⇒ “6.2 Removing and installing mounting bracket (allroad)”, page
264
⇒ “6.3 Unbolting upper link from allroad mounting bracket”, page
265
⇒ “6.4 Removing and installing air spring”, page 265

6.1 Removing and installing front axle sus‐

pension strut (allroad)
Removing
– Deactivate the adaptive suspension at normal level
⇒ page 304 .
– Bleed the suspension strut system ⇒ page 249 .
– Remove wheels.
– Secure brake disc with one wheel bolt.
– Remove the cover for the plenum chamber/battery.

Note

So as not to damage the joints of the lower links, support must be

provided for example by way of the engine and gearbox lifter -
V.A.G 1383 A- to prevent excessive rebound.

– Only unscrew the air hose connection at the suspension strut

to the extent required to allow air to escape.
– Once the pressure in the suspension strut/air hose has been
fully dissipated, remove the air hose by unfastening the screw
connection at the suspension strut.
– Unfasten the vehicle level sender at the track control link.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Pay attention to the installation position.
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.
Pay attention to the adaptive suspension/headlight range control
⇒ page 69 .

260 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove bolts -2-. Tightening torque: 45 Nm and turn 55° fur‐

ther.

– Unscrew bolt -arrow-. Tightening torque: 45 Nm and turn 55°

further.
– Protect the steering rack boot against damage.
For greater clarity, the steering rack has been removed in the il‐
lustration.

The protective sleeve -1- can be ordered under part no. -893 512
137- .
– A strip, dimension -A- 20...25 mm, must be cut out of protective
sleeve -1- .
– Carefully deburr the cut surfaces.
– Push the protective sleeve over the steering rack boot. The
open, slit section should face downwards.

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. Front axle suspension strut (allroad) 261

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove nut -1-.

Do not attempt to enlarge slots in wheel bearing housing using a
chisel or similar.
– Take out hexagon bolt and lift out link -2-.
– Swing wheel bearing housing away to the side in direction of
arrow.
Bolts -3- and -4- are never to be slackened off.
Otherwise the wheel alignment must be checked.
To unscrew the hexagon bolt from the suspension strut/track con‐
trol link, the guide link must first be detached from the wheel
bearing housing.

Note

♦ Use a leather cloth for example to protect the boot against

damage.
♦ For safety reasons, screw the collared nut at the joint pin of
the track control link back on again by approx. 4 turns such
that it is flush.
♦ Make sure both lever arms are in parallel when applying max‐
imum force and adjust if necessary.

Counterhold joint pin with 4 mm Allen key.

– Unscrew nut from guide link joint pin and press off joint pin.
Take care not to damage boot.

– Unscrew the suspension strut/track control link bolt -2-.

– Remove suspension strut downwards.

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.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– As shown, only grasp hold of the suspension strut at the

mounting bracket and shock absorber tube.

Note

Take care not to damage the boot when removing the suspension
strut.

– Mark the shock absorber/mounting bracket positions.

Installing
Hold suspension strut against mounting bracket and damping
pipe.
– Position the mounting bracket in line with the mark.

– Attach suspension strut with mounting bracket to body.

Use new bolts.
The numbering of the attachment sequence shown is mandatory.
Tightening torque: 45 Nm and turn 55° further.
– Bolt suspension strut to track control link. Tightening torque:
90 Nm.
– Bonded rubber bushes can only be turned to a limited extent.
The bolt connection between the suspension strut and the
track control link should therefore only be tightened when the
vehicle is standing on the ground.

Note

♦ The vehicle must not be standing on its wheels before charg‐

ing has been performed.
♦ Remove any remnants of adhesive on thread of joint pin.

– Tighten new nut to 100 Nm. Provide support at the joint pin
with a 4 mm Allen key when doing so.

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. Front axle suspension strut (allroad) 263

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Insert upper link into wheel bearing housing and tighten new
nut -6- to 40 Nm.
– When screwing on, press down the upper links as far as pos‐
sible.
– Screw on the VOSS air connection (2 Nm).
– Correctly position the scuff guard -7-.
– Fit new nuts for suspension strut and tighten to 20 Nm.
Take care not to damage the surface of the brake pipes.
– Attach the adaptive suspension holder to the track control link.
– Insert rubber grommets in plenum chamber.
– Charge the air spring ⇒ page 244 .

Note

The vehicle must not be standing on its wheels before charging

has been performed.

– Fit wheel and tighten. ⇒ Wheels and tyres; Rep. gr. 44

– Perform adaptive suspension basic setting ⇒ page 244 .

6.2 Removing and installing mounting

bracket (allroad)
– Remove the suspension strut beforehand ⇒ page 260 .
– Clamp suspension strut in vice in area of fork (use soft jaws).
– Mark the shock absorber/air spring piston/mounting bracket
positions.
– Slacken off the bolt -arrow- (6x). Tightening torque: 23 Nm.
Use new bolts and rubber seals!
– Grease the new upper rubber seal ⇒ page 265 .

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.

264 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

6.3 Unbolting upper link from allroad mount‐

ing bracket
Removing
– Remove the suspension strut beforehand ⇒ page 260 .
– Slacken off the bolt -1- (2x).

Installing
– Place a straight edge -2- e.g. a ruler on the bearing block as
shown in the illustration.
Dimension -A- = 65 mm ± 2 mm.
Dimension -B- = 49.5 mm ± 2 mm.
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
Measured from straight edge to highest point
with respect to theat steering
correctness wheel. in this document. Copyright by AUDI AG.
of information

– Renew all bolts and nuts.

– Tighten hexagon bolts -1- for both links to 50 Nm and turn 90°
further.

6.4 Removing and installing air spring

Removing
– Remove the suspension strut beforehand ⇒ page 260 .
– Mark the shock absorber/air spring piston/mounting bracket
positions.
– Detach the mounting bracket ⇒ page 264 .
– Remove nut -1-.
– Use new nut.
Tightening torque: 60 Nm
– Pull air spring bellow upwards.

6. Front axle suspension strut (allroad) 265

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Installing
Install in reverse order of removal.
– Coat the rubber seal -2- with lithium grease - G 052 150 A2- .
– Align the shock absorber/air spring piston/mounting bracket in
accordance with the marks.
– Make sure the auxiliary spring in the cover is firmly attached.
The lower rubber seal and the shock absorber tube must be dry
and free from dust. 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.

– The lower rubber seal must rest on the second stage of the
shock absorber tube from the top.
– Fit the air spring on the rubber seal and carefully slide down‐
wards into the end position. Before moving the air spring to the
end position, check proper attachment of the rubber seal
(twisting).

Note

Take care to keep the air spring straight when pressing down.

The movement of the piston causes the rubber seal to roll as far
as the 3rd shoulder, on which the air spring rests and provides a
seal.
• Correct fitting of the rubber seal must be checked in the next
operation.

– Push the air spring back out of the end position -arrow- by
approx. 5 cm.
– Visually inspect the rubber seal -1-.

Note

The rubber seal -1- must not be damaged, misshapen or twisted.

– Move the air spring back into the end position.

266 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Prior to charging, the dimension -A- between the centre of the

hole for the air spring/track control link bolted joint and the
bottom end of the air spring must be less than 262 mm.
– Check cross movement of piston.
It must not be possible to turn air spring on damper.
– Fit the mounting bracket ⇒ page 264 .
– Install suspension strut ⇒ page 263 .

– As shown, only grasp hold of the suspension strut at the

mounting bracket and shock absorber 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.

6. Front axle suspension strut (allroad) 267

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

7 Rear axle air spring damper (allroad)

⇒ “7.1 Exploded view: Rear axle air spring damper (allroad)”,
page 268
⇒ “7.2 Removing and installing shock absorber/spring”,
page 269

7.1 Exploded view: Rear axle air spring damper (allroad)

1 - Self-locking hexagon nut,

27 Nm
❑ Always renew after re‐
moving
❑ Remove air-tight seal‐
ing plug beforehand
2 - Air spring
❑ Fitting ⇒ page 238
3 - Shock absorber
4 - Clip
5 - Self-locking nut, 70 Nm +
turn 90° further
❑ Always renew after re‐
moving
6 - Washer
7 - Air spring strut
8 - Hexagon bolt M 12 x 1.5 x
95
❑ Always renew after re‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
moving 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.
9 - Connection piece
❑ Heed the note
⇒ page 231
10 - Air pipe
❑ Clip in the air pipes at
the marked locations
❑ Heed the note
⇒ page 231
11 - Connection piece
❑ Heed the note
⇒ page 231
12 - Hexagon bolt, 45 Nm

268 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Fitting air spring strut

The bayonet catch must be absolutely clean.
– Coat the rubber seals -1- and -2- with lithium grease - G 052
150 A2- .
– Fasten the bayonet catch by simultaneously pressing and
turning.

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.

7.2 Removing and installing shock absorb‐

er/spring
The removal and installation operations are the same as for the
2-wheel air suspension ⇒ page 238 .
Removing
– Bleed the system ⇒ page 249 .
Installing
– Charge the air spring ⇒ page 244 .

Note

The vehicle must not be standing on its wheels before charging

has been performed.

7. Rear axle air spring damper (allroad) 269

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

8 Dynamic Ride Control DRC -RS 6-

⇒ “8.1 Fitting locations”, page 270
⇒ “8.2 Central valve and pipe connections for suspension struts”,
page 271
⇒ “8.3 DRC fault-finding”, page 272
⇒ “8.4 DRC system pressure test”, page 273
⇒ “8.5 Discharging and charging Dynamic Ride Control (DRC)”,
page 275
⇒ “8.6 Removing and installing central valve”, page 285
⇒ “8.7 Service installation of dust sleeve for shock absorber piston
rod”, page 286

8.1 Fitting locations

Dynamic Ride Control (DRC)
Illustration applies to Saloon and Avant.

1 - Suspension strut (front

right)
⇒ page 271

2 - Right line
3 - Rear right suspension strut
⇒ page 272

4 - Right central valve

⇒ page 271

5 - Left central valve

⇒ page 271
6 - Rear left suspension strut
⇒ page 272

7 - Left line
8 - Suspension strut (front left)
⇒ page 271

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.

270 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

8.2 Central valve and pipe connections for suspension struts

1 - DRC pipe to rear suspen‐

sion strut
2 - DRC pipe to rear suspen‐
sion strut
3 - Central valve
4 - Hexagon bolt
❑ Tightening torque: 23
Nm
5 - Gasket
6 - Hexagon 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
❑ Tightening torque: 23 with respect to the correctness of information in this document. Copyright by AUDI AG.
Nm
7 - Retainer
8 - Retainer
9 - Bolt
❑ Tightening torque: 9 Nm

Front suspension strut

-1- Tightening torque: 18 Nm
-2- Tightening torque: 16 Nm
-3- Tightening torque: 16 Nm
-4- Tightening torque: 18 Nm

8. Dynamic Ride Control DRC -RS 6- 271

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Rear suspension strut

-1- Tightening torque: 25 Nm
-2- Tightening torque: 18 Nm

8.3 DRC fault-finding

Start
Rattling noise Exces‐
coming from sus‐ sive body
pension or rear of roll when
vehicle when entering
driving over a bend
rough surfaces
→ Visible fluid leakage? ←
↓ ↓
♦ Check com‐ ← Yes No → Check
ponents proper at‐
tachment
♦ Seal (O-rings) of all
quick-release quick-re‐
fasteners or lease fas‐
replace teners
♦ Renew leak‐
ing shock ab‐
sorbers

↓ ↓
↓ Problem eliminated?
↓ ↓ ↓
↓ No ↓ Yes ↓
↓ ♦ Unfas‐ ↓
ten
front
quick-
re‐
lease
fasten‐
ers
♦ Check
system
pres‐
sure in
both
lines

↓ ↓ ↓
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
↓permitted unless authorised by AUDISystem
AG. AUDIpressure
AG does not guarantee↓ or accept any liability
higher than 12.0
with respect to the correctness of information in this document. Copyright by AUDI AG.

bar?
↓ No ↓ Yes ↓ ↓

272 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Drain, evacuate and charge the entire ↓ ↓

DRC section with the DRC system
charging device - VAS 6544- , perform
leak test ⇒ page 275 .
↓ ↓ ↓
↓ ↓
↓
End

8.4 DRC system pressure test

Special tools and workshop equipment required
♦ Oil pressure tester - V.A.G 1342/- and adapter - V.A.G
1342/18-

The system pressure test is carried out at the front shock absorber
of the section of the system that is to be tested.
– Apply full steering lock in the direction of the side to be
checked.
The front wheel need not be removed.
– Unfasten the lock nut -1- at the suspension strut holder.
– Unscrew the union nut -2- and detach the pipe from the sus‐
pension strut.

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
On disconnecting the coupling, integrated
permitted unless authorisedvalve
by AUDIinserts
AG. AUDIautomat‐
AG does not guarantee or accept any liability
ically seal the pipe connections. The
with respect leakage
to the quantity
correctness of approx.
of information 1 Copyright by AUDI AG.
in this document.
cubic centimetre is system-related and not critical. Considerable
leakage is however an indication of a defective coupling and will
inevitably lead to system failure.

– Screw the adapter - V.A.G 1342/18- to the oil pressure tester

- V.A.G 1342/- and tighten to 15 Nm.

8. Dynamic Ride Control DRC -RS 6- 273

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Hold the oil pressure tester - V.A.G 1342/- with the adapter -
V.A.G 1342/18- facing upwards at the now vacant connection
of the DRC pipe. Screw the union nut -1- as far as it will go
onto the oil pressure tester - V.A.G 1342/- and hand-tighten
without using a tool.

Caution

Never turn the oil pressure tester, but rather only the union nut
of the pipe connection. Otherwise there is a danger of the valve
insert of the coupling working loose and oil escaping. Consid‐
erable leakage will inevitably lead to system failure and ne‐
cessitates recharging of the relevant DRC section.

Note

The pressure in the oil pressure tester only builds up slowly and
takes roughly 2 minutes. The DRC system pressure reading is not
to be taken until the pointer of the oil pressure tester has finally
settled.

– Read the system pressure off the oil pressure tester - V.A.G
1342/- .
– After taking the measurement, disconnect the oil pressure
tester from the pipe.

Note

The small quantity of oil escaping from the connection on pulling

out the oil pressure tester is not critical. Repeat measurements
are to be avoided, as a small quantity of oil is drawn from the
system each time the oil pressure tester is connected. On re‐
newed connection, this results in a pressure reduction of ap‐
prox. 0.5 bar with respect to the preceding measurement. Several
repeated measurements will thus cause the pressure in the sys‐
tem to drop below the minimum limit and recharging of the rele‐
vant section of the DRC system will be required.

– If the pressure is OK, fit the oil pipe at the suspension strut and
screw on the union nut -2-.
– Fit the lock nut -1- at the suspension strut holder.
– If the pressure is not OK, trace the cause of the fault and repair
the system. 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
DRC system pressure values with respect to the correctness of information in this document. Copyright by AUDI AG.

These pressure values are based on a reference temperature of

20 °C.
♦ 16 bar = Maximum pressure
♦ 15 bar -16 bar = Central valve new or in as-new condition
♦ 12 bar -15 bar = Normal working range; system OK
♦ < 12 bar = System leaking or not fully charged; air trapped in
system; central valve depressurised/empty.

274 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

8.5 Discharging and charging Dynamic Ride

Control (DRC)
General notes

Note

Drainage, evacuation and charging of the entire DRC section

(pipes/shock absorbers and central valve) are performed using
the DRC system charging device - VAS 6544- . Depending on the
equipment available in your workshop for the DRC system, it may
be necessary to modify/convert the existing equipment with the
appropriate supplementary, upgrade or retrofit kits to meet the
standard of the filling device for DRC system - VAS 6544- . Op‐
tions available:

Special tools and workshop equipment required

♦ Upgrading kit, DRC system charging device - VAS 6209/4-

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.

♦ The upgrading kit, DRC system charging device - VAS 6209/4-

is designed for the upgrading of workshop Audi RS 6 DRC
system charging devices - VAS 6209- .
♦ Retrofit kit, filling device DRC system - VAS 6209/5-

♦ The retrofit kit, DRC system - VAS 6209/5- is required by

workshops in possession of a pressure pump - VAS 6209/3-
who wish to upgrade this to the technical standard of the DRC
system charging device - VAS 6544- . The supplementary kit,
DRC system - VAS 6209/6- must also be obtained.

8. Dynamic Ride Control DRC -RS 6- 275

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Supplementary kit, DRC system - VAS 6209/6-

♦ The supplementary kit, DRC system - VAS 6209/6- is required

to upgrade the existing pressure pump - VAS 6209/3- to the
technical standard of the DRC system charging device - VAS
6544- . Workshops must however already beProtected
in possession
by copyright.ofCopying for private or commercial purposes, in part or in whole, is not
the Audi RS 6 DRC system charging device permitted
- VAS 6209- . If by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
the workshop is not equipped with the charging with
device
respectfor Audi
to the correctness of information in this document. Copyright by AUDI AG.
RS 6 DRC system - VAS 6209- the retrofit kit, filling device
DRC system - VAS 6209/5- must be obtained additionally.
♦ Filling device for DRC system - VAS 6544-

Note

The equipment for the DRC system only needs to be modified

once in your workshop. It is not necessary to convert the equip‐
ment back to its original condition. The further operations for
draining and charging the entire DRC system are described using
the DRC system charging device - V.A.S 6544- .

Use only the approved type of fluid when charging and topping
up the system. Please refer to ⇒ Electronic parts catalogue “ET‐
KA” .
Replacement shock absorbers and pipes are supplied empty.
Charging is only to be performed at ambient temperature (approx.
20° C).
Pipes/shock absorbers and central valves may only be dis‐
charged, evacuated and charged when they are connected and
installed in the vehicle.
The vehicle must never be lowered onto its wheels when the DRC
system is separated from the individual components (e.g. con‐
nection between pipe/shock absorbers/central valve).
When charging the DRC system, the gas accumulator leading to
the pressure chambers at the piston in the central valve is auto‐
matically checked for leaks.

276 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

If it is not possible to attain a pressure of 22 bar during charging

of the DRC system or if there is a continuous drop in pressure,
check the isolating couplings for proper attachment and the O-
rings of the connections for damage. If no irregularities are visible
on the outside, the piston of the gas accumulator inside the central
valve leading to the pressure chambers is leaking, so the central
valve must be renewed.
Drainage, evacuation and charging of the DRC system are to be
performed at the joints with the adapter ⇒ Item 1 (page 277) and
⇒ Item 2 (page 277) of the corresponding shock absorber of the
section concerned connected. Observe the following:

WARNING

Safety goggles must be worn for all operations.

The valves on the workshop equipment are open when the cut-
off lever is in line with the direction of flow.
Pipes must not be bent.
Workshop equipment required

1 - Adapter for front shock ab‐

sorber
2 - Adapter for rear shock ab‐
sorber
3 - Charging lines with quick-
release couplings
4 - Venturi nozzle with air outlet
hose
❑ From Audi RS 6 DRC
system charging device
- VAS 6209-
5 - Connecting hose
❑ From Audi RS 6 DRC
system charging device
- VAS 6209-
6 - Filling device for DRC sys‐
tem - VAS 6544- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
7 - Used fluid container 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.
❑ Empty before starting
work
❑ Identified by red dot

8. Dynamic Ride Control DRC -RS 6- 277

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Note

♦ Before starting to charge the DRC system, it must be ensured

that the oil container of the DRC system charging device - VAS
6544- and the connecting pipe between the pressure pump
and the oil container have been filled with oil.
♦ The used fluid container of the filling device for DRC system -
VAS 6544- must be empty.

Draining used oil container

– Unscrew the cap -arrow- from the used oil container -1- and
dispose of the used oil.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Screw the cap -arrow- onto the used fluid container -1-.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.

Filling and bleeding filling device for DRC system - VAS 6544-
– Fill the oil container -2- with fresh oil as far as the mark and
position the O-ring in line with the oil level ⇒ Electronic parts
catalogue “ETKA” .

278 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Close the check valves -A- and -C- of the DRC system charg‐
ing device - VAS 6544- .
– Close needle valve -B-.

– Connect hose -2- to used fluid container -arrow- and quick-

release coupling -4- of filling device for DRC system - VAS
6544- .

– Connect the venturi nozzle -3- with exhaust air hose to the
used oil container -arrow- as shown.
– Connect compressed air line to venturi nozzle -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.

8. Dynamic Ride Control DRC -RS 6- 279

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Open shut-off valve -C-.

– Open shut-off valve -A- briefly (for about 1-2 seconds) until line
-1- between fluid tank -2- and pressure pump is filled with bub‐
ble-free fluid.
– Close shut-off valve -C-. Disconnect compressed air line from
venturi nozzle.

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.

280 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Draining and charging

WARNING

Safety goggles must be worn for all operations.

– Remove the front wheel on the side to be drained.

– Unfasten the lock nut -1- at the holder of the section to be
drained at the front suspension strut.
– Unscrew the union nut -2- and detach the pipe from the sus‐
pension strut.

Note

On disconnecting the coupling, integrated valve inserts automat‐

ically seal the pipe connections. The leakage quantity of approx. 1
cubic centimetre is system-related and not critical. Considerable
leakage is however an indication of a defective coupling and will
inevitably lead to system failure.

– Screw adapters -1- to the now vacant connections at the shock

absorber -arrow- and screw on the pipe -arrow- hand-tight as
far as it will go.

– Unfasten the lock nut -2- at the holder of the section to be

drained at the rear suspension strut and take the pipe out of
the holder.
– Unscrew the union nut -2- and pull the pipes apart.

Note

On disconnecting the coupling, integrated valve inserts automat‐

icallyProtected
seal the pipe connections. The leakage quantity of approx. 1
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
cubic centimetre is correctness
with respect to the system-related and
of information not
in this critical.
document. Considerable
Copyright by AUDI AG.
leakage is however an indication of a defective coupling and will
inevitably lead to system failure.

8. Dynamic Ride Control DRC -RS 6- 281

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Screw adapters -1- to the now vacant connections at the shock

absorber -arrow- and screw on the pipe -arrow- hand-tight as
far as it will go.

– Connect charging lines ⇒ Item 3 (page 277) to connections

-A- and -B- of the filling device for DRC system - VAS 6544- .

– Connect the unused quick-release coupling -2- of the charging

pipes ⇒ Item 3 (page 277) to the adapter previously fitted at
the front of the 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

282 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Connect the unused quick-release coupling -2- of the charging

pipes ⇒ Item 3 (page 277) to the adapter previously fitted at
the rear of the vehicle.

Shut-off valves -A- and -C- of filling device for DRC system - VAS
6544- closed.
Needle valve -B- closed.

Hose -2- connected to used fluid container -arrow- and to filling

device for DRC system - VAS 6544- -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.

8. Dynamic Ride Control DRC -RS 6- 283

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Venturi nozzle -3- with air outlet hose connected to used fluid
container -arrow- of filling device for DRC system - VAS 6544- .
Compressed air connected to venturi nozzle -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.

– Open valve -C- until fluid is discharged from DRC system

down to the smallest possible remainder. (This is visible at re‐
turn hose -2- going to used fluid container).
– At a pressure gauge reading of approx. minus 0.9 bar, close
valve -C- and disconnect compressed air line from venturi
nozzle.
• Perform a leak test.

Note

Vacuum must be maintained stable at minus 0.9 bar for at least

2 minutes.

– Check fluid level in fluid container, fill up fluid container with

fresh fluid as far as the mark (if necessary) and position O-ring
in line with fluid level ⇒ Electronic parts catalogue “ETKA” .

– Open the needle valve -B- by approx. two turns and allow the
oil from the oil container of the DRC system charging device -
VAS 6544- to run into the evacuated DRC system.
The fluid will flow out of the fluid container and into the connected
DRC system. This can be seen from the dropping fluid level in the
fluid container. This process may take several minutes, depend‐
ing on the quantity of fluid remaining after drainage. The rate at
which the fluid level drops decreases as system charging pro‐
gresses. When the fluid level stops moving, the first step in the
charging process is complete.
– Close needle valve -B-.

284 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Open valve -A- and charge DRC system to 22 bar by repeat‐

edly pumping lever of hand-operated pump -1-.

Note

Make sure the oil container of the DRC system charging device -
VAS 6544- does not run empty whilst charging. Top up the oil
container with fresh oil if necessary.

• When a pressure of 22 bar has been reached, close valve

-A- and stop pumping lever of hand-operated pump.

Note

If the pressure of 22 bar could not be reached, or if the pressure

drops continuously, the separating couplings must be checked to
ensure they are properly seated and the O-rings on the connec‐
tions checked for damage. If no irregularities are visible on the
outside, the piston of the gas accumulator inside the central valve
leading to the pressure chambers is leaking, so the central valve
must be renewed.

– Open needle valve -B- slightly and allow pressure to drop to

16 bar.
• Once the pointer of the pressure gauge has reached the 16
bar mark, close the valve -B-.
Charging of the DRC system is now completed.
– Detach the charging pipes at the isolating couplings from the
adapters.
– Remove the rear and front adapters from the vehicle and con‐
nect the joints at the couplings to the shock absorbers
⇒ page 271 ⇒ page 272 .

Note

On disconnecting the coupling, integrated valve inserts automat‐

ically seal the pipe connections. The leakage quantity of approx. 1
cubic centimetre is system-related and not critical. Considerable
leakage is however an indication of a defective coupling and will
inevitably lead to system failure.

8.6 Removing and installing central valve

General notes
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
The DRC system equipment available in the workshop may have
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

to be modified/converted with the corresponding supplementary,

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

upgrading or retrofit kit ⇒ page 275 .

Special tools and workshop equipment required

8. Dynamic Ride Control DRC -RS 6- 285

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Filling device for DRC system - VAS 6544-

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.

Pipes/shock absorbers and central valves may only be dis‐

charged, evacuated and charged when they are connected and
installed in the vehicle.
The vehicle must never be lowered onto its wheels when the DRC
system is separated from the individual components (e.g. con‐
nection between pipe/shock absorbers/central valve).
Removing
– Remove heat shield in area of exhaust system.

WARNING

Safety goggles must be worn for all operations.

– Drain the corresponding pipe section

⇒ “8.5 Discharging and charging Dynamic Ride Control
(DRC)”, page 275 .
– Detach the central valve at the predetermined separating
points from the damper and the pipe.

Note

On disconnecting the coupling, integrated valve inserts automat‐

ically seal the pipe connections. The leakage quantity of approx. 1
cubic centimetre is system-related and not critical. Considerable
leakage is however an indication of a defective coupling and will
inevitably lead to system failure.

– Unfasten bolted joint of central unit at spare wheel well.

– Take out central valve.
Installing
Installation is performed in reverse sequence; note the following:
Central valve and bolted joints with suspension struts
⇒ page 271 .
– Charge the corresponding pipe section
⇒ “8.5 Discharging and charging Dynamic Ride Control
(DRC)”, page 275 .

8.7 Service installation of dust sleeve for

shock absorber piston rod
Retrofitting dust sleeve for shock absorber piston rod
⇒ page 158

286 Rep. gr.43 - Self-levelling suspension

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

44 – Wheels, tyres, vehicle geometry

1 Wheels and tyres
Refer to the wheels/tyres workshop manual for this information.
⇒ Wheels and tyres; Rep. gr. 44

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 287

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

2 Tyre Pressure Monitoring System

⇒ “2.1 Overview of Tyre Pressure Monitoring System compo‐
nents”, page 288
⇒ “2.2 Servicing Tyre Pressure Monitoring System”, page 288
⇒ “2.3 Removing and installing receiving aerials”, page 292
⇒ “2.4 Activating and deactivating Tyre Pressure Monitoring Sys‐
tem”, page 293
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2.1 Overview
permitted unless authorised of AUDI
by AUDI AG. Tyre Pressure
AG does Monitoring
not guarantee or accept any liability System components
with respect to the correctness of information in this document. Copyright by AUDI AG.

1 - Tyre pressure monitoring

aerials
❑ Front left Tyre Pressure
Monitoring System aer‐
ial (01472) - R59-
❑ Front right Tyre Pres‐
sure Monitoring System
aerial (01473) - R60-
❑ Rear left Tyre Pressure
Monitoring System aer‐
ial (01474) - R61-
❑ Rear right Tyre Pres‐
sure Monitoring System
aerial (01475) - R62-
2 - Display in dash panel ⇒
Running gear, self-diagnosis
for adaptive suspension, TPM;
Rep. gr. 01
3 - Control unit -J502-
❑ in luggage compartment
on rear left in control unit
carrier
4 - Tyre pressure sensors
❑ Front left tyre pressure
sensor (01467) - G222-
❑ Front right tyre pressure
sensor (01468) - G223-
❑ Rear left tyre pressure
sensor (01469) - G224-
❑ Rear right tyre pressure
sensor (01470) - G225-

2.2 Servicing Tyre Pressure Monitoring

System
Special tools and workshop equipment required

288 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Torque wrench - V.A.G 1410-

Heed the instructions in the owner's manual.

If the micro-encapsulated bolt for the wheel electronics has been
slackened off, it is always to be replaced.
For safety reasons, damaged wheel electronics or valves must
be renewed.
Do not use steam cleaners or a powerful jet of compressed air for
cleaning wheel electronics.
The wheel electronics must be renewed if tyre sealant has been
applied, as liquid deposits on the pressure sensor could lead to
incorrect displays.

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. Tyre Pressure Monitoring System 289

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Metal valve body

❑ Use only correct valves
as specified in ⇒ Elec‐
tronic parts catalogue
“ETKA”
❑ Supplied as complete
unit
❑ Always renew valve
core when changing
tyre 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
❑ Removing and installing
with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ page 291
2 - Valve core
3 - Seal
❑ Removing and installing
⇒ page 291
4 - Rim
❑ Remove tyre
⇒ page 292
❑ Fit tyre ⇒ page 292 .
5 - Tyre pressure sensors
❑ Front left tyre pressure
sensor (01467) - G222-
❑ Front right tyre pressure
sensor (01468) - G223-
❑ Rear left tyre pressure
sensor (01469) - G224-
❑ Rear right tyre pressure
sensor (01470) - G225-
❑ Battery service life ap‐
prox. 7 years
❑ Remaining service life
can be read out by way
of diagnosis function ⇒ Running gear, self-diagnosis for adaptive suspension, TPM; Rep. gr. 01
❑ Renew as complete unit
❑ Removing and installing receiver aerials ⇒ page 292
6 - Micro-encapsulated bolt (Torx T20)
❑ Tightening torque: 4 Nm
7 - Union nut
❑ Removing and installing ⇒ page 291
❑ Tightening torque: 4 Nm
8 - Chamfered washer

290 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Removing and installing metal valve body

– Push metal valve with rubber seal through the rim from the
inside.
– Fit the chamfered washer and union nut from outside and
tighten by hand.
– Use a counterhold -1- (e.g. ∅ 2 mm drill bit) to prevent turning.
Tightening torque: 4 Nm

– Press the wheel electronics -1- into the well base and screw
to the back of the valve with a micro-encapsulated bolt.
Tightening torque: 4 Nm
Changing a tyre
The nickel-plated valve core must always be renewed if a tyre is
changed.
The metal valve and wheel electronics can be re-used.
– Release air from tyre by unscrewing nickel-plated valve core.
– Remove the tyre ⇒ page 292 .
Perform visual inspection for loose or damaged components. Re‐
new complete valve assembly if attachment points are loosened/
detached.
Always renew wheel electronics if damaged.
– Fit the tyre ⇒ page 292 .
– Screw in a newProtected
nickel-plated
by copyright.valve
Copyinginsert.
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
– Inflate tyre and screw plastic
with respect to the cap backof on.
correctness information in this document. Copyright by AUDI AG.

– Balance the tyre.

2. Tyre Pressure Monitoring System 291

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Removing tyre
Roll off or unseat tyre.
When using an unseating tool, first press off the tyre on the side
opposite the valve.

Unseating tools must not be used in hatched area -a-.

– Position the tool head close to the valve such that the tyre iron
can be applied approx. 30 degrees -b- on from the valve.
– Then pull off the tyre in the valve area first.

Fitting tyre
Unseating tools must not be used in valve area.
– Position wheel electronics approx. 180 degrees opposite pull‐
er knob.
– Press the tyre into the well base approx. 90 degrees before
the tool head (-arrow-).
– Fit tyre.

2.3 Removing and installing receiving aer‐

ials
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
The receiving aerials are located behind
permittedthe wheel
unless housing
authorised by AUDIliners.
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 and installing wheel housing liners ⇒ General body
repairs, exterior; Rep. gr. 66
– Switch off ignition.
– Unplug the connector to the aerial.
– Unfasten the aerial screw connection at the holder.
– Tightening torque: 2 Nm
– Take out the aerial.
Removing and installing front receiver aerial with holder

292 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unfasten the holder screw connection at the body.

Tightening torque: 3.5 Nm
– Unfasten the aerial screw connection at the holder.
– Tightening torque: 2 Nm
Install in reverse order of removal.

2.4 Activating and deactivating Tyre Pres‐

sure Monitoring System
The system is automatically activated (“tick symbol” in front of
“On”) on storing the inflation pressures.
In order to switch the system off, call up the setting menu and set
a “square symbol” in front of “On” instead of the tick.
To remind the driver, the yellow tyre symbol briefly appears in the
display every time the ignition is switched on with the information:
“Off”.

WARNING

The Tyre Pressure Monitoring System and warnings are not

available with the system switched off. For user safety, the
system should therefore always be left activated.

Function
The system monitors the tyre inflation pressures that have been
set by the operator and stored as reference values.
The following steps must be carried out beforehand:
Checking and correcting inflation pressures
– Start by checking and correcting the inflation pressure of the
tyres on the vehicle (including the spare wheel) in line with the
data given in the: ⇒ Wheel/Tyre Guide .
Storing inflation pressures
After checking the tyre pressures and correctly filling the tyres,
the current pressures must be stored in the check system. The
system will then automatically learn the new figures.
Proceed as follows:
– Switch on ignition and call up the start-up menu.
The setting menu is accessed by way of the “Setting -> inflation
pressure” menu.
– Place a tick in front of “Store pressures”.
The system indicates the correct input of the request to save with
the message:
The current tyre pressures have been saved.
– Turn the selector arrow to “Return” to exit from the input menu.
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.

Adaption to new monitoring conditions must be re-started by se‐

lecting the “Store pressures” menu item whenever the inflation
pressure or a wheel has been changed.

2. Tyre Pressure Monitoring System 293

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

3 Wheel alignment
⇒ “3.1 General notes”, page 294
⇒ “3.2 Sequence of operations for checking and adjusting wheel
alignment”, page 295
⇒ “3.3 Checking centre position of steering rack (mechanical
method)”, page 295
⇒ “3.4 Vehicles with Electronic Stabilising Program (ESP)”, page
296
⇒ “3.5 Explanatory notes on factory codes (PR nos.)”,
page 296
⇒ “3.6 Wheel alignment must be performed:”, page 297
⇒ “3.7 Wheel alignment specifications, front-wheel drive vehicles
except V8 engine”, page 298
⇒ “3.8 Wheel alignment specifications, four-wheel drive vehicles
except V8 engine”, page 300
⇒ “3.9 Wheel alignment specifications, vehicles with V8 engines”,
page 302
⇒ “3.10 Requirements for test”, page 304
⇒ “3.11 Measurement procedure”, page 305
⇒ “3.12 Adjusting toe-in curve at front wheels”, page 307
⇒ “3.13 Move vehicle into starting position for measuring.”,
page 307
⇒ “3.14 Checking rear axle camber (FWD vehicles)”, page 310
⇒ “3.15 Centralising toe setting at rear wheels (front-wheel drive
vehicles)”, page 310
⇒ “3.16 Adjusting camber at rear wheels (four-wheel drive vehi‐
cles)”, page 310
⇒ “3.17 Adjusting rear axle toe (four-wheel drive vehicles)”, page
311
⇒ “3.18 Centralising camber at front wheels”, page 311
⇒ “3.19 Adjusting toe-constant S ”, page 313
⇒ “3.20 Adjusting toe setting at front wheels”, page 313

3.1 General notes

Note

♦ Wheel alignment should not be checked until the vehicle has

completed 1000 to 2000 km, when the coil springs have had
time to settle.
♦ Vibrations can also be caused by excessive residual imbal‐
ance and/or radial runout of the wheels.

Wheel alignment must always be performed using wheel align‐

ment equipment approved by VW/Audi.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
The alignment check must always include bothauthorised
permitted unless the front andAG.
by AUDI theAUDI AG does not guarantee or accept any liability
rear axles. with respect to the correctness of information in this document. Copyright by AUDI AG.

294 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Note

When making adjustments, try to obtain the specified settings as

accurately as possible.

This is important to achieve proper handling and road behaviour.

Please note:
• Measuring instruments properly attached and adjusted Heed
the equipment manufacturer's ⇒ usage instructions .
If appropriate, have the manufacturer of the wheel alignment
equipment provide a course of instruction.
Wheel alignment platforms and computer measuring equipment
can lose their original levelling setting and calibration over a pe‐
riod of time.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
The wheel alignment platform and wheel alignment equipment/
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.
computer should be checked and if necessary adjusted at least
once a year as part of maintenance work.
– Treat these highly sensitive units with care!

3.2 Sequence of operations for checking

and adjusting wheel alignment
Always keep to the following sequence of operations.
1 - For vehicles with air suspension, heed the test prerequisites
⇒ page 304 .
2 - If necessary, check centre position of rack ⇒ page 295 .
3 - Carry out wheel rim runout compensation.
4 - Check camber at front wheels and centralise if necessary
⇒ page 311 .
5 - Check camber at rear wheels and adjust if necessary
⇒ page 310 .
6 - Check toe setting at rear wheels and adjust if necessary
⇒ page 310 .
7 - If necessary, check profile of toe constant “S” at front axle.
8 - Whether or not the toe-in curve/toe constant “S” has to be
adjusted is indicated in the table on ⇒ page 298 and on
⇒ page 307 .
9 - Check toe setting at front wheels with suspension in initial po‐
sition and adjust if necessary ⇒ page 313 .
10 - If the running gear settings have been changed, zero position
compensation must be performed for the steering angle sender -
G85- . (vehicles with ESP only) ⇒ Running gear, self-diagnosis
for ABS, ESP, TPM; Rep. gr. 01 ; Self-diagnosis, electrical
checks; basic setting; zero position compensation for steering
angle sender - G85- .

3.3 Checking centre position of steering

rack (mechanical method)
The mechanical centre position (steering centring) of the rack can
be checked using -V.A.G 1907- .
Left-hand drive vehicles ⇒ page 335
Right-hand drive vehicles ⇒ page 342

3. Wheel alignment 295

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

3.4 Vehicles with Electronic Stabilising Pro‐

gram (ESP)
If the position of the steering wheel is changed on these vehicles,
the basic setting of the steering angle sender - G85- must be
checked ⇒ Running gear, self-diagnosis for ABS, ESP, TPM;
Rep. gr. 01 ; Self-diagnosis, electrical checks; basic setting; zero
position compensation for steering angle sender - G85- .

3.5 Explanatory notes on factory codes (PR

nos.)
Various running gear versions are available as optional extras.
These are identified by their PR numbers.
The running gear version fitted in the vehicle is indicated by the
PR number on the vehicle data sticker.
Vehicle data sticker (example)
The vehicle data sticker can be found at the rear of the spare
wheel well and in the Service Schedule.
The following table shows the coding of the PR numbers which
are decisive for the wheel alignment.

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.

296 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

The PR number for the running gear version can be seen in the
illustration -arrow-.
In this example the vehicle is fitted with standard running gear,
version 1BA -arrow-.
1BA = Standard running gear
1BE = Sports running gear
1 BP = Heavy-duty running gear 1 (unladen state as for 1BA,
however with limited bump)
1 BT = Heavy-duty running gear 1 and light tanks + (approx. 7
mm higher)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1 permitted
BB = Heavy-duty
unless authorisedrunning gear
by AUDI AG. AUDI2
AG(approx. 20 mm
does not guarantee higher)
or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
1BR = Convenience heavy duty running gear
1BG = Running gear with adaptive suspension system
1BC = Special vehicles (fire engines, emergency doctor, police
etc)
1BH = Vehicle for USA
1 BD = Sports running gear Audi S6
1BJ = Running gear for light tanks
1BY = Running gear for allroad (4-wheel air suspension)
1BV = Sports running gear Audi RS6 quattro GmbH
2MC = Sports running gear Audi RS6 quattro GmbH (sports run‐
ning gear with variable damping)
2ME = Sports running gear Audi RS6 quattro GmbH (super sports
running gear with variable damping)
K8L = Saloon China, long

3.6 Wheel alignment must be performed:

♦ In the event of handling problems
♦ Following accident damage
♦ If suspension components have been removed.
♦ If tyres are worn unevenly.
Front axle Wheel align‐ Adjustment of toe-constant “S” Rear axle Wheel alignment
components ment check re‐ required components check required
quired
Ye No Yes No Ye No
s s
Rear upper X X Shock ab‐ X
transverse sorbers
link
Front upper X X
transverse
link
Guide link X X Coil spring X
with hydro-
bush
Suspension X X
strut
Track control X X Upper link 5) X
link 1

3. Wheel alignment 297

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Front axle Wheel align‐ Adjustment of toe-constant “S” Rear axle Wheel alignment
components ment check re‐ required components check required
quired
Ye No Yes No Ye No
s s
Mounting X X Lower link 5) X
bracket 1
Wheel bear‐ X X Wheel bear‐ X
ing housing ing housing
5)
1
Track rod X X Track rod 5) 1 X
Steering rack X X Subframe 5) 1 X
Subframe X X Torsion X
beam axle
assembly
(front-wheel
drive)
Anti-roll bar X Anti-roll bar X

5) 1/ Only applies to four-wheel drive vehicles

3.7 Wheel alignment specifications, front-wheel drive vehicles except V8 en‐

gine
Front axle Running gear Sports run‐ Heavy duty Heavy-duty run‐ Self-levelling Comfort /
(1BA,
Protected 1BH,Copying for
by copyright. ning gear
private or commercialrunning gear
purposes, in part or ning gear
in whole, is not(1BT) system heavy-duty
1BP,
permitted unless1BC)
authorised by AUDI(1BE)
AG. AUDI AG does (1BB, K8L) or accept any liability
not guarantee (1BG) running gear
with respect to the correctness of information in this document. Copyright by AUDI AG.
(1BR)
Camber - 50′ ± 25′ - 1° 05′ ± 25′ - 35′ ± 25′ - 45′ ± 25′ - 50′ ± 25′ - 40′ ± 25′
Maximum 30′ 30′ 30′ 30′ 30′ 30′
permissi‐
ble differ‐
ence be‐
tween left
and right
Toe angle + 10′ ± 2′ + 10′ ± 2′ + 10′ ± 2′ + 10′ ± 2′ + 10′ ± 2′ + 10′ ± 2′
at each
wheel
(specifica‐
tion when
making
adjust‐
ment, sus‐
pension in
initial posi‐
tion)
Toe angle + 10′ ± 5′ + 10′ ± 5′ + 10′ ± 5′ + 10′ ± 5′ + 10′ ± 5′ + 10′ ± 5′
at each
wheel
(specifica‐
tion when
checking
adjust‐
ment, sus‐
pension in
initial posi‐
tion)

298 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Front axle Running gear Sports run‐ Heavy duty Heavy-duty run‐ Self-levelling Comfort /
(1BA, 1BH, ning gear running gear ning gear (1BT) system heavy-duty
1BP, 1BC) (1BE) (1BB, K8L) (1BG) running gear
(1BR)
Toe-con‐ + 7′ ± 2′ + 7′ ± 2′ + 7′ ± 2′ + 7′ ± 2′ + 7′ ± 2′ + 7′ ± 2′
stant for
each
wheel
(specifica‐
tion when
making
adjust‐
ment)
Toe-con‐ + 7′ ± 7′ + 7′ ± 7′ + 7′ ± 7′ + 7′ ± 7′ + 7′ ± 7′ + 7′ ± 7′
stant for
each
wheel
(specifica‐
tion when
checking
adjust‐
ment)
Toe-out on 1° 30′ ± 30′ 1° 30′ ± 30′ 1° 30′ ± 30′ 1° 30′ ± 30′ 1° 30′ ± 30′ 1° 30′ ± 30′
turns at 20
degrees 6)
1

6) 1/ Angle of wheel on outside of bend is smaller by this amount. It can be dis‐

played as a negative value on the wheel alignment computer, depending on the
manufacturer.

Rear axle Running Sports running Heavy duty Heavy-duty Self-levelling Comfort /
gear (1BA, gear (1BE) running gear running gear system (1BG) heavy-duty
1BH, 1BP, (1BB, K8L) (1BT) running gear
1BC) (1BR)
Camber - 1° 30′ ± 20′ - 1° 30′ ± 20′ - 1° 30′ ± 20′ - 1° 30′ ± 20′ - 1° 30′ ± 20′ - 1° 30′ ± 20′
Maximum 30′ 30′ 30′ 30′ 30′ 30′
permissible
difference
between left Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
and right 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.
Total toe + 20′ + 28′ +15'/-10' + 14′ +15'/-10' + 17′ +15'/-10' + 26′ +15'/-10' + 16′ +15'/-10'
+15'/
-10'
Maximum ± 15′ ± 15′ ± 15′ ± 15′ ± 15′ ± 15′
permissible
deviation in
direction of
travel rela‐
tive to longi‐
tudinal axis
of vehicle

Additional vehicle data:

Size Unit Running Sports Heavy duty Heavy-duty Self-levelling Comfort /
gear (1BA, running running gear running gear system (1BG) heavy-duty
1BH, 1BP, gear (1BE) (1BB, K8L) (1BT) running gear
1BC) (1BR)
Wheel mm 2765 2762 27677) 1 2766 2763 2767
base

3. Wheel alignment 299

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Size Unit Running Sports Heavy duty Heavy-duty Self-levelling Comfort /

gear (1BA, running running gear running gear system (1BG) heavy-duty
1BH, 1BP, gear (1BE) (1BB, K8L) (1BT) running gear
1BC) (1BR)
Front mm 1542 1545 1536 1540 1542 1538
track
Track mm 1569 1569 1569 1569 1569 1569
width
(rear)
Max. Degrees 41 41 41 41 41 41
steer‐
ing
angle

7) 1 Vehicles with PR number K8L have a 90 mm longer wheelbase

Note

♦ Specifications for rim offset 45

♦ The additional databylisted
Protected here
copyright. areforintended
Copying only topurposes,
private or commercial facilitate
in part or in whole, is not
diagnosis after an accident.
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.

3.8 Wheel alignment specifications, four-

wheel drive vehicles except V8 engine
The specifications for normal level are given for vehicles with all‐
road 4-wheel air suspension 1BY.
Front axle Running Sports Heavy-duty Comfort / Heavy duty Self-lev‐ Allroad (4
gear running running gear heavy-duty running gear elling wheel air
(1BA, gear (1BB) running gear 1BT, 1BJ system suspension)
1BH, (1BE, (1BR) (1BG) (1BY)
1BP, 1BV)
1BC)
Camber - 50′ ± - 1° 05′ ± - 35′ ± 25′ - 40′ ± 25′ - 45′ ± 25′ - 50′ ± 25′ -1° ± 25′
25′ 25′
Maximum 30′ 30′ 30′ 30′ 30′ 30′ 30′
permissi‐
ble differ‐
ence be‐
tween left
and right
Toe angle + 10′ ± 2′ + 10′ ± 2′ + 10′ ± 2′ + 10′ ± 2′ + 10′ ± 2′ + 10′ ± 2′ + 10′ ± 2′
at each
wheel
(specifica‐
tion when
making
adjust‐
ment, sus‐
pension in
initial posi‐
tion)

300 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Front axle Running Sports Heavy-duty Comfort / Heavy duty Self-lev‐ Allroad (4
gear running running gear heavy-duty running gear elling wheel air
(1BA, gear (1BB) running gear 1BT, 1BJ system suspension)
1BH, (1BE, (1BR) (1BG) (1BY)
1BP, 1BV)
1BC)
Toe angle + 10′ ± 5′ + 10′ ± 5′ + 10′ ± 5′ + 10′ ± 5′ + 10′ ± 5′ + 10′ ± 5′ + 10′ ± 5′
at each
wheel
(specifica‐
tion when
checking
adjust‐
ment, sus‐
pension in
initial posi‐
tion)
Toe-con‐ + 7′ ± 2′ + 7′ ± 2′ + 7′ ± 2′ + 7′ ± 2′ + 7′ ± 2′ + 7′ ± 2′ + 7′ ± 2′
stant for
each
wheel
(specifica‐
tion when
making
adjust‐
ment)
Toe-con‐ + 7′ ± 7′ + 7′ ± 7′ + 7′ ± 7′ + 7′ ± 7′ + 7′ ± 7′ + 7′ ± 7′ + 7′ ± 7′
stant for
each
wheel
(specifica‐
tion when
checking
adjust‐
ment)
Toe-out on 1° 30′ ± 1° 30′ ± 1° 30′ ± 30′ 1° 30′ ± 30′ 1° 30′ ± 30′ 1° 30′ ± 1° 25′ ± 30′
turns at 20 30′ 30′ 30′
degrees
steering
angle 8)

8) The wheel on the outside of a curve is turned in less than the inside wheel. This
value shows the difference in the steering angles. It can be displayed as a negative
value on the wheel alignment computer, depending on the manufacturer.

Rear axle Running Sports Heavy-duty Comfort / Heavy du‐ Self-level‐ Allroad (4
gear (1BA, running running gear heavy-duty ty running ling sys‐ wheel air
1BH, 1BP, gear (1BE, (1BB) running gear gear 1BT, tem (1BG) suspen‐
1BC) 1BV) (1BR) 1BJ sion) (1BY)
Camber - 40′ ± 30′ - 40′ ± 30′ - 40′ ± 30′ - 40′ ± 30′ - 40′ ± 30′ - 1° 10′ ± - 60′ ± 30′
30′
Maximum 30′ 30′ 30′ 30′ 30′ 30′ 30′
permissi‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

ble differ‐
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.
ence be‐
tween left
and right
Toe per + 8′ ± 5′ + 8′ ± 5′ + 8′ ± 5′ + 8′ ± 5′ + 8′ ± 5′ + 8′ ± 5′ + 9′ ± 4′
wheel

3. Wheel alignment 301

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Rear axle Running Sports Heavy-duty Comfort / Heavy du‐ Self-level‐ Allroad (4
gear (1BA, running running gear heavy-duty ty running ling sys‐ wheel air
1BH, 1BP, gear (1BE, (1BB) running gear gear 1BT, tem (1BG) suspen‐
1BC) 1BV) (1BR) 1BJ sion) (1BY)
Maximum ± 10′ ± 10′ ± 10′ ± 10′ ± 10′ ± 10′ ± 10′
permissi‐
ble devia‐
tion in di‐
rection of
travel rela‐
tive to lon‐
gitudinal
axis of ve‐
hicle

Additional vehicle data:

Size Unit Running Sports Heavy-du‐ Comfort / Heavy duty Self-levelling Allroad (4
gear running ty running heavy-du‐ running gear system (1BG) wheel air
(1BA, gear gear (1BB) ty running (1BT, 1BJ) suspension)
1BH, (1BE, gear (1BR) (1BY)
1BP, 1BV)
1BC)
Whe mm 2758 2759 2757 2758 2758 2759 2760
el‐
base
Front mm 1542 1545 1536 1540 1540 1542 1586
track
Trac mm 1565 1566 1563 1564 1564 1570 1597
k
width
(rear
)
Max. De‐ 41 41 41 41 41 41 41
steer grees
ing
an‐
gle

Note

♦ Specifications for rim offset 45 except 1BY

♦ Specifications for rim offset 25 for 1BY only
♦ The additional data listed here are intended only to facilitate
diagnosis after an accident.

3.9 Wheel alignment specifications, vehi‐

cles with V8 engines
The specifications for normal level are given for vehicles with all‐
road 4-wheel air suspension 1BY.
Front axle Running gear Sports run‐ Sports run‐ Heavy-duty run‐ Self-levelling Allroad (4
(1BA, 1BH) ning gear ning gear
Protectedning gearCopying
by copyright. (1BR)for private
system (1BG)purposes,
or commercial wheel
in part air
or in whole, is not
(1BE, 1BD) (1BV, 2ME, suspension)
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

2MC) (1BY)
with respect to the correctness of information in this document. Copyright by AUDI AG.

Camber -1° ± 25′ - 1° 05′ ± 25′ - 1° 20′ ± 25′ - 50′ ± 25′ - 1° ± 25′ -1° ± 25′

302 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Front axle Running gear Sports run‐ Sports run‐ Heavy-duty run‐ Self-levelling Allroad (4
(1BA, 1BH) ning gear ning gear ning gear (1BR) system (1BG) wheel air
(1BE, 1BD) (1BV, 2ME, suspension)
2MC) (1BY)
Maximum 30′ 30′ 30′ 30′ 30′ 30′
permissible
difference
between left
and right
Toe angle + 10′ ± 2′ + 10′ ± 2′ + 10′ ± 2′ + 10′ ± 2′ + 10′ ± 2′ + 10′ ± 2′
at each
wheel
(specifica‐
tion when
making ad‐
justment,
suspension
in initial po‐
sition)
Toe angle + 10′ ± 5′ + 10′ ± 5′ + 10′ ± 5′ + 10′ ± 5′ + 10′ ± 5′ + 10′ ± 5′
at each
wheel
(specifica‐
tion when
checking
adjustment,
suspension
in initial po‐
sition)
Toe-con‐ + 7′ ± 2′ + 7′ ± 2′ + 7′ ± 2′ + 7′ ± 2′ + 7′ ± 2′ + 7′ ± 2′
stant for
each wheel
(specifica‐
tion when Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
making ad‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
justment) with respect to the correctness of information in this document. Copyright by AUDI AG.

Toe-con‐ + 7′ ± 7′ + 7′ ± 7′ + 7′ ± 7′ + 7′ ± 7′ + 7′ ± 7′ + 7′ ± 7′
stant for
each wheel
(specifica‐
tion when
checking
adjustment)
Toe-out on 1° 30′ ± 30′ 1° 30′ ± 30′ 1° 30′ ± 30′ 1° 30′ ± 30′ 1° 30′ ± 30′ 1° 25′ ± 30′
turns at 20
degrees
steering an‐
gle 9)

9) The wheel on the outside of a curve is turned in less than the inside wheel. This
value shows the difference in the steering angles. It can be displayed as a negative
value on the wheel alignment computer, depending on the manufacturer.

Rear axle Running Sports run‐ Sports run‐ Heavy-duty run‐ Self-levelling Allroad (4
gear (1BA, ning gear ning gear ning gear (1BR) system (1BG) wheel air
1BH) (1BE, 1BD) (1BV, 2ME, suspen‐
2MC) sion) (1BY)
Camber - 60′ ± 30′ - 60′ ± 30′ - 60′ ± 30′ - 60′ ± 30′ - 1° 10′ ± 30′ - 60′ ± 30′
Maximum 30′ 30′ 30′ 30′ 30′ 30′
permissible
difference be‐
tween left and
right
Toe per wheel + 8′ ± 5′ + 8′ ± 5′ + 8′ ± 5′ + 8′ ± 5′ + 8′ ± 5′ + 9′ ± 4′

3. Wheel alignment 303

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Rear axle Running Sports run‐ Sports run‐ Heavy-duty run‐ Self-levelling Allroad (4
gear (1BA, ning gear ning gear ning gear (1BR) system (1BG) wheel air
1BH) (1BE, 1BD) (1BV, 2ME, suspen‐
2MC) sion) (1BY)
Maximum ± 10′ ± 10′ ± 10′ ± 10′ ± 10′ ± 10′
permissible
deviation in di‐
rection of trav‐
el relative to
longitudinal
axis of vehicle

Additional vehicle data:

Size Unit Running Sports run‐ Sports running Heavy-duty Self-levelling Allroad (4
Protected bygear (1BA,
copyright. Copying forning
privategear
or commercialgear (1BV,
purposes, in part or in running
whole, is notgear
system wheel air sus‐
permitted unless1BH) (1BE,
authorised by AUDI 1BD)
AG. AUDI AG does2MC, 2ME)
not guarantee or accept any(1BR) (1BG)
liability pension) (1BY)
with respect to the correctness of information in this document. Copyright by AUDI AG.
Wheel mm 2758 2759 2759 2758 2759 2760
base
Front mm 1576 1577 1577 1575 1576 1586
track
Track mm 1586 1586 1586 1585 1592 1597
width
(rear)
Max. De‐ 41 41 41 41 41 41
steer‐ gree
ing s
angle

Note

♦ Specifications for rim offset 35 except 1BY

♦ Specifications for rim offset 25 for 1BY only
♦ The additional data listed here are intended only to facilitate
diagnosis after an accident.

3.10 Requirements for test

• Suspension, wheel bearings, steering and steering linkage
checked for impermissible play and damage
• Tread depth difference of no more than 2 mm on one axle.
• Tyres inflated to correct pressures
• Vehicle kerb weight
• Fuel tank full
• Spare wheel and tool kit at specified location in vehicle
• Windscreen/headlight washer system fluid reservoir full
• On vehicles with adaptive suspension (1BG) or 4-wheel air
suspension (1BY), there must not be any faults stored in the
air spring control unit. The yellow warning lamp in the dash
panel insert must not light.
• On vehicles with adaptive suspension (1BG), switch on the
ignition prior to measurement and wait for completion of the
vehicle level regulation process.

304 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

• On vehicles with 4-wheel air suspension (1BY), the vehicle

must be moved with the engine running (vehicle standing on
wheel alignment platform) from low to normal level. Deactivate
the self-levelling suspension. Make sure there is sufficient
pressure in the pressure container. Press both the high and
low button in the adaptive suspension operating unit for longer
than 5 seconds until the LED displays light. The display in the
dash panel insert also lights. The automatic height regulation
switches on independently at a speed higher than 5 km/h.
• For vehicles with 4-wheel air suspension (1BY), check the
specified height between centre of wheel and lower edge of
wing. Specification: 402 mm ± 5 mm. If this is not the case,
basic setting must first be performed.
• Ensure that the sliding plates and turntables are not touching
the end stop when checking the alignment.

3.11 Measurement procedure

Special tools and workshop

equipment required
♦ -V.A.G 1813- 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 1907- with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ -V.A.G 1925-
♦ -V.A.G 1925/3-
♦ -V.A.G 1925/4-
♦ -V.A.G 1925/6-

Use either adapter - V.A.G 1925/3- or -V.A.G 1925/4- , depending

on the type of lifting platform.

3. Wheel alignment 305

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

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

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
Ensure that
respect to the sliding
the correctness plates inand
of information turntables
this document. arebynot
Copyright AUDItouching
AG.
the end stop when checking the alignment.
• Vehicle accurately aligned, suspension bounced and rocked
several times.
• Sensors properly attached and adjusted Heed the equipment
manufacturer's ⇒ usage instructions .
– Carry out wheel rim runout compensation.
The permissible lateral rim run-out may already lead to the toe-in
tolerance being exceeded. In such cases it is not possible to set
the toe-in correctly without first compensating for the wheel run‐
out.
With the Audi allroad, it may be necessary to move the sliding
bases after raising to provide sufficient clearance for the sensor.
– Insert brake pedal depressor.

Caution

The vehicle is not to be raised by way of moving axle compo‐

nents.

Assignment of adapters to running gear for wheel alignment:

Adapter Running Sports running Heavy duty Heavy duty Self-levelling

gear (1BA, gear (1BE, running gear running gear system
1BH, 1BP, 1BD, 1BV, (1BB, 1BR, (1BT, 1BJ) (1BG)
1BC) 2ME, 2MC) K8L)
-V.A.G 1925- X X X X X
-V.A.G 1925/4- X X X X X
-V.A.G 1925/6- X X
-V.A.G 1925/3- 10)1 X X

10) 1/ Only necessary on certain lifting platforms ( -V.A.G 1925/3- replaces -

V.A.G 1925/4- ).

Adapter Running gear (1BY)

-V.A.G 1925- X
-V.A.G 1925/4- X
-V.A.G 1925/6- X

306 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Adapter Running gear (1BY)

-V.A.G 1925/3- 11)
2 X

11) 2/ Only necessary on certain lifting platforms ( -V.A.G 1925/3- replaces -

V.A.G 1925/4- ).

3.12 Adjusting toe-in curve at front wheels

Explanatory notes:
The compression and rebound movement of the front wheels al‐
ters the toe value as a function of the compression/rebound travel.
The resulting toe values are referred to as the toe-in curve.
The change in the toe constant “S” is set with the vehicle raised
by way of vertical adjustment of the track rod end ⇒ page 313 .
The electronic wheel alignment equipment determines the toe-
constant “S” by comparing one value measured with the suspen‐
sion in the initial position and one value measured with the vehicle
lifted. It compares the actual values with the specifications and
displays them on the screen.
Different adapters are needed for lifting depending on the running
gear.
Running gear and adapter assignment table ⇒ page 306

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
An permitted
incorrectly
unless set toe-constant
authorised causes
by AUDI AG. AUDI AG does steering deviation
not guarantee when
or accept any liability
braking/accelerating or when
with respect to the correctness driving
of information over
in this uneven
document. ground.
Copyright by AUDI AG.

3.13 Move vehicle into starting position for

measuring.
Initial position for toe constant only
Running gear 1BA, 1BC,1BR, 1BH, 1BP, 1BT, 1BJ. 1BG,1BE,
1BD, 1BV, 2MC, 2ME

Note

Depending on the type of wheel alignment equipment, it may be

necessary to raise the front axle of the vehicle in order to insert
spacer - V.A.G 1925- . Bounce suspension after lowering vehicle.

– Insert the spacer gauge - V.A.G 1925- with the adapters -

V.A.G 1925/3- or -V.A.G 1925/4- and screw out both threaded
spindles such that they just make contact with the front bolts
-arrow- of the subframe.
This must not cause the vehicle to be raised.
The suspension is now in the initial position.
– On vehicles with adaptive suspension system, switch on the
ignition and wait for adjustment of the vehicle level.

3. Wheel alignment 307

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Running gear 1BE, 1BD, 1BV, 2MC, 2ME

– Position axle lift under front jacking points and raise vehicle.
– Fit adapter - V.A.G 1925/6- onto adapter - V.A.G 1925/3- or -
V.A.G 1925/4- of gap setting gauge.
– Lower vehicle onto adapters.
The suspension is now in the initial position.
Vehicle with heavy duty running gear 1BB, K8L and 4-wheel air
suspension 1BY

Note

Depending on the type of wheel alignment equipment, it may be

necessary to raise the front axle of the vehicle in order to insert
spacer - V.A.G 1925- . Bounce suspension after lowering vehicle.

– Insert gap setting gauge - V.A.G 1925- with adapters -

V.A.G 1925/3- or -V.A.G 1925/4- and -V.A.G 1925/6- .

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.

308 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Screw out the two threaded spindles so that they just make
contact with the front bolts -arrow- of the subframe.
This must not cause the vehicle to be raised.
The suspension is now in the initial position.

Note

In this position, the wheel alignment program checks whether the

actual toe-in value per wheel corresponds to a specification of +
10' ± 30' (coarse pre-setting) for all running gear versions (except
sports running gear). If necessary, the toe-in must be corrected
by adjusting the track rod length.

Wheel alignment specifications ⇒ page 298

The wheel alignment software will only show the relevant display
if a correction is required.
Raising vehicle, running gear 1BA, 1BC, 1BE, 1BG, 1BH, 1BP,
1BT, 1BJ, 1BY. 1BR, 1BD, 1BV, 2MC, 2ME
When performing the next step, ensure that the wheels do not
lose contact with the turntables when the vehicle is lifted.
If this happens, the turntables must not be moved. Reading will
otherwise be falsified.
– Position axle lift under front jacking points and raise vehicle.

Note

The vehicle must be lifted 60 mm.

– Push cylinders out of threaded spindles and secure in position

with locking pins.

Ensure that locking pins -arrows- are correctly positioned.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Lower
permittedvehicle onto by
unless authorised spacer - AUDI
AUDI AG. V.A.G 1925-
AG does .
not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Raising vehicle, heavy duty running gear 1BB, K8L
When performing the next step, ensure that the wheels do not
lose contact with the turntables when the vehicle is lifted.
If this happens, the turntables must not be moved. Reading will
otherwise be falsified.
– Position axle lift under front jacking points and raise vehicle.

Note

The vehicle must be lifted 40 mm.

– Detach the adapters - V.A.G 1925/6- .

– Push cylinders out of threaded spindles and secure in position
with locking pins.

3. Wheel alignment 309

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Ensure that locking pins -arrows- are correctly positioned.

– Lower vehicle onto spacer - V.A.G 1925- .

3.14 Checking rear axle camber (FWD vehi‐

cles) 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
On front-wheel drive vehicles,withthe camber can be checked but not
respect to the correctness of information in this document. Copyright by AUDI AG.

adjusted.
If the measured values are outside the permitted tolerance, check
the subframe for damage and replace if necessary.

3.15 Centralising toe setting at rear wheels

(front-wheel drive vehicles)
Wheel alignment specifications ⇒ page 300
The total toe setting at the rear wheels cannot be adjusted.
The individual toe values can be balanced out by moving the rear
axle in the elongated holes.
– Release fastening bolts on mounting brackets.
– Loosen brake setter.
– Balance out the individual toe values by moving the subframe
in the elongated holes of the mounting brackets.
– Insert brake setter.
If the overall toe value is outside the permissible tolerance or if
the individual toe values cannot be balanced out, check the sub‐
frame for damage and replace if necessary.
The body dimensions/alignment at the rear axle mounting points
must be checked and the body repaired as required ⇒ Body Re‐
pairs; Rep. gr. ; Audi A6 1998 ► .

3.16 Adjusting camber at rear wheels (four-

wheel drive vehicles)
Wheel alignment specifications ⇒ page 300

310 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unfasten hexagon nut -1-.

Note

♦ The maximum adjustment range is 90° to the left or right of the

centre position.
♦ If the camber cannot be adjusted within the tolerances on ve‐
hicles with adaptive suspension, check the basic setting
⇒ page 221 .

– Adjust camber by turning eccentric bolt.

– Tighten fastening nut, check camber
Protectedagain andCopying
by copyright. re-adjust, if or commercial purposes, in part or in whole, is not
for private
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.

3.17 Adjusting rear axle toe (four-wheel drive

vehicles)
Wheel alignment specifications ⇒ page 300
– Unfasten hexagon nut -1-.

Note

The maximum adjustment range is 90° to the left or right of the

centre position.

– Adjust individual toe settings as required by turning eccentric

bolt.
– Tighten fastening nut, check camber again and re-adjust, if
necessary.

3.18 Centralising camber at front wheels

The camber cannot be adjusted.
By moving the subframe, it is possible to centralise the camber
setting symmetrically within the specified tolerance range.
– Remove noise insulation tray.
– Loosen hexagon bolts -1-, -2-, -3-, -4-, -5-, -6-, -7- and -8-.

3. Wheel alignment 311

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Use plastic-coated tyre iron or similar -arrow- to move sub‐

frame to required position.
Apply pressure in centre of subframe between subframe and lon‐
gitudinal member of body.
If no plastic-coated tyre iron is available, wrap adhesive tape
around a conventional tyre iron.

Caution

Take care not to damage any components.

Wheel alignment specifications ⇒ page 298

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
– Screw in newwithhexagon bolts
respect to the -7- and
correctness -8-. in this document. Copyright by AUDI AG.
of information

– Tighten to 110 Nm + 90°.

– Screw in new front hexagon bolts -5- and -6-.
– Tighten to 110 Nm + 90°.
– Tighten new hexagon bolts -1-, -2-, -3- and -4- to 75 Nm.
Please note:
All wheel alignment settings must be checked if camber setting
has been altered.

312 Rep. gr.44 - Wheels, tyres, vehicle geometry

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

3.19 Adjusting toe-constant “S”

– Loosen bolt -A-.
– Screw out the bolt -B- and screw in a new bolt by approx. 4
mm.
– Push track rod ball joint downwards onto stop.
– Screw in the adjusting screw -B- until the exact specification
is obtained.
– Tighten hexagon nut -A- ⇒ Item 7 (page 12) and check value.
Always use new hexagon bolts!
– Tighten bolt -B- ⇒ Item 5 (page 12) .
– Lower vehicle to starting position B1 again.
– Screw down threaded spindle.
Not valid for vehicles with sports running gear!
– Bounce suspension of vehicles with standard running gear
several times.
Checking toe constant “S” following adjustment
The wheel alignment equipment will then re-check the toe-con‐
stant.
If the second check shows that the values are within the tolerance
(specification when checking adjustment), the setting is OK.
Adjustment must be repeated in position B2 (+60 mm) if the
measured values do not comply with the check value.

Note

With a wheel bearing housing without groove and a track rod ball
joint with ring the adjusting path towards the top is less by approx.
2 mm. The ring at the track rod end is to be removed if the ad‐
justment travel is not sufficient.

3.20 Adjusting toe setting at front wheels

Wheel
Protectedalignment specifications
by copyright. Copying ⇒ pagepurposes,
for private or commercial 300 in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– with
Loosen lock
respect to nut -B-.of information in this document. Copyright by AUDI AG.
the correctness

– Adjust toe setting at left and right wheels via hexagon flats
-A-.
Make sure the boots are not twisted after turning the track rods.
Twisted rubber boots wear out quickly.
– Tighten lock nut -B- to 40 Nm and check toe-in setting again.
The setting may change slightly after tightening lock nut -B-.
However, the adjustment is correct if the measured toe value is
still inside the tolerance.

3. Wheel alignment 313

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

48 – Steering
1 Steering wheel with airbag
⇒ “1.1 Removing and installing driver's airbag unit with standard
steering wheel”, page 314
⇒ “1.2 Removing and installing driver’s airbag unit for sports
steering wheel”, page 315
⇒ “1.3 Removing and installing steering angle sender G85 ”, page
316
⇒ “1.4 Remove steering column switch.”, page 317

1.1 Removing and installing driver's airbag

unit with standard steering wheel
Safety precautions for working on airbags ⇒ General body re‐
pairs, interior; Rep. gr. 69 ; Airbag safety regulations; Safety
precautions for working on airbags
Necessary measures after repairs: After connecting the battery,
heed the instructions ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .
Removing and installing driver's airbag unit with standard steering
wheel ⇒ General body repairs, interior; Rep. gr. 69 ; Servicing
driver's airbag
Removing
– Remove the airbag unit ⇒ Rep. gr. 69 .
– Centre the steering wheel (wheels in straight-ahead position).
– Remove bolt -5-.
– Pull off connectors -2- and-10-.
Installing
– Attach steering wheel in centre position (wheels straight
ahead).
– The connectors must be heard to engage fully.
– Replace the bolt -5- and tighten to 50 Nm.
– Fit the airbag unit ⇒ Rep. gr. 69 .

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.

314 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1.2 Removing and installing driver’s airbag

unit for sports steering wheel
Safety precautions for working on airbags ⇒ General body re‐
pairs, interior; Rep. gr. 69 ; Airbag safety regulations; Safety
precautions for working on airbags
Necessary measures after repairs: After connecting the battery,
heed the instructions ⇒ Electrical
Protectedsystem;
by copyright.Rep. gr.for private
Copying 27 ; Battery;
or commercial purposes, in part or in whole, is not
Removing and installing battery . 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.
Removing and installing driver's airbag unit with standard steering
wheel ⇒ General body repairs, interior; Rep. gr. 69 ; Servicing
driver's airbag
Removing
– Remove the airbag unit ⇒ Rep. gr. 69 .
– Centre the steering wheel (wheels in straight-ahead position).
– Remove bolt -4-.
Installing
– Attach steering wheel in centre position (wheels straight
ahead).
– Replace the bolt -4- and tighten to 50 Nm.

1. Steering wheel with airbag 315

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Fit the airbag unit ⇒ Rep. gr. 69 .

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.

1.3 Removing and installing steering angle

sender - G85-
Removing

WARNING

Wheels must be in straight-ahead position before removing

steering wheel.
Observe safety precautions for working on airbags ⇒ Rep. gr.
69 .
Failure to comply with these measures may lead to subsequent
failure of the airbag system!

– Remove airbag unit ⇒ Rep. gr. 69 .

– Detach the clip for the airbag.

316 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unplug the connector for the steering angle sender -arrow-.

– Remove steering 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
1.4 Remove steering column switch.
with respect to the correctness of information in this document. Copyright by AUDI AG.

Removing
– Release steering column adjuster.
– Pull steering column all the way out.
– Remove bolt -1- (2x). Tightening torque: 3 Nm
– Remove handle -2-.

– Remove two cross-head screws -arrows-.

– Tightening torque 0.6 Nm
– Detach the upper trim for the steering column switch -1-.
To install, insert the upper section into the hooks of the lower
section, swivel it down and screw it in place.

– Remove bolts -2- (2x). Tightening torque 0.6 Nm

– Remove hexagon socket head bolt -1-.
– Tightening torque 0.6 Nm
– Take off lower trim on steering column switch -3-.

1. Steering wheel with airbag 317

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Disengage the steering angle sender at the fasteners

-arrows-.

– Unplug the connectors -arrows-.

Installing
Install in reverse order of removal.
– Perform zero position compensation for the steering angle
sender - G85- ⇒ Running gear, self-diagnosis; Rep. gr. 01 .

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.

318 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

2 Steering column
⇒ “2.1 Removing and installing steering column”, page 319
⇒ “2.2 Checking steering column for damage”, page 323
⇒ “2.3 Removing and installing steering lock housing”,
page 324

2.1 Removing and installing steering col‐

umn
Removing
The replacement steering column is only supplied as a complete
unit. Repair is not possible.
The steering lock housing can be transferred.

WARNING

Wheels must be in straight-ahead position before removing

steering wheel.
Observe safety precautions for working on airbags ⇒ Rep. gr.
69 .
Failure to comply with these measures may lead to subsequent
failure of the airbag system!

– Remove airbag unit ⇒ page 314 , for sports steering wheels

⇒ page 315 .
– Remove steering wheel ⇒ page 314 , for sports steering wheel
⇒ page 315 .
– On vehicles with electronic stability program (ESP), pay at‐
tention to the removal procedure for the steering angle sender
⇒ page 316 .
Remove steering column switch.
– Release steering column adjuster.
– Pull steering column all the way out.
– Remove bolt -1- (2x). Tightening torque: 3 Nm
– Remove handle -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.

2. Steering column 319

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove two cross-head screws -arrows-.

– Tightening torque 0.6 Nm
– Take off upper trim on steering column switch -1-.
To install, fit upper section into the retainers on lower section,
pivot down and secure with screws.

– Remove bolts -2- (2x). Tightening torque 0.6 Nm

– Remove hexagon socket head bolt -1-.
– Tightening torque 0.6 Nm
– Take off lower trim on steering column switch -3-.

– Unplug connector -1-.

– Loosen bolt -2-.
– Tightening torque 3 Nm
– Unplug connector -3-.
– Remove steering column switch -4-.

– Release cable ties and plugs on steering Protected

column. 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 locking cable must be disengaged on vehicles with automatic
with respect to the correctness of information in this document. Copyright by AUDI AG.
gearbox.
– Move selector lever to position "P".

320 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Ignition key in position -B-, ignition on.

– Lift locking piece -1- slightly and pull locking cable -2- out of
ignition lock 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.

– Remove nut -1- on universal joint.

– Slacken off eccentric by turning tensioning bolt (Torx T50)
clockwise and take out bolt.
– Release steering column adjuster.

– Swivel aside universal joint.

– Unscrew hexagon socket head bolts-1- of steering column and

take out steering column.
– Removing and installing steering lock housing ⇒ page 324
– Check steering column for damage ⇒ page 323 .
Removing and installing lock cylinder ⇒ Electrical system; Rep.
gr. 94

2. Steering column 321

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Installing
– Attach steering column to cross member with 4 hexagon sock‐
et head bolts -1-.
– Release steering column adjuster.

– Fit universal joint onto steering pinion.

– Insert clamping bolt (Torx T50) through bottom part and pre-
tension by turning anti-clockwise.
– Fit hexagon nut in position and tighten to 30 Nm.
With vehicles with automatic gearbox attach locking cable:

– To engage the locking cable, turn the ignition key to position

-B-, ignition on.
– Move selector lever to position "P".
– Insert locking cable -2- in ignition lock housing. Make sure that
locking piece -1- engages.

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.

322 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Checking operation of locking cable

Ignition key in position -B-, ignition on.
– It should be possible to move the selector lever freely out of
Park position.
– It should only be possible to remove the ignition key when the
selector lever is in the Park position.
Move selector lever to position "P".
– It must be possible to operate the ignition lock smoothly.
– With the ignition key in position -A-, ignition off, it must not be
possible to shift the gear lever out of the park position. The
ignition key may be removed.
– For basic setting and routing of locking cable, refer to ⇒ Rep.
gr. 37 .
– Install steering column switch with trim.
– Align the steering column such that the trim joints are even.

– Tighten steering column hexagon socket head bolts -1- to 25

Nm.
Vehicles with electrically adjustable steering column only
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Tighten
permittedthe tolerance
unless authorised bycompensation
AUDI AG. AUDI AG screw does not guarantee or accept any liability
⇒ Item
with 7 (page
respect 325)
to the .
correctness of information in this document. Copyright by AUDI AG.

– Connect connectors for servo motors.

– Secure electrical wiring to steering column using cable ties.
All vehicles (continued)
– Install driver's side storage compartment.
– Install steering wheel ⇒ page 314 , for sports steering wheel
⇒ page 315
– Install airbag unit ⇒ page 314 , for sports steering wheels
⇒ page 315 .

2.2 Checking steering column for damage

Visual inspection
– Check all steering column parts for damage.
Functional check
– Check that steering column turns easily and smoothly.
– Check that steering column can be adjusted for height and
reach.

2. Steering column 323

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Check whether there is a gap -dimension A- between the slide

and the mounting bracket.
– If dimension -A- is larger than 0.5 mm, the steering column is
damaged and must be renewed.

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.

2.3 Removing and installing steering lock

housing
Removing

WARNING

Wheels must be in straight-ahead position before removing

steering wheel.
Observe safety precautions for working on airbags ⇒ Rep. gr.
69 .
Failure to comply with these measures may lead to subsequent
failure of the airbag system!

– Remove airbag unit ⇒ page 314 , for sports steering wheel

⇒ page 315 .
– Remove steering wheel ⇒ page 314 , for sports steering wheel
⇒ page 315 .
– Remove steering column switch ⇒ page 319 .
– On vehicles with automatic gearbox, disengage locking cable
⇒ page 320 .
– Drill out the shear bolts -1- or chisel off with a suitable tool.
Removing and installing lock cylinder ⇒ Electrical system; Rep.
gr. 94
Installing
– Screw in the new shear bolts.
– Tighten the shear bolts until the head shears off.
– On vehicles with automatic gearbox, engage locking cable
⇒ page 320 .

– Check operation of locking cable ⇒ page 323 .

– Fit steering column switch.
– Install steering wheel ⇒ page 314 , for sports steering wheel
⇒ page 315
– Install airbag unit ⇒ page 314 , for sports steering wheels
⇒ page 315 .

324 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

3 Electrically adjustable steering col‐

umn, steering column/belt height ad‐
justment control unit - J352-
⇒ “3.1 Exploded view of electrically adjustable steering column”,
page 325
⇒ “3.2 Description of operation”, page 326
⇒ “3.3 Electrical adjustment”, page 326
⇒ “3.4 Steering column/belt height adjustment control unit J352
”, page 327

3.1 Exploded view of electrically adjustable steering column

The replacement steering column is only supplied as a complete
unit. Repair is not possible.
The steering lock housing can be transferred from the old unit.

1 - Shear bolt, 20 Nm
2 - Steering column
3 - Steering/starting lock
Different versions available

Refer to ⇒ Electronic parts

catalogue “ETKA”

4 - Bolt, 22 Nm
5 - Transport lock
6 - Steering column/belt height
adjustment control unit - J352-
❑ No self-diagnosis capa‐
bility
7 - Tolerance screw
Tightening torque: 22 Nm
❑ Only fitted with electri‐
cally adjustable steering
column
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Before tightening the permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
tolerance compensation with respect to the correctness of information in this document. Copyright by AUDI AG.
screw, all 4 bolts for at‐
taching the steering col‐
umn to the assembly
cross member must
have been tightened to
torque
❑ Avoid applying force to
the steering column or
steering wheel whilst
tightening the tolerance
compensation screw

3. Electrically adjustable steering column, steering column/belt height adjustment control unit J352 325
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Note

♦ The movable splines between

the top section and the bottom
section of the steering column
must on no account be separa‐
ted.
♦ Movement beyond a range of
± 5 cm can cause damage to the
steering column.

3.2 Description of operation

Refer to illustration on ⇒ page 325 .
An electrically adjustable steering column is available as optional
extra.
The steering column/belt height adjustment control unit - J352-
has no self-diagnosis capability.
In the event of problems, perform fault-finding in line with ⇒ Cur‐
rent flow diagrams, Electrical fault finding and Fitting locations.
Description of operation
With automatic adjustment, the belt and steering column (height/
depth) are adjusted simultaneously.
Safety functions
So as not to overload the vehicle battery, the control motors are
not activated simultaneously with automatic adjustment, but rath‐
er at short intervals.
If the voltage drops below 10.5 V, each motor is adjusted in turn.
Blockage detection (1.5 seconds) and a running time error (max.
30 seconds/motor) result in direct deactivation of the motor con‐
cerned.
Easy-entry facility (adjustment of steering column)
To make it easier to get out of and into the vehicle, breaking of
the S-contact (ignition off) causes the steering column to move to
its horizontal and tilt end position and, conversely, to return to its
original position when the S-contact is made (ignition on).
Switching off the easy-entry facility switch completely deactivates
the easy-entry function or immediately terminates the current ad‐
justment process.
Special features
Only the belt height is adjusted if a P button is pressed with the
S-contact off. The steering column only assumes the memory
position with “S-contact on”.
The steering column does not return to its original position with
“S-contact on” if the entry position has been altered beforehand,
for example by way of manual adjustment.

3.3 Electrical adjustment

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
The switch -A- can be used to electrically adjust
permitted the height
unless and
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
length of the steering column. The adjustmentwithalso functions
respect with of information in this document. Copyright by AUDI AG.
to the correctness
the ignition switched off.

326 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Height adjustment
– Press the switch up/down.
The height is adjusted for as long as the switch is pressed.
Axial adjustment
– Press the switch to front/rear.
The height is adjusted for as long as the switch is pressed.
Steering column adjustment memory
On vehicles with seat memory, the corresponding setting can be
stored together with the seat position.
Easy-entry facility
The easy-entry facility adjusts the steering column to make it eas‐
ier to get into and out of the vehicle.

– The easy-entry facility can be activated/deactivated by press‐

ing the button -B-.
If the easy-entry facility is active (button -B- pressed), the steering
column moves into the park position (forwards and upwards)
when the ignition key is removed.
After getting in, the steering column is moved into the stored po‐
sition as soon as the vehicle key is turned to switch on the ignition
system.
The stored steering wheel position is only called up if the seat
memory button is in “ON” position (pressed).
With the entry aid switched off, the steering column is moved into
the stored position as soon as the seat memory button is actu‐
ated.

3.4 Steering column/belt height adjustment

control unit - J352- 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
Fitting location with respect to the correctness of information in this document. Copyright by AUDI AG.

Behind glove box compartment at central support

3. Electrically adjustable steering column, steering column/belt height adjustment control unit J352 327
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

4 Power-assisted steering rack (left-

hand drive vehicles)
⇒ “4.1 Exploded view of power steering rack, left-hand drive ve‐
hicles including Model Year '98”, page 328
⇒ “4.2 Exploded view of power steering rack, left-hand drive ve‐
hicles as of Model Year '99”, page 330
⇒ “4.3 Removing and installing power steering rack (left-hand
drive vehicles)”, page 331
⇒ “4.4 Removing and installing power steering rack (Audi RS 6)”,
page 336

4.1 Exploded view of power steering rack, left-hand drive vehicles including
Model Year '98

1 - Hexagon bolt, 67 Nm
2 - Boot
❑ Check for splits and
chafing
3 - Eccentric bolt
❑ Torx T50
❑ Turn clockwise to slack‐
en off
❑ Turn anti-clockwise to
tension
4 - Steering column
5 - Self-locking hexagon nut,
30 Nm
❑ Always renew
6 - Bolt with washer, 5 Nm
❑ Always renew after re‐
moving
❑ For adjusting toe con‐
stant “S”
7 - Bolt
8 - Self-locking nut
❑ Always renew after re‐
moving
❑ 40 Nm for steel wheel
bearing housing
❑ 45 Nm for aluminium
wheel bearing housing
9 - Return hose
10 - Expansion hose
11 - Socket head bolt, 13 Nm
❑ Steering centring screw plug ⇒ page 329
12 - Power steering rack with track rods
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing and installing ⇒ page
permitted 331 by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised

❑ Servicing ⇒ page 359

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

328 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

13 - Banjo bolt, 40 Nm
❑ With integrated non-return valve
14 - Seal, 14 x 20 mm
❑ Always renew
15 - Banjo bolt, 47 Nm
16 - Seal, 16 x 22 mm
❑ Always renew
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
17 - Hexagon bolt, 35 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.
18 - Steering damper on outside
❑ Only for:
❑ 6-cyl. models
❑ 4-cyl. quattro models
❑ 4-cyl. as of 132 kW
19 - Socket
20 - Rubber mounting
❑ Two-piece
21 - Hexagon nut, 10 Nm
❑ To release and tighten, counterhold on hexagon of steering damper piston rod

Steering centring screw plug

1 - Steering centring screw plug 13 Nm
2 - Tapped hole in steering rack

4. Power-assisted steering rack (left-hand drive vehicles) 329

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

4.2 Exploded view of power steering rack, left-hand drive vehicles as of Model
Year '99

1 - Hexagon bolt, 67 Nm
2 - Boot
❑ Check for splits and
chafing
3 - Eccentric bolt
❑ Torx T50
❑ Turn clockwise to slack‐
en off
❑ Turn anti-clockwise to
tension
4 - Steering column
5 - Self-locking hexagon nut,
30 Nm
❑ Always renew
6 - Bolt with washer, 5 Nm
❑ Always renew after re‐
moving
❑ For adjusting toe con‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
stant “S” 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 - Bolt
8 - Self-locking nut
❑ Always renew after re‐
moving
❑ 40 Nm for steel wheel
bearing housing
❑ 45 Nm for aluminium
wheel bearing housing
9 - Steering arm on wheel
bearing housing
10 - Pressure pipe
❑ Tighten union nut to 40
Nm ⇒ Item 4 (page 427)
❑ Note installation position on steering rack ⇒ page 331
11 - Return hose
❑ Note installation position on steering rack ⇒ page 331
12 - Socket head bolt, 13 Nm
❑ Steering centring screw plug ⇒ page 331
13 - Power steering rack with track rods
❑ Removing and installing ⇒ page 331
❑ Servicing ⇒ page 359
14 - Seal, 16 x 22 mm
❑ Always renew
15 - Banjo bolt, 47 Nm
16 - Seal, 14 x 20 mm
❑ Always renew

330 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

17 - Banjo bolt, 40 Nm
❑ With integrated non-return valve

Steering centring screw plug

1 - Steering centring screw plug 13 Nm
2 - Tapped hole in steering rack

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 return pipe and pressure pipe at steering

rack on left-hand drive vehicles
Pressure pipe angle -a-: Approx. 45°
Return hose angle -b-: Approx. 116°

4.3 Removing and installing power steering

rack (left-hand drive vehicles)
Special tools and workshop equipment required
♦ Hose clamps - 3094-

4. Power-assisted steering rack (left-hand drive vehicles) 331

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Steering centring bolt - V.A.G 1907-

Removing
– Take out plenum chamber cover.
– Remove battery
– Remove driver's storage compartment ⇒ General body re‐
pairs, interior; Rep. gr. 68 .
– Turn wheels to straight ahead position.
– Remove nut -1- on universal joint.
– Slacken off eccentric by turning tensioning bolt (Torx T50)
clockwise and take out bolt.

– Swivel aside universal joint.

– Remove ignition key with steering wheel in centre position.
– Move steering wheel slightly so that steering lock engages.
If the steering wheel turns uncontrollably with the steering rack
removed, the coil springs in the airbag system may overwind and
sustain damage.
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.

– Clamp off suction and return lines using hose clamps - 3094- .
– Remove front wheels.

332 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unscrew hexagon bolt -1- and bolt -2-.

– Pull out track rod.

– Unbolt nut -1-.

– Prise out clips -2-.
– Take out cover.

Note

Due to better illustration shown without wheel bearing housing

and suspension strut.

Working instructions applicable only to 2.7 Biturbo

– Lower the subframe at the rear.
For working instructions, refer to the relevant gearbox workshop
manual, ⇒ Rep. gr. 34 , Removing and installing gearbox.
– Remove the left exhaust pipe ⇒ 6-cylinder engine (5-valve
turbo), mechanics; Rep. gr. 26 .
Working instructions applicable only to 6-cyl. TDI / 6-cyl. petrol
engine and 8-cyl. petrol engine in allroad
Remove the left exhaust pipe.
– ⇒ 6-cylinder diesel direct injection engine (TDI), mechanics;
Rep. gr. 26
– ⇒ 6-cylinder engine (5-valve), mechanics; Rep. gr. 26
– ⇒ 8-cylinder engine, mechanics; Rep. gr. 26
Working instructions applicable 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
– Remove the splash plate. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Place a drip tray underneath to catch hydraulic fluid.

4. Power-assisted steering rack (left-hand drive vehicles) 333

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unscrew banjo bolt (22 mm) for return hose from steering rack.

– Unscrew banjo bolt (19 mm) for pressure hose from steering
rack.
– Vehicles with Servotronic: Unplug the connector from the Ser‐
votronic valve.

– Remove steering rack securing points-1-,-2- and -3-.

– Take out steering rack through left-hand wheel housing (sec‐
ond mechanic 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.

334 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Installing
Before installing, centralise steering rack using steering centring
bolt - V.A.G 1907- .
– To do this, remove hexagon socket head bolt -1- on steering
rack.
– Move rack until centre marking (indentation) on rack -arrow-
aligns with threaded hole -2-.
– Screw in steering centring bolt - V.A.G 1907- hand-tight.
– Pay attention to the bulkhead collar.
♦ Any damaged seals must be replaced.
♦ Make sure gasket is correctly positioned.

– Position the steering rack on the plenum chamber.

Make sure threads and contact surfaces of bolts are free from oil
and grease.
– Insert bolts -1- and -2- but do not tighten.
– Screw in and tighten bolt -3-.
– Then tighten the bolts -1- and -2-.
– Screw on the return hose and tighten the banjo bolt -22 mm-
to 50 Nm.
– Screw on the pressure hose and tighten the banjo bolt -19 mm-
to 40 Nm.
– Release steering lock.
– Set steering wheel to centre position and then attach universal
joint to steering pinion.
– Insert tensioning bolt (Torx T50) and pre-tension in anti-clock‐
wise direction.

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. Power-assisted steering rack (left-hand drive vehicles) 335

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Then screw the steering centring bolt - V.A.G 1907- out of the
steering rack.
1 - Hexagon socket head bolt
2 - Threaded hole in steering rack
– Seal the steering rack with the hexagon socket head bolt -1-,
tightening torque 13 Nm.
– Tighten hexagon nut on tensioning bolt to 30 Nm.
– Install driver's side storage compartment.
– Install wheel housing trim.
– Remove the hose clamps - 3094- on completion of steering
rack assembly.
– On the 2.7 Biturbo, secure the exhaust pipe, splash plate and
subframe ⇒ 6-cylinder engine (5-valve turbo), mechanics;
Rep. gr. 26 .
– On the 6-cyl. diesel direct injection engine, secure the exhaust
pipe ⇒ 6-cylinder diesel direct injection engine (TDI), me‐
chanics; Rep. gr. 26 .
– On the 6-cyl. petrol engine, secure the exhaust pipe ⇒ 6-cyl‐
inder engine (5-valve), mechanics; Rep. gr. 26 .
– Install battery.
– Check hydraulic fluid level ⇒ page 369 .
– Bleed steering system ⇒ page 369 .
– Checking steering system for leaks ⇒ page 370
– Check the running gear geometry ⇒ page 294 .

4.4 Removing and installing power steering

rack (Audi RS 6)
Removing
– Remove the engine ⇒ 8-cylinder engine (turbo), mechanics;
Rep. gr. 10 .
– Remove the splash plates.
– Further removal operations as for all other vehicles
⇒ page 332 .
Installing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Installation operations
permitted unless as
authorised by forAG.
AUDI allAUDI
other vehicles
AG does ⇒ page
not guarantee 335any. liability
or accept
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Fit the splash plates.
Tightening torque: 2 Nm
– Install the engine ⇒ 8-cylinder engine (turbo), mechanics;
Rep. gr. 10 .

336 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

5 Power-assisted steering rack (right-

hand drive vehicles)
⇒ “5.1 Exploded view of power steering rack, right-hand drive ve‐
hicles up to and including Model Year '98”, page 337
⇒ “5.2 Exploded view of power steering rack, right-hand drive ve‐
hicles as of Model Year '99”, page 338
⇒ “5.3 Removing and installing power steering rack (right-hand
drive vehicles)”, page 338
⇒ “5.4 Removing and installing power steering rack, right-hand
vehicles with 8-cyl. Petrol engine”, page 344
⇒ “5.5 Removing and installing power steering rack (Audi RS 6)”,
page 357

5.1 Exploded view of power steering rack, right-hand drive vehicles up to and
including Model Year '98

1 - Power steering rack

2 - Socket head bolt, 13 Nm
❑ Steering centring screw
plug ⇒ page 329
3 - Banjo bolt, 40 Nm
❑ With integrated non-re‐
turn valve
4 - Banjo bolt, 47 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
5 - Adjuster screw with respect to the correctness of information in this document. Copyright by AUDI AG.

6 - Seal, 16 x 22 mm
❑ Renew
7 - Return line
8 - Seal, 14 x 20 mm
❑ Renew
9 - Pressure line
10 - Hexagon socket head bolt,
21.5 Nm
❑ For attachment of the
pressure and return line
to the steering rack
11 - Socket
12 - Hexagon nut, 10 Nm
❑ To release and tighten,
counterhold on hexagon
of steering damper pis‐
ton rod
13 - Rubber mounting
❑ Two-piece
14 - Steering damper on out‐
side
❑ Not fitted with all engines
15 - Hexagon bolt, 35 Nm

5. Power-assisted steering rack (right-hand drive vehicles) 337

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

5.2 Exploded view of power steering rack, right-hand drive vehicles as of Model
Year '99

1 - Power steering rack

❑ with integrated steering
damper
2 - Socket head bolt, 13 Nm
❑ Steering
Protected centring
by copyright. screw
Copying for private or commercial purposes, in part or in whole, is not
plug
permitted ⇒ page
unless 329
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 - Banjo bolt, 40 Nm
❑ With integrated non-re‐
turn valve
4 - Banjo bolt, 50 Nm
5 - Adjuster screw
6 - Seal, 16 x 22 mm
❑ Renew
7 - Return line
8 - Seal, 14 x 20 mm
❑ Renew
9 - Pressure line
10 - Hexagon socket head bolt,
21.5 Nm
❑ For securing the pres‐
sure and return line to
the steering rack
11 - Connector for Servotronic

5.3 Removing and installing power steering

rack (right-hand drive vehicles)
Special tools and workshop equipment required
♦ Hose clamps - 3094-

338 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Steering centring bolt - V.A.G 1907-

Removing
– Take out the plenum chamber cover -A-.

Note

♦ Note down or obtain the radio unit code.

♦ For vehicles with electric seat adjustment move driver’s seat
backwards (more movement in footwell).

– Remove battery

– Unscrew battery console -arrows-.

– Remove driver's storage compartment ⇒ General body re‐
pairs, interior; Rep. gr. 68 .
– Turn wheels to straight ahead position.

– Remove nut -1- on universal joint.

– Slacken off eccentric by turning tensioning bolt (Torx T50)
clockwise and take out bolt.
– Remove ignition key with steering wheel in centre position.
– Move steering wheel slightly so that steering lock engages.
If the steering wheel rotates out of control while the steering rank
is removed, the coil springs in the airbag system may overwind
and sustain damage.

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. Power-assisted steering rack (right-hand drive vehicles) 339

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Swivel aside universal joint.

– Remove front wheels.

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 hexagon bolt -1- and bolt -2-.

– Pull out track rod.

– Unbolt nut -1-.

– Prise out clips -2-.
– Take out cover.

Note

Due to better illustration shown without wheel bearing housing

and suspension strut.

– Unscrew nut -2- and self-tapping screws -3-.

340 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Take out protective plate -1-.

– Clamp off suction and return lines using hose clamps - 3094- .
– Place a drip tray underneath to catch hydraulic fluid.

– Unscrew the pressure pipe -1- and return pipe -2- from the
steering rack.
– Detach connector from Servotronic valve on vehicles equip‐
ped with Servotronic.

– Unscrew hexagon socket head bolt for pressure and return

line from steering rack. 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

Tightening torque ⇒ Item 10 (page 337)

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

5. Power-assisted steering rack (right-hand drive vehicles) 341

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Right side of vehicle:

– Remove right-hand securing bolt for steering rack.

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.

– Remove bolt -1- for securing steering rack.

– Unscrew the bolt -arrow- for attaching the steering rack.

This is located to the side of the brake servo.
– Pull steering rack out to right-hand side (second mechanic re‐
quired).

Installing
Before installing, centralise steering rack using steering centring
bolt - V.A.G 1907- .
– To do this, remove hexagon socket head bolt -1- on steering
rack.
– Move rack until centre marking (indentation) on rack -arrow-
aligns with threaded hole -2-.
– Screw in steering centring bolt - V.A.G 1907- hand-tight.

342 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Make sure the water drain sockets are correctly positioned and
not damaged.
– Pay attention to the bulkhead collar.
♦ A damaged collar or socket must be replaced.
♦ Make sure gasket is correctly positioned!
Make sure the internal threads and contact surfaces at the steer‐
ing rack are free from oil and grease.

– Insert steering rack (2 mechanics required).

Take particular care not to damage the boot or the brake pipe in
the wheel 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.

– Position the steering rack on the plenum chamber.

Make sure threads and contact surfaces of bolts are free from oil
and grease.
– Insert bolts -1- and -2- but do not tighten.
– Screw in and tighten bolt -3-.
– Then tighten the bolts -1- and -2-.

– Position hexagon socket head bolt for pressure and return line
on steering rack.
Tightening torque ⇒ Item 10 (page 337)
Watch for free movement of hydraulic hoses and wires.

5. Power-assisted steering rack (right-hand drive vehicles) 343

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Screw on the return pipe and tighten the banjo bolt -22 mm-
to 50 Nm.
– Screw on the pressure hose and tighten the banjo bolt -19 mm-
to 40 Nm.
– Tighten hexagon socket head bolt for pressure and return line
on steering rack.
Tightening torque ⇒ Item 10 (page 337)
– Release steering lock.
– Set steering wheel to centre position and then attach universal
joint to steering pinion.

– Then screw the steering centring bolt - V.A.G 1907- out of the
steering rack.
1 - Hexagon socket head bolt
2 - Threaded hole in steering rack
– Seal the steering rack with the hexagon socket head bolt  -1-,
tightening torque 13 Nm.
– Insert tensioning bolt (Torx T50) and pre-tension in anti-clock‐
wise direction.
– Tighten hexagon nut on tensioning bolt to 30 Nm.
– Install driver's side storage compartment.
– Remove the hose clamps - 3094- on completion of steering
rack assembly.
– Install wheel housing trim.
– Fit heat shield.
– Remove noise insulation panel.
– Install
permitted battery.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Check hydraulic fluid level ⇒ page 369 .

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

– Bleed steering system ⇒ page 369 .

– Checking steering system for leaks ⇒ page 370
– Perform wheel alignment ⇒ page 294 .

5.4 Removing and installing power steering

rack, right-hand vehicles with 8-cyl. Pet‐
rol engine
Special tools and workshop equipment required
♦ Hose clamps - 3094-

344 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Steering centring bolt - V.A.G 1907-

Removing
– Unfasten the bolted joints -arrows- and detach the engine cov‐
er -A-.
– Detach the cover -B-.
– Detach the sealing lip at the plenum chamber and take out the
cover -C-.

Note

♦ Note down or obtain the radio unit code.

For vehicles with electric seat adjustment move driver’s seat
♦by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
backwards (more movement in footwell).
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.

– Remove battery

– Unscrew battery console -arrows-.

– Remove driver's storage compartment ⇒ General body re‐
pairs, interior; Rep. gr. 68 .
– Turn wheels to straight ahead position.

– Remove nut -1- on universal joint.

– Slacken off eccentric by turning tensioning bolt (Torx T50)
clockwise and take out bolt.
– Remove ignition key with steering wheel in centre position.
– Move steering wheel slightly so that steering lock engages.
If the steering wheel rotates out of control while the steering rank
is removed, the coil springs in the airbag system may overwind
and sustain damage.

5. Power-assisted steering rack (right-hand drive vehicles) 345

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Swivel aside universal joint.

– Pull out air duct to air filter.

– Remove top part of air filter with air mass meter and air collar.

– Detach black connector of lambda probe.

– Expose the wiring piece to the probe.

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.

346 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unscrew the right splash plate -A- at the top.

– To do so, slacken off the bolt -1- and unscrew the bolt -2-.

– Unscrew coolant reservoir.

– Detach connector for fluid level and put container to the side
(hoses remain connected).

– Unfasten the cable ties -arrows- and lay bare the engine wiring
harness in the area of the splash plate -A-.

– Unscrew the left splash plate -A- at the top.

– To do so, unscrew the nut -1- and slacken off the bolt -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.

5. Power-assisted steering rack (right-hand drive vehicles) 347

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Clamp off suction pipe with hose clamp - 3094- .

– Remove front wheels.

– Unscrew hexagon bolt -1- and bolt -2-.

– Pull out track rod.

– Unbolt nut -1-.

– Prise out clips -2-.
– Take out cover.

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
Due to better illustration shown without wheel bearing housing
with respect to the correctness of information in this document. Copyright by AUDI AG.
and suspension strut.

– Remove noise insulation panel.

348 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove the heat shields for the left right drive shafts
-arrows-.
– Remove the right catalytic converter, refer to ⇒ Rep. gr. 26 .

– Unscrew the right gearbox support complete with bonded rub‐

ber bush from the gearbox and the subframe. To do so, screw
out the bolts -1- and -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.

– Unscrew the nut -3- and take out the right splash plate -A-.

– Unscrew the nut -2- and slide the left splash plate -A- down‐
wards as far as possible.

5. Power-assisted steering rack (right-hand drive vehicles) 349

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Pinch off return pipe with hose clamp - 3094- .

– Place a drip tray underneath to catch hydraulic fluid.
– Left side of vehicle:

– Unscrew the pressure pipe from the expansion hose -1- whilst
providing support at the hexagon of the expansion hose.
For vehicles with Servotronic:
– Unplug the Servotronic connector (right -arrow-).
– Right side of vehicle:

– Unscrew the banjo bolt -2- for the return pipe. Leave the pres‐
sure pipe -1- on the steering rack.
The cable of the Servotronic valve is attached by means of cable
ties to the pressure pipe -1-. They are not accessible when the
steering rack is installed.
Therefore remove and install the steering rack with the pressure
pipe attached.
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.

350 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

For vehicles without Servotronic:

– Unscrew the banjo bolts for the pressure pipe -1- and return
pipe -2- from the steering rack.

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.

All models:
– Remove right-hand securing bolt for steering rack from below.

– Unscrew hexagon socket head bolt for pressure and return

line from steering rack.
1 - 6 mm hexagon socket head bolt
2 - Pressure line
3 - Return line
4 - Projection with internal thread at steering rack

– Screw out the upper bolts -1- and -2-.

The bolt -1- is located to the side of the brake servo.

5. Power-assisted steering rack (right-hand drive vehicles) 351

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Pull steering rack out to right-hand side (second mechanic re‐

quired).
Take particular care not to damage the boot or the brake pipe in
the wheel housing on removal.
Installing
Before installing, centralise steering rack using steering centring
bolt - V.A.G 1907- .

– To do this, remove hexagon socket head bolt -1- on steering

rack.
– Move rack until centre marking (indentation) on rack -arrow-
aligns with threaded hole -2-.
– Screw in steering centring bolt - V.A.G 1907- hand-tight.
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.

For vehicles with Servotronic:

– Screw the pressure pipe with the banjo bolt and new seals to
the steering rack. However, do not tighten banjo bolt.
– Attach cable of Servotronic valve with cable ties to the pres‐
sure line.

All models:
– Make sure the water drain sockets are correctly positioned and
not damaged.
– Pay attention to the bulkhead collar.
♦ A damaged collar or socket must be replaced.
♦ Make sure gasket is correctly positioned!
Make sure the internal threads and contact surfaces at the steer‐
ing rack are free from oil and grease.

352 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Insert steering rack (2 mechanics required).

Take particular care not to damage the boot or the brake pipe in
the wheel housing.

– Insert the steering rack in the bulkhead collar and position on

the plenum chamber (2 mechanicsProtected
required).
by copyright. Copying for private or commercial purposes, in part or in whole, is not

Make sure threads and contact surfaceswith

of respect
bolts toare
the free fromof oil
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
correctness information in this document. Copyright by AUDI AG.
and grease.
– Insert bolts -1- and -2- but do not tighten.
– Screw in and tighten bolt -3-.
– Then tighten the bolts -1- and -2-.

For vehicles without Servotronic:

– Insert pressure line.
– Fit the banjo bolts for the pressure pipe -1- and return pipe
-2-.

For vehicles with Servotronic:

– Screw the return pipe with the banjo bolt -1- and new seals to
the steering rack. However, do not tighten banjo bolt.

5. Power-assisted steering rack (right-hand drive vehicles) 353

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

All models:
– Attach pressure and return line with hexagon socket head bolt.
1 - 6 mm hexagon socket head bolt
2 - Pressure line
3 - Return line
4 - Projection with internal thread at steering rack

Note

♦ Insert the bolt -1- from above between the plenum chamber
wall and cylinder head and fit in position.
♦ Tighten from below with torque wrench, extensions, joint and
hexagon insert.

– Tighten pressure and return line.

1 - Banjo bolt (19 mm) for pressure pipe, 40 Nm
2 - Banjo bolt (22 mm) for return pipe, 47 Nm
Left 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Screw the pressure pipe to the expansion hose -1-. To do so,

provide support at the hexagon of the expansion hose, 40 Nm.
For vehicles with Servotronic:
– Plug in the Servotronic connector and attach the wire with a
cable tie in a manner guarding against abrasion.
All models:
– Release steering lock.
– Set steering wheel to centre position and then attach universal
joint to steering pinion.

354 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Now unscrew steering centring bolt - V.A.G 1907- from steer‐

ing rack.
1 - Hexagon socket head bolt
2 - Threaded hole in steering rack
– Seal the steering rack with the hexagon socket head bolt -1-,
tightening torque 13 Nm.

– Insert tensioning bolt (Torx T50) and pre-tension in anti-clock‐

wise direction.
– Tighten hexagon nut on tensioning bolt to 30 Nm.

– Insert the left splash plate -A- and secure it from underneath
with the nut -2-.
– Secure the upper splash plate -A-.
– To do so, tighten the nut -1- and the bolt -3-.
– Lay and secure the engine wiring harness.

– Attach connector for fluid level and coolant container.

– Install heat shield for left 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.

5. Power-assisted steering rack (right-hand drive vehicles) 355

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Insert the right splash plate -A- and secure it from underneath
with the nut -3-.
– Secure the upper splash plate -A-.
– To do so, tighten the bolts -1- and -2-.
– Route wiring of lambda probe and attach.
– Remove top part of air filter with air mass meter and air collar.
– Install air duct to air filter.

– Install the right final drive support.

1 - Hexagon socket (w.a.f. 8 mm): 40 Nm
2 - Hexagon head (w.a.f. 13 mm): 23 Nm
– Install the right catalytic converter.
– Install heat shield for right drive shaft.
– Detach the hose clamp - 3094- from the return hose.

– Install covers on left and right.

Note

Due to better illustration shown without wheel bearing housing

and suspension strut.

– Insert track rods.

– Screw on a new self-locking nut -2- and initially tighten to 20
Nm.
Only finish-tighten the nut -2- in the course of wheel alignment.
– Screw in the hexagon bolt -1-.
– Screw on the front wheels.
– Install battery console and battery.
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.

356 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Note

Removing and installing the battery may dislodge the spacers.

– The spacers must be positioned on the brake pipes between

the battery and the plenum chamber front wall.
1 - Brake pipe to brake master cylinder secondary piston circuit,
dimension -b-: Approx. 60 mm
2 - Brake pipe to brake master cylinder primary piston circuit, di‐
mension -a-: Approx. 30 mm

– Make sure the brake pipes are inserted in the recesses of the
spacers.
1 - Brake pipe to brake master cylinder secondary piston circuit
2 - Brake pipe to brake master cylinder primary piston circuit
F - Direction of travel
– Insert plenum chamber cover and secure with seal
– Detach the hose clamp - 3094- from the suction hose.
– Install engine cover panel.
– Fill up with hydraulic fluid.
– Bleed steering system ⇒ page 369 .
– Checking steering system for leaks ⇒ page 370

– Fit the noise insulation.

– Fit the driver's storage compartment ⇒ General body repairs,
interior; Rep. gr. 68 .
– Perform wheel alignment ⇒ page 294 .

5.5 Removing and installing power 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
rack (Audi RS 6)
with respect to the correctness of information in this document. Copyright by AUDI AG.

Removing
– Remove the engine ⇒ 8-cylinder engine (turbo), mechanics;
Rep. gr. 10 .

5. Power-assisted steering rack (right-hand drive vehicles) 357

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove the splash plates.

– Further removal operations as for all other vehicles
⇒ page 339 .
Installing
– Installation operations as for all other vehicles ⇒ page 339 .
– Fit the splash plates.
Tightening torque: 2 Nm
– Install the engine ⇒ 8-cylinder engine (turbo), mechanics;
Rep. gr. 10 .

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.

358 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

6 Servicing power steering rack

⇒ “6.1 Steering rack without/with integrated steering damper”,
page 359
⇒ “6.2 Steering rack with external steering damper”, page 360

6.1 Steering rack without/with integrated steering damper

This overview is applicable to LHD and RHD vehicles (layout is
similar).

Note

♦ Renew self-locking nuts and bolts.

♦ Welding and straightening work on steering components is not permitted.
♦ Use only steering rack grease - A0F 063 000 04- for greasing rack.
♦ Use only hydraulic fluid - G 002 000- .

1 - Track rod ball joint

❑ Check that dust caps
are seated correctly and
not damaged
2 - Hexagon nut, 40 Nm
3 - Spring-type clip
❑ Use spring-type clip pli‐
ers - V.A.G 1921- when
opening clip
4 - Boot
❑ Check for damage
❑ Must not be twisted after
adjusting toe setting
5 - Hose clip
❑ Tighten using hose clip
pliers - V.A.G 1275-
❑ Renew 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 - Inside track rod joint, 100 with respect to the correctness of information in this document. Copyright by AUDI AG.
Nm
❑ Grease joint with steer‐
ing rack grease -
A0F 063 000 04-
7 - O-ring
❑ Renew
8 - Power steering rack
❑ Grease rack with steer‐
ing rack grease -
A0F 063 000 04-
❑ Different versions with
and without steering
damper ⇒ Electronic
parts catalogue “ETKA”
9 - Socket head bolt, 13 Nm
❑ Steering centring screw plug

6. Servicing power steering rack 359

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

6.2 Steering rack with external steering damper

This overview covers LHD and RHD vehicles (layout is similar)

Note

♦ Renew self-locking nuts and bolts.

♦ Welding and straightening work on steering components is not permitted.
♦ Use only steering rack grease - A0F 063 000 04- for greasing rack.
♦ Use only hydraulic fluid - G 002 000- .

1 - Track rod ball joint

❑ Check that dust caps
Protectedare seatedCopying
by copyright. correctly andor commercial purposes, in part or in whole, is not
for private
permittednot damaged
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

❑ Version with and without

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

ring
❑ New version only avail‐
able from ⇒ Electronic
parts catalogue “ETKA”
2 - Hexagon nut, 40 Nm
3 - Spring-type clip
❑ Use spring-type clip pli‐
ers - V.A.G 1921- when
opening clip
4 - Boot
❑ Check for damage
❑ Must not be twisted after
adjusting toe setting
5 - Hose clip
❑ Tighten using hose clip
pliers - V.A.G 1275-
❑ Renew
6 - O-ring
❑ Renew
7 - Inside track rod joint, 100
Nm
❑ Grease joint with steer‐
ing rack grease -
A0F 063 000 04-
8 - Holder for steering damper
9 - O-ring
❑ Renew
10 - Dished spring
11 - Hose clip
❑ Tighten using hose clip pliers - V.A.G 1275-
❑ Renew
12 - Boot
❑ Check for damage

360 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

13 - Power steering rack

❑ Grease rack with steering rack grease - A0F 063 000 04-
14 - Hexagon nut, 10 Nm
❑ To release and tighten, counterhold on hexagon of steering damper piston rod
15 - Socket
16 - Rubber mounting
❑ Two-piece
17 - Steering damper
18 - Hexagon bolt, 35 Nm
19 - Socket head bolt, 13 Nm
❑ Steering centring screw plug

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. Servicing power steering rack 361

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

7 Servotronic steering rack

⇒ “7.1 Servotronic steering rack - exploded view”, page 362
⇒ “7.2 Servicing Servotronic steering rack”, page 363
⇒ “7.3 Checking voltage supply for servotronic”, page 363
⇒ “7.4 Checking speed signal”, page 364
⇒ “7.5 Checking servotronic solenoid valve N119 ”, page 365

7.1 Servotronic steering rack - exploded view

1 - Power steering rack with

track rods
❑ Exploded view for left-
hand drive vehicles:
⇒ page 328
❑ Exploded view for right-
hand drive vehicles:
⇒ page 337
2 - Connector for Servotronic
3 - Servotronic control unit -
J236- in 13-position relay car‐
rier
❑ Located underneath
trim in driver's footwell
⇒ Current flow dia‐
grams, Electrical fault
finding and Fitting loca‐
tions
❑ Servotronic control unit -
J236- , position 13
❑ Check voltage supply
⇒ page 363
❑ Checking speed signal
⇒ page 364
4 - Hexagon socket head bolt,
3 Nm
❑ 2.5 mm
Do not slacken Torx bolts

5 - Servotronic solenoid valve

- N119-
❑ Steering rack must be
removed in order to re‐
new Servotronic sole‐
noid 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
❑ Checking ⇒ page 365 with respect to the correctness of information in this document. Copyright by AUDI AG.
Do not slacken Torx bolts

6 - Seal
❑ Always renew
7 - Seal
❑ Always renew
8 - Strainer
❑ Always renew

362 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

7.2 Servicing Servotronic steering rack

♦ On vehicles with Servotronic steering rack the degree of power
assistance is varied electronically in accordance with the road
speed.
♦ Should the electronics fail, the steering functions in the same
manner as normal power-assisted steering.
♦ The Servotronic control unit - J236- does not have a self-di‐
agnosis capability
Fault table 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

Possible faults Possible cause of fault Fault remedy

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

♦ More than the normal steering ♦ Open circuit in voltage supply ♦ Check voltage supply ⇒ page 363
effort required to manoeuvre
the vehicle. ♦ Open circuit in speed signal ♦ Checking vehicle speed signal
⇒ page 364
♦ Steering unusually light at ♦ Servotronic solenoid valve
high vehicle speed. defective ♦ Check Servotronic solenoid valve
⇒ page 365

♦ Power steering heavy on one ♦ Hydraulic fault in power steer‐ ♦ Renew power steering rack
side only, e.g.: steering is light ing rack
when on right lock and heavy Left-hand drive vehicles: ⇒ page 328
on left lock Right-hand drive vehicles:
⇒ page 337

7.3 Checking voltage supply for servotronic

– Remove driver's storage compartment ⇒ General body re‐
pairs, interior; Rep. gr. 68 .
– Right-hand drive vehicles:
– Unscrew safety retainer and remove.

7. Servotronic steering rack 363

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Pull out Servotronic control unit - J236- , position 13.

– Switch on ignition.
– Set digital multimeter - V.A.G 1526- to voltage test range (up
to 20 Volt).
– Take the measurement at the relay connector between con‐
tacts 6 and 8.
Specification: approx. 12 Volt
– If specification is not attained, check electrical wiring ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.

7.4 Checking speed signal

The vehicle speed signal is supplied by the speedometer - G21-
in the dash panel insert.
– Remove driver's storage compartment ⇒ General body re‐
pairs, interior; Rep. gr. 68 .
– Right-hand drive vehicles:
– Unscrew safety retainer and remove.

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.

– Pull out Servotronic control unit - J236- , position 13.

– If the power supply, the Servotronic solenoid valve and the
speedometer reading are OK, check the wiring between con‐
tact 4 and the speedometer - G21- ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– If the wiring between contact 4 and the speedometer - G21- is
OK, replace the Servotronic control unit - J236- .

364 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

7.5 Checking servotronic solenoid valve -

N119-
– Remove driver's storage compartment ⇒ General body re‐
pairs, interior; Rep. gr. 68 .
– Right-hand drive vehicles:
– Unscrew safety retainer and remove.

– Pull out Servotronic control unit - J236- , position 13.

– Set digital multimeter - V.A.G 1526- to resistance test range
(up to 200 Ohm).
– Take the measurement at the relay connector between con‐
tacts 2 and 5.
Specification: 5 to 20 Ohm.
If reading does not match specification:
– Unplug the Servotronic connector (in the left wheel housing
⇒ page 350 ).
– Check for short circuit and open circuit in the wiring between
the relay connector and the connector for the Servotronic sol‐
enoid valve ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
– If the wiring is OK, remove the steering rack and replace the
Servotronic solenoid 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.

7. Servotronic steering rack 365

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

8 Adjusting power steering rack

Two mechanics are required to perform adjustment. Perform ad‐
justment with engine switched off.
– Raise vehicle on lifting platform.
– Wheels in straight-ahead position.
– If there is excessive play in the steering, a knocking noise will
be audible when the steering wheel is turned backwards and
forwards (about 30° either side of centre position).
– In this case, have the second mechanic carefully screw in the
adjusting screw -arrow- until the knocking noise can no longer
be heard inside the vehicle.
– Road-test vehicle.
– Check that the steering centres smoothly by itself back to the
straight-ahead position after a turn. Correct the adjustment 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.

366 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

9 Removing and installing track rods

Special tools and workshop equipment required
♦ Open-end spanner attachment - V.A.G 1923-

♦ Torque wrench - V.A.G 1332-

Left and right track rods are identical.

They can be removed and installed with the steering rack in the
vehicle.
Removing
– Unscrew front wheel.
– Unscrew hexagon bolt -1- and bolt -2-.
– Pull out track rod.

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.

9. Removing and installing track rods 367

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove plastic nut -1-.

– Prise out clips -2-.
– Take out cover for track rod.

Note

Due to better illustration shown without wheel bearing housing

and suspension strut.

– Open hose clips on rubber boot.

– Pull bellows outwards as far as possible.

– Unscrew track rod using open-end spanner attachment -

V.A.G 1923- .
– Then replace the boot or track rods depending on the extent
of the damage.
Installing
– Tighten the track rod to 100 Nm.
– When fitting the boot, make sure that:
♦ the smaller diameter of the rubber boot clips into the groove
on the track rod
♦ the boot is not twisted.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Replace
permittedthe inner
unless (large)
authorised clamp.
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 running gear geometry ⇒ page 294 .

368 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

10 Checking fluid level, bleeding steer‐

ing system and checking for leaks
⇒ “10.1 Checking fluid level of power steering”, page 369
⇒ “10.2 Bleeding steering system”, page 369
⇒ “10.3 Checking steering system for leaks”, page 370

10.1 Checking fluid level of power steering

– Do not start engine. Set front wheels to straight-ahead posi‐
tion.
When hydraulic fluid is cold (ambient temperature approx. +20°
C)
– Unscrew filler cap.
– Wipe
Protected dipstick
by copyright. with
Copying a clean
for private cloth. purposes, in part or in whole, is not
or commercial
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– respect
with Screw filler
to the cap on
correctness hand tight
of information in thisand unscrew
document. again.
Copyright by AUDI AG.

The cap must first be fully screwed on in order to obtain an ac‐

curate fluid level reading.
– Check fluid level: fluid level should be close to “MAX” mark.
When fluid is at operating temperature (engine oil temperature
+80°C)
– Check fluid level: fluid level should be 10 mm above “MAX”
mark.

Note

♦ Excess fluid must be drained off if the level is above the range
specified above.
♦ If the fluid level is below the range specified, the hydraulic
system must be checked for leaks. In this case it is not suffi‐
cient to merely top up the fluid.
♦ Do not re-use hydraulic fluid which has been drained off.

10.2 Bleeding steering system

The bleeding procedure differs depending on the extent of the
work performed on the steering system.
Following replacement of entire steering system or steering rack
– Check hydraulic fluid level and top up if necessary.
– Raise vehicle until front wheels are free.
– Start engine and let it run briefly (2 seconds maximum).
The pump must not draw in air. The steering wheel MUST NOT
be turned.
Wait approx. 30 seconds between engine starts.
– Check hydraulic fluid level and top up if necessary.
– Keep repeating this procedure until fluid level remains con‐
stant.
– With engine switched off, turn steering wheel 10 times from
lock to lock.
– Check hydraulic fluid level and top up if necessary.

10. Checking fluid level, bleeding steering system and checking for leaks 369
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Start engine.
– Turn steering wheel 10 times from lock to lock.
– Check hydraulic fluid level and top up if necessary.
Any air remaining in the steering system will dissipate when the
vehicle has been driven 10…20 km.
On conversion of steering system component other than steering
rack (pump, hoses, etc.)
– Check hydraulic fluid level and top up if necessary.
– Start engine and let it run briefly (2 seconds maximum).
The pump must not draw in air. The steering wheel MUST NOT
be turned.
Wait approx. 30 seconds between engine starts.
– Check hydraulic fluid level and top up if necessary.
– Keep repeating this procedure until fluid level remains con‐
stant.
– Start the engine and let it run for 2 to 3 minutes without turning
the steering wheel.
Any air remaining in the steering system will dissipate when the
vehicle has been driven 10…20 km.

10.3 Checking steering system for leaks

– Start engine.
– Turn steering to full lock on both sides and hold briefly.
This builds up the maximum possible pressure.
To avoid pump damage, do not run the engine for more than
10 seconds when performing this test.
Check the following components for leaks with the steering in this
position:
♦ Pinion seal on steering rack valve housing
♦ All pipe connections
♦ Steering rack seals
This test can only be carried out when the cable tie of the bellows
is accessible without great effort.
– Open hose clamp for bellows.
– Push back 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
The steering rack must be renewed if fluid is visible in the steering
with respect to the correctness of information in this document. Copyright by AUDI AG.
rack housing and/or in the rubber boots.

370 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

11 Power steering pump, hydraulic

pipes and hoses, fluid reservoir - ve‐
hicles with 4-cylinder petrol and die‐
sel engine
⇒ “11.1 Exploded view - vehicles with 4-cyl. petrol and diesel en‐
gine”, page 371
⇒ “11.2 Checking delivery pressure of power steering pump, ve‐
hicles with 4-cyl. petrol and diesel engine”, page 373
⇒ “11.3 Exploded view of power steering pump, vehicles with 4-
cyl. petrol and diesel engine”, page 376
⇒ “11.4 Removing and installing power steering pump - vehicles
with 4-cyl. petrol and diesel engine”, page 377

11.1 Exploded view permitted

- vehicles withby4-cyl.
AUDI AG.pet‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised AUDI AG does not guarantee or accept any liability

rol and diesel engine

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

General notes
There is no provision for repairing the power steering pump. If
problems are reported, trace the fault by means of a pressure test
and a leakage test. Renew the power steering pump if there is a
fault.
The hydraulic fluid circuit on right-hand drive vehicles is the same
as on left-hand drive vehicles, except that the hydraulic pipes are
extended from left to right on the steering rack.
♦ Always check steering system for leaks in the event of a lack
of fluid in the reservoir.
♦ If leakage is visible at the pipe connections first tighten con‐
nections and wipe dry, then check for leaks again.
♦ Replacement pumps are not filled with fluid. Prior to installa‐
tion they are therefore to be filled with hydraulic fluid -
G 002 000- and cranked by hand to avoid the possibility of
noise whilst driving or pump damage.
♦ Fluid type: Hydraulic fluid - G 002 000-

11. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 4-cylinder petrol and diesel engine 371
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Power steering rack

❑ Exploded view:
❑ Left-hand drive vehicles
⇒ page 328
❑ Right-hand drive vehi‐
cles ⇒ page 337
❑ Servicing ⇒ page 359
2 - Expansion hose
3 - Return hose
4 - Cap with dipstick
❑ Checking fluid level
⇒ page 369
5 - Hexagon bolt, 9 Nm
6 - Reservoir
❑ Capacity approx. 0.85 l
7 - Rubber mounting
8 - Hose clip
❑ Tighten using hose clip
pliers - V.A.G 1275-
9 - Return hose
Between reservoir and cooling
pipe

10 - Cable tie
11 - Cooling pipe
12 - Torx bolts (T 30)
❑ 9 Nm
13 - Hose clip
❑ Tighten using hose clip
pliers - V.A.G 1275-
14 - Suction hose
❑ Installation position ⇒ page 373 and ⇒ page 373
15 - Power steering pump
❑ Fill with fluid before installing ⇒ page 371
❑ Checking delivery pressure ⇒ page 373
❑ Exploded view ⇒ page 376
16 - Seal, 16 x 22 mm
❑ Always renew
17 - Banjo bolt, 47 Nm
18 - Speed nut
19 - Bolt with washer
20 - Heat shield
21 - Expanding 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.

372 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Installation position of suction hose at power steering pump for 4-

cyl. petrol and diesel engine
– Marking -P- on suction hose must be aligned with seam on
pump.

Installation position of suction hose to reservoir (all engines)

– The mark at the suction hose -1- must be aligned with the
seam at the reservoir.

11.2 Checking delivery pressure of power steering pump, vehicles with 4-cyl.
petrol and diesel
Protected engine
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. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 4-cylinder petrol and diesel engine 373
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Special tools and workshop

equipment required
♦ Hose clamp - 3094-
♦ Power steering tester -
V.A.G 1402-
♦ Adapter - V.A.G 1402/3-

– Clamp off suction and return lines using 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.

374 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unbolt expansion hose -1- from power steering pump.

– Screw the adapter - V.A.G 1402/3- into the power steering

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- .

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.

– Close cut-off valve on pressure gauge (lever pointing to the

left).
– Detach the hose clamps up to 25 mm - 3094- and top up the
fluid level in the reservoir if necessary.
Checking pressure
To avoid damaging the pump, please note the following points:
♦ Do not run the engine for more than 10 seconds when per‐
forming this check.
♦ Start engine without pressing accelerator and leave it running
at idling speed.
♦ Take pump pressure reading at idling speed immediately after
starting engine (have second mechanic take reading).
♦ The pressure will drop during the test; the highest pressure
reading is therefore the required test value.
Specification: 110 - 120 bar.
– Renew power steering pump if specification is not attained
⇒ page 378 .
– Switch off engine.
– Check hydraulic fluid level ⇒ page 369 .
– Bleed steering system ⇒ page 369 .
– Checking steering system for leaks ⇒ page 370

11. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 4-cylinder petrol and diesel engine 375
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

11.3 Exploded view of power steering pump, vehicles with 4-cyl. petrol and diesel
engine

Note

♦ Renew seals.
♦ Do not re-use hydraulic fluid which has been drained off.
♦ Hydraulic fluid - G 002 000- 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 - Compact holder
❑ For alternator, power
steering pump and vis‐
cous fan
❑ Removing and installing
❑ For removing and instal‐
ling, refer to Engine, Me‐
chanics workshop man‐
ual ⇒ Rep. gr. 13
2 - Hexagon socket head bolt,
25 Nm
❑ Attachment of power
steering pump to holder
at rear
3 - Seal
❑ Always renew
4 - Banjo bolt, 47 Nm
5 - Expansion hose
❑ For 4-cyl. TDI left-hand
drive vehicles, attach in‐
to fastening bracket
⇒ Item 6 (page 376)
6 - Retaining bracket
❑ Only for 4-cyl. TDI left-
hand drive vehicles
❑ Engage expansion hose
⇒ Item 5 (page 376)
7 - Suction hose
❑ Marking -P- on suction
hose must be aligned
with seam on pump.
8 - Hose clip
❑ Always renew
9 - Power steering pump
❑ Fill with fluid before installing ⇒ page 371
❑ Checking delivery pressure ⇒ page 373
❑ Removing and installing ⇒ page 377
10 - Belt pulley
❑ For power steering pump
11 - Belt pulley
❑ For 4-cylinder petrol engine 1.8 l Turbo

376 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

12 - Hexagon socket head bolt, 25 Nm

13 - V-belts
❑ for coolant pump
❑ For 4-cylinder petrol engine 1.8 l Turbo
14 - Hexagon socket head bolt, 25 Nm
❑ For 4-cylinder petrol engine 1.8 l Turbo
15 - Pulleys
❑ Installation position: Straight pulley half facing coolant pump
❑ For 4-cylinder petrol engine 1.8 l Turbo
16 - Poly V-belt
❑ For removing and installing, refer to Engine, Mechanics workshop manual ⇒ Rep. gr. 13
❑ Check for wear
❑ Do not kink
17 - Hexagon bolt, 25 Nm

11.4 Removing and installing power steering

pump - vehicles with 4-cyl. petrol and
diesel engine
Special tools and workshop equipment required
♦ Locking pin - 3204- 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.

♦ Hose clamp - 3094-

♦ Allen key with w.a.f 3/8 inch

11. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 4-cylinder petrol and diesel engine 377
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Removing
– Remove noise insulation panel.

Note

Before removing the poly V-belt, mark the direction of rotation. A

used belt can break if it runs in the opposite direction. Ensure that
the belt is properly seated in the pulleys when installing.

– Remove poly V-belt ⇒ Rep. gr. 13 .

– Clamp off suction and return lines using hose clamps - 3094- .
– Place a drip tray underneath to catch hydraulic fluid.

– Remove hose clamp from suction hose -1-.

– Disconnect suction hose and move hose to one side.
– Disconnect expansion hose -2-.
Vehicles with bolted 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.

– Use mandrel to secure belt pulley of power steering pump.

– Unscrew bolts at two-piece belt pulley of coolant pump to the
extent required to permit removal of the V-belt.

378 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unscrew the pulleys from the power steering pump. When do‐
ing so, provided support with an Allen key w.a.f. 3/8 inch.

– Depending on version, unbolt steering pump pulley, using pin

wrench 3212 to counterhold.

– Remove bolts -1- and -2-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Take out power steering 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.
Vehicles with press-fitted pulley

– Unscrew the bolted joints -1- of the power steering pump

through the holes in the V-belt pulley.

11. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 4-cylinder petrol and diesel engine 379
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove bolt -arrow- on back of power steering pump.

– Take out power steering pump.
Installing
Installation is performed in reverse sequence; note the following:
♦ Renew gaskets and seals.
♦ Before fitting a new pump, put in hydraulic fluid at the inlet and
turn pump by hand until fluid flows out at the pressure outlet.
♦ Secure all hose connections with new hose clips. ⇒ Parts
catalogue

– Tighten banjo bolt for pressure hose -2- to 47 Nm.

– Fit suction hose -1-.
– Marking -P- on suction hose must be aligned with seam on
pump.
– Remove hose clamps - 3094- .
– Fit the poly V-belt ⇒ Engine, Mechanics; Rep. Gr. 13 .
– Check hydraulic fluid level ⇒ page 369 .
– Bleed steering system ⇒ page 369 .
– Checking steering system for leaks ⇒ page 370

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.

380 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

12 Power steering pump, hydraulic

pipes and hoses, fluid reservoir - ve‐
hicles with 6-cylinder Diesel engine
⇒ “12.1 Exploded view - vehicles with 6-cyl. Diesel engine”, page
381
⇒ “12.2 Checking delivery pressure of power steering pump, ve‐
hicles with 6-cyl. Diesel engine”, page 383
⇒ “12.3 Exploded view of power steering pump, vehicles with 6-
cyl. Diesel engine”, page 386
⇒ “12.4 Removing and installing power steering pump - vehicles
with 6-cyl. Diesel engine”, page 387
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

12.1 Exploded view - vehicles with 6-cyl. Die‐

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

sel engine
General notes
There is no provision for repairing the power steering pump. If
problems are reported, trace the fault by means of a pressure test
and a leakage test. Renew the power steering pump if there is a
fault.
The hydraulic fluid circuit on right-hand drive vehicles is the same
as on left-hand drive vehicles, except that the hydraulic pipes are
extended from left to right on the steering rack.
♦ Always check steering system for leaks in the event of a lack
of fluid in the reservoir.
♦ If leakage is visible at the pipe connections first tighten con‐
nections and wipe dry, then check for leaks again.
♦ Replacement pumps are not filled with fluid. Prior to installa‐
tion they are therefore to be filled with hydraulic fluid -
G 002 000- and cranked by hand to avoid the possibility of
noise whilst driving or pump damage.
♦ Fluid type: Hydraulic fluid - G 002 000-

12. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder Diesel engine 381
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Power steering rack

❑ Exploded view:
❑ LHD
❑ RHD
❑ Servicing
2 - Expansion hose
3 - Return hose
4 - Heat shield
5 - Cap with dipstick
❑ Check fluid level
6 - Hexagon bolt, 9 Nm
7 - Reservoir
❑ Capacity approx. 0.85 l
8 - Rubber mounting
9 - Hose clip
❑ Tighten using hose clip
pliers - V.A.G 1275-
10 - Return hose
Between reservoir and cooling
pipe

11 - Cable tie
12 - Hexagon nut, 9 Nm
13 - Rubber mounting
14 - Combi bolts
❑ 9 Nm
15 - Hose clip
❑ Tighten using hose clip
pliers - V.A.G 1275-
16 - Suction hose
❑ Installation position ⇒ page 383 and ⇒ page 383
17 - Cooling pipe
❑ Fill with fluid before installing
❑ Check delivery pressure
❑ Exploded view
18 - Power steering pump
19 - Seal, 16 x 22 mm
❑ Always renew
20 - Banjo bolt, 47 Nm
21 - Speed nut
❑ 1.3 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
22 - Bolt with washer with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 2 Nm
23 - Heat shield
24 - Expanding nut

382 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Installation position of suction hose at power steering pump for 6-

cyl. Diesel engine
– Marking -P- on suction hose must be aligned with seam on
pump.

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 suction hose to reservoir (all engines)

– The mark at the suction hose -1- must be aligned with the
seam at the reservoir.

12.2 Checking delivery pressure of power steering pump, vehicles with 6-cyl.
Diesel engine

12. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder Diesel engine 383
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Special tools and workshop

equipment required
♦ Hose clamp - 3094-
♦ Power steering tester -
V.A.G 1402-
♦ Adapter - V.A.G 1402/3-

– Clamp off suction and return lines using 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.

384 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unbolt expansion hose -1- from power steering pump.

– Screw the adapter - V.A.G 1402/3- into the power steering

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 cut-off valve on pressure gauge (lever pointing to the

left).
– Detach the hose clamp - 3094- and top up the fluid level in the
reservoir if necessary.
Checking pressure
To avoid damaging the pump, please note the following points:
♦ Do not run the engine for more than 10 seconds when per‐
forming this check.
♦ Start engine without pressing accelerator and leave it running
at idling speed.
♦ Take pump pressure reading at idling speed immediately after
starting engine (have second mechanic take reading).
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 pressure will drop during the test; the highest pressure
with respect to the correctness of information in this document. Copyright by AUDI AG.

reading is therefore the required test value.

Specification for Audi A6: 110 - 120 bar.
Specification for Audi allroad: 123 - 130 bar.
Renew power steering pump if specification is not attained
⇒ page 387 .
– Switch off engine.
– Check hydraulic fluid level ⇒ page 369 .
– Bleed steering system ⇒ page 369 .
– Checking steering system for leaks ⇒ page 370

12. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder Diesel engine 385
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

12.3 Exploded view of power steering pump, vehicles with 6-cyl. Diesel engine

Note

♦ Renew seals.
♦ Do not re-use hydraulic fluid which has been drained off.
♦ Hydraulic fluid - G 002 000-
♦ The projection line -B- runs in parallel with the pump axis -A-.

1 - Bolt with washer, 22 Nm

2 - Retainer
❑ Pay attention to the at‐
tachment holes for the
pump ⇒ page 387
3 - Hexagon bolt, 22 Nm
4 - Retaining plate
5 - Banjo bolt, 47 Nm
6 - Expansion hose
❑ Power steering pump -
steering rack
❑ Note installation posi‐
tion; danger of abrasion
❑ The projection line -B-
runs in parallel with the
pump axis -A-.
7 - Suction hose 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
❑ Power steering pump - with respect to the correctness of information in this document. Copyright by AUDI AG.
reservoir
❑ Heed installation posi‐
tion, risk of abrasion
⇒ page 383
8 - Hose clip
❑ Tighten using hose clip
pliers - V.A.G 1275-
9 - Power steering pump
❑ Fill with fluid before in‐
stalling ⇒ page 381
❑ Checking delivery pres‐
sure ⇒ page 383
❑ Removing and installing
⇒ page 387
10 - Belt pulley
11 - Hexagon socket head bolt, 22 Nm
❑ Counterhold with pin wrench - 3212- when slackening off and tightening
12 - Seals
❑ Always renew

386 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Attachment holes for power steering pump

– Bolt pump onto bracket -A- at holes marked -B-.

12.4 Removing and installing power steering pump - vehicles with 6-cyl. Diesel
engine

Special tools and workshop

equipment required
♦ Hose clamp - 3094-
♦ Locking pin - 3204-
♦ 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

♦ Open-end spanner - 3312-

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

♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-

12. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder Diesel engine 387
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Removing
– Detach the noise insulation.
– Remove the bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Front bumper .
– Move the lock carrier to the service position ⇒ General body
repairs, exterior; Rep. gr. 50 ; Body - front .

– Remove the cover over 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.

– Detach green plug for solenoid clutch/air conditioning com‐

pressor and detach bottom part of connector from retainer.
– Move wiring to compressor clear.
– Unscrew the viscous fan.

– 2 open-end spanners (32 mm) are required.

– To unfasten, provide support with one wrench and turn in
-arrow direction- with the other.

388 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unbolt cover for poly V-belt (3x).

Note

♦ Note position of spacer sleeves for belt cover.

♦ Mark the direction of rotation before removing the poly V-belt.
A used belt can break if it runs in the opposite direction. Ensure
that the belt is properly seated in the pulleys when installing.

– Removing poly V-belt for A/C compressor:

– Slacken off bolt -A- on tensioning roller for air-conditioner

compressor and detach poly V-belt.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Removing poly V-beltpermitted
for powerunless steering
authorised bypump:
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, turn in -arrow direction- with an

Allen key (17 mm) and insert a pin ∅ 4 mm -1- (e. g. pin punch).
– Take off belt.
– Detaching compressor for air conditioner:

Note

♦ The lines remain connected and must not be bent.

♦ After detaching, tie up compressor on longitudinal member
using wire or similar; do not leave it suspended on refrigerant
lines.
♦ Ensure centring bush -B- is properly seated when installing
compressor.

– Remove the bolts -A- (tightening torque 25 Nm).

12. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder Diesel engine 389
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unscrew the poly V-belt sprocket of the hydraulic pump. Use

pin wrench - 3212- to counterhold pulley.

Note

Shown with engine removed for illustration purposes.

– Clamp off suction and return lines using hose clamps - 3094- .
– Place a drip tray underneath to catch hydraulic fluid.

– Detach hose clip from suction hose -1-.

– Disconnect suction hose and move hose to one side.
– Disconnect expansion hose -2-.
– Seal off connections 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.

– Unbolt pump from bracket -1- and -2- and take out pump.
Installing
– Before fitting a new pump, put in hydraulic fluid at the inlet and
turn pump by hand until fluid flows out at the pressure outlet.
– Clean off fluid in engine compartment where necessary.

390 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Bolt pump onto bracket -A- at holes marked -B-.

– Fit all bolts and tighten first the two front bolts, then the two
rear bolts.
– Fit new seals on banjo bolt.

– Tighten banjo bolt for pressure hose -2- to 47 Nm.

– Fit suction hose -1-.
– Marking -P- on suction hose must be aligned with seam on
pump.
– Remove hose clamps - 3094- .
– Screw on the pulley.

– Screw the air conditioner compressor to the holder (25 Nm).

Ensure centring bush -B- is properly seated when installing com‐
pressor.
Installing poly V-belt for power steering pump:
– Fit poly V-belt on crankshaft pulley and idler wheels first; fit
onto tensioningProtected
roller last.
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 poly V-belt ⇒ Rep. gr. 13

12. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder Diesel engine 391
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Turn Allen key in direction of arrow and remove pin -1-.

Installing poly V-belt for A/C compressor:
– Fit poly V-belt for air conditioner compressor.

– Apply the torque wrench -C- as shown and pretension the poly
V-belt to 7 Nm by turning in arrow direction (Allen key w.a.f 8
mm).
– Tighten the bolt -A- with a torque wrench (tightening torque 25
Nm).

– Unscrew cover of poly V-belt (3x).

– Screw in the viscous fan.
Tightening torque for viscous fan
Torque wrench - V.A.G 1331- and open-ended 37 Nm
wrench - 3312-
Torque wrench - V.A.G 1331- without open-ended 70 Nm
wrench - 3312-
– Install lock carrier.
– Fit bumper.
– Check hydraulic fluid level ⇒ page 369 .
– Bleed steering system ⇒ page 369 .
– Checking steering system for leaks ⇒ page 370

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.

392 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

13 Power steering pump, hydraulic

pipes and hoses, fluid reservoir - ve‐
hicles with 6-cylinder petrol engine
⇒ “13.1 Exploded view, vehicles with 6 cyl. 2.7 l petrol engine”,
page 393
⇒ “13.2 Checking delivery pressure of power steering pump, ve‐
hicles with 6 cyl. 2.7 l petrol engine”, page 395
⇒ “13.3 Exploded view of power steering pump, vehicles with 6
cyl. 2.7 l petrol engine”, page 397
⇒ “13.4 Removing and installing power steering pump, vehicles
with 6-cyl. 2.7 l petrol engine”, page 399
⇒ “13.5 Exploded view - vehicles with 6-cyl. 2.4l, 2.8l and 3.0l
petrol engine”, page 404
⇒ “13.6 Checking delivery pressure of power steering pump - ve‐
hicles with 6-cyl. 2.4l, 2.8l and 3.0l petrol engine”, page 407
⇒ “13.7 Exploded view of power steering pump - vehicles with 6-
cyl. 2.4l, 2.8l and 3.0l petrol engine”, page 409
⇒ “13.8 Removing and installing power steering pump - vehicles
with 6-cyl. 2.4l, 2.8l and 3.0l petrol engine”, page 411

13.1 Exploded view, vehicles with 6 cyl. 2.7 l

petrol engine
General notes
There is no provision for repairing the power steering pump. If
problems are reported, trace the fault by means of a pressure test
and a leakage test. Renew the power steering pump if there is a
fault.
The hydraulic fluid circuit on right-hand drive vehicles is the same
as on left-hand drive vehicles, except that the hydraulic pipes are
extended from left to right on the steering rack.
♦ Always check steering system for leaks in the event of a lack
of fluid in the reservoir.
♦ If leakage is visible at the pipe connections first tighten con‐
nections and wipe dry, then check for leaks again.
♦ Replacement pumps are not filled with fluid. Prior to installa‐
tion they are therefore to be filled with hydraulic fluid -
G 002 000- and cranked by hand to avoid the possibility of
noise whilst driving or pump damage.
♦ Fluid type: Hydraulic fluid - G 002 000-

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. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder petrol engine 393
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Power steering rack

❑ Exploded view:
❑ Left-hand drive vehicles
⇒ page 328
❑ Right-hand drive vehi‐
cles ⇒ page 337
❑ Servicing ⇒ page 359
2 - Expansion hose
❑ Tighten union nut to 40
Nm at
⇒ Item 19 (page 395)
whilst providing support
at hexagon
3 - Return hose
4 - Cap with dipstick
❑ Checking fluid level
⇒ page 369
5 - Hexagon bolt, 9 Nm
6 - Reservoir
❑ Capacity approx. 0.85 l
7 - Rubber mounting
8 - Return hose
Between reservoir and cooling
pipe

9 - Suction hose
❑ Installation position
⇒ page 395
❑ Marks must align
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
10 - Hose clip 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 using hose clip
pliers - V.A.G 1275-
11 - Hose clip
❑ Tighten using hose clip pliers - V.A.G 1275-
12 - Bolt with washer
❑ 9 Nm
13 - Cooling pipe
14 - Pipe
❑ Mark must coincide with suction hose mark
15 - Suction hose
❑ Mark -P- faces pump
16 - Power steering pump
❑ Fill with fluid before installing ⇒ page 393
❑ Checking delivery pressure ⇒ page 395
❑ Exploded view ⇒ page 397
17 - Seal, 16 x 22 mm
❑ Always renew
18 - Banjo bolt, 47 Nm
❑ M16×1.5

394 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

19 - Expansion hose
❑ Section with pipe, leads to steering rack
20 - Hexagon bolt, 6 Nm
❑ M6×20
21 - Coolant pipe
22 - Hexagon nut, 20 Nm
❑ M8
❑ For attaching expansion hose to coolant pipe
23 - Self-tapping combi bolt
❑ 2 Nm
24 - Heat shield
25 - Speed nut
❑ 1.3 Nm

Installation position of suction hose to reservoir (all engines)

– The mark at the suction hose -1- must be aligned with the
seam at the reservoir.

13.2 Checking delivery pressure of power

steering pump, vehicles with 6 cyl. 2.7 l
petrol engine
Special tools and workshop equipment required
♦ 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.

13. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder petrol engine 395
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Power steering tester - V.A.G 1402-

– Unclip engine top cover and remove.

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.

– Clamp off suction and return lines using hose clamps - 3094- .

– Unscrew pipe from expansion hose -arrow-. (Counterhold hex‐

agon flats on expansion hose.)
– Screw the hose of the pressure gauge - V.A.G 1402- to the
section of the expansion hose leading to the pump.

396 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Close cut-off valve on pressure gauge (lever pointing to the

left).
– Remove hose clamps - 3094- .
– Top up fluid in reservoir if necessary.
Checking pressure
To avoid damaging the pump, please note the following points:
♦ Do not run the engine for more than 10 seconds when per‐
forming this check.
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

♦ Start engine without pressing accelerator and leave it running

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

at idling speed.
♦ Take pump pressure reading at idling speed immediately after
starting engine (have second mechanic take reading).
♦ The pressure will drop during the test; the highest pressure
reading is therefore the required test value.
Specification: 110 -120 bar.
– Renew power steering pump if specification is not attained
⇒ page 399 .
– Switch off engine.
– Check hydraulic fluid level ⇒ page 369 .
– Bleed steering system ⇒ page 369 .
– Checking steering system for leaks ⇒ page 370

13.3 Exploded view of power steering pump, vehicles with 6 cyl. 2.7 l petrol en‐
gine

Note

♦ Renew seals.
♦ Do not re-use hydraulic fluid which has been drained off.
♦ Hydraulic fluid - G 002 000-

13. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder petrol engine 397
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Expansion hose
❑ Section with pipe, leads
to steering rack
2 - Hexagon bolt, 6 Nm
3 - Hexagon bolt, 9 Nm
4 - Ignition coils with bracket
5 - Power steering pump
❑ Fill with fluid before in‐
stalling ⇒ page 393
❑ Checking delivery pres‐
sure ⇒ page 395
❑ Removing and installing
⇒ page 399
6 - Hose clip
❑ Always renew
❑ Tighten using hose clip
pliers - V.A.G 1275-
7 - Suction hoseby copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Markwith -P-respect
faces pump
to the correctness of information in this document. Copyright by AUDI AG.

8 - Pipe for suction hose

9 - Hexagon socket head bolt,
22 Nm
❑ Attachment of power
steering pump to brack‐
et at rear
10 - Slotted bushing
❑ For tolerance compen‐
sation
11 - Hexagon socket head bolt,
22 Nm
❑ For attaching power steering pump bracket to crankcase
12 - Hexagon socket head bolt, 22 Nm
❑ For attaching power steering pump bracket to crankcase
13 - Hexagon socket head bolt, 22 Nm
❑ Attachment of power steering pump to bracket at front
14 - Bracket for power steering pump
15 - Hexagon socket head bolt, 22 Nm
❑ Counterhold with pin wrench - 3212- when slackening off and tightening
16 - Belt pulley
17 - Seal
❑ Always renew
18 - Banjo bolt, 47 Nm

398 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

13.4 Removing and installing power steering pump, vehicles with 6-cyl. 2.7 l pet‐
rol engine

Special tools and workshop

equipment required
♦ Hose clamps - 3094-
♦ Locking pin - 3204-
♦ Pin wrench - 3212-
♦ Open-end spanner - 3312-
♦ Torque wrench -
V.A.G 1331-
♦ 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.

♦ Hose clip pliers - V.A.G 1275-

13. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder petrol engine 399
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Removing
– Unclip engine top cover and remove.

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 air duct to air filter at front end and lift out air duct.

– Unplug 5-pin connector from ignition coils.

– Unplug three rear connectors -A- from ignition coils.
– Unscrew the four retaining bolts.
– Swivel ignition coil bracket to the rear.

400 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Provide support for the viscous fan pulley with the pin wrench
- 3212- and unscrew the viscous fan with the open-ended
wrench - 3312- (left-hand thread).
– Lift out the viscous fan.

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.

– Remove the electric fan. To do so, remove bolt -1-.

– The wire of the electric fan is clipped to the viscous fan air duct.
Pull off these clamps.
– To remove, turn the electric fan slightly in -arrow direction-.
– Set down the electric fan sideways to the right.

Note

Before removing the poly V-belt, mark the direction of rotation. A

used belt can break if it runs in the opposite direction. Ensure that
the belt is properly seated in the pulleys when installing.

– Use a long torque wrench and a socket wrench attachment

(w.a.f 17 mm) to turn the tensioner clockwise.
– When the two holes coincide -arrows-, secure with a locking
pin - 3204- .
– Remove poly V-belt from belt pulley.

13. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder petrol engine 401
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unbolt power steering pump pulley. Use a pin wrench - 3212-

to provide support.

– Clamp off suction and return lines using hose clamps - 3094- .

– The pipe of the expansion hose is screwed to the cylinder head

⇒ Item 20 (page 395) .
– Unscrew this bolt.

– Open clamp -1- and pull off suction hose.

– Disconnect expansion hose -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.

402 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unscrew power steering pump bracket.

– Remove bracket with pump.
– Then screw power steering pump off bracket.
Installing
– Before fitting a new pump, put in hydraulic fluid at the inlet and
turn pump by hand until fluid flows out at the pressure outlet.
– Clean off fluid in engine compartment where necessary.
– Bolt pump to bracket (22 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Insert pump with bracket.

– Tighten two front bolts first and then the rear bolt, 22 Nm.
– Fit new seals on banjo bolt.

– Tighten the banjo bolt for the expansion hose -2- to 47 Nm.
– Screw the pipe of the expansion hose to the cylinder head (6
Nm) ⇒ Item 20 (page 395) .
– Fit the suction hose -1-, mark -P- faces pump.
– Remove hose clamps - 3094- .

– Tighten hexagon socket head bolts for power steering pump

belt pulley to 22 Nm.
– First of all fit poly V-belt over the crankshaft belt pulley and
guide pulley and push it onto the tensioning roller last.

13. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder petrol engine 403
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Installation position of poly V-belt ⇒ Rep. gr. 13

Note

When installing the poly V-belt ensure correct running direction

and correct seating of the belt in the pulley.

Poly V-belt routing:

♦ D1 - without air conditioner
♦ D2 - with air conditioner
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
– Take out the locking pin - 3204- .
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Fit the electric fan and then the viscous fan.

– Tightening torque for viscous fan ⇒ Rep. gr. 19
Tightening torque for viscous fan
Torque wrench - V.A.G 1331- and open-ended 37 Nm
wrench - 3312-
Torque wrench - V.A.G 1331- without open-ended 70 Nm
wrench - 3312-
– Check hydraulic fluid level ⇒ page 369 .
– Bleed steering system ⇒ page 369 .
– Checking steering system for leaks ⇒ page 370

13.5 Exploded view - vehicles with 6-cyl. 2.4l, 2.8l and 3.0l petrol engine
There is no provision for repairing the power steering pump. If
problems are reported, trace the fault by means of a pressure test
and a leakage test. Renew the power steering pump if there is a
fault.

Note

♦ Always check steering system for leaks if fluid level is low in reservoir.
♦ If leakage is visible at the pipe connections first tighten connections and wipe dry, then check for leaks again.
♦ The power steering pump is supplied without fluid filling. Prior to installation, the pump must therefore always
be filled with hydraulic fluid and turned by hand. Otherwise, there is a possibility of pump damage or noise
while driving.

404 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Power steering rack

❑ For correct version refer
to ⇒ Electronic parts
catalogue “ETKA”
2 - Pressure hose
❑ Note correct position on
steering rack
⇒ page 407
3 - Return hose
❑ Note correct position on
steering rack
⇒ page 407
4 - Cap with dipstick
❑ Checking fluid level
⇒ page 369
5 - Bolt, 5 Nm
6 - Reservoir
7 - Rubber mounting
8 - Hose clip
❑ Tighten using hose clip
pliers - V.A.G 1275- or
locking pliers for steer‐
ing rack - VAS 6199-
❑ Always renew
9 - Return hose
❑ Between reservoir and
cooling pipe
❑ Note correct position on
reservoir ⇒ page 406
10 - Hose clip
❑ Tighten using hose clip
pliers - V.A.G 1275- or
locking pliers for steering rack - VASProtected
6199-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 renew with respect to the correctness of information in this document. Copyright by AUDI AG.

11 - Bolt, 9 Nm
12 - Cooling pipe
13 - Cable tie
14 - Hose clip
❑ Tighten using hose clip pliers - V.A.G 1275- or locking pliers for steering rack - VAS 6199-
❑ Always renew
15 - Suction hose
❑ Note correct position on reservoir ⇒ page 406
16 - Hose clip
❑ Tighten using hose clip pliers - V.A.G 1275- or locking pliers for steering rack - VAS 6199-
❑ Always renew
17 - Suction hose
❑ Note correct position on power steering pump ⇒ page 409
18 - Hose clip
❑ Tighten using hose clip pliers - V.A.G 1275- or locking pliers for steering rack - VAS 6199-
❑ Always renew

13. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder petrol engine 405
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

19 - Power steering pump

❑ For correct version refer to ⇒ Electronic parts catalogue “ETKA”
❑ Fill with hydraulic fluid before installing
❑ Checking delivery pressure ⇒ page 407
❑ Removing and installing ⇒ page 412
20 - Seal
❑ Always renew
21 - Pressure hose
❑ Note correct position on power steering pump ⇒ page 409
❑ Attachment to engine ⇒ page 406
22 - Seal
❑ Always renew
23 - Banjo bolt, 50 Nm
24 - Bolt, 8 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

25 - Union nut, 40 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.

Installation position of suction hose at reservoir (applicable to all

models)
– The mark at the suction hose -1- must be aligned with the
seam at the reservoir.

Attachment of pressure pipe to engine

– Secure pressure pipe -2- with bolt -1- at front right of engine.
– Secure pressure pipe -2- with bolt -3- at rear right of engine.

406 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Installation position of return pipe and pressure pipe at steering

rack (left-hand drive vehicles)
Angle -a- for pressure pipe: Approx. 45°
Angle -b- for return hose: Approx. 116°

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.

13.6 Checking delivery pressure of power steering pump - vehicles with 6-cyl.
2.4l, 2.8l and 3.0l petrol engine

Special tools and workshop

equipment required
♦ Hose clamps - 3094-
♦ Power steering tester -
V.A.G 1402-
♦ Adapter - V.A.G 1402/2-
♦ Adapter - V.A.G 1402/3-
♦ Adapter set - V.A.G 1402/6-

Test requirements:
• Belt condition/ belt tension OK
• No leaks in system
• Hoses and pipes not kinked or constricted

13. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder petrol engine 407
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Checking
– Unclip the engine cover panel at the top -arrows- and detach.

– Clamp off suction and return lines using hose clamps - 3094- .

– Unscrew pipe from pressure hose -arrow-. (Counterhold hex‐

agon flats on pressure hose.)

Note

♦ Place a cloth under the union to catch escaping hydraulic fluid.

♦ If necessary, unbolt bracket for hydraulic line to give easier
access.

– Connect V.A.G adapters, banjo bolt and pressure hose as

shown in illustration.
1 - Adapter set - V.A.G 1402/6-
2 - Adapter - V.A.G 1402/2-
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
3 - Pressure hosewith respect to the correctness of information in this document. Copyright by AUDI AG.
4 - Seal (4x)
5 - Banjo bolt
6 - Adapter - V.A.G 1402/3-
7 - Line from power steering tester - V.A.G 1402-
– Remove hose clamps - 3094- .

408 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Make sure lever on pressure gauge is in position -2-.

– Start engine but do not press accelerator.
– Turn steering wheel approx. 10 times from lock to lock.
– Switch off engine and top up hydraulic fluid in reservoir if nec‐
essary.

Note

♦ To avoid damaging the power steering pump, please note the

following points:
♦ Cut-off valve of pressure gauge must not remain closed for
more than 10 seconds during this test.
♦ Start engine without pressing accelerator and leave it running
at idling speed.
♦ Take pump pressure reading at idling speed immediately after
starting engine (have second mechanic take reading).
♦ The pressure will drop during the test; take the highest pres‐
sure reading as the test value.

– Then check delivery pressure.

– Start engine, close cut-off valve (position -1-) with engine idling
and read off pressure (lever must face away from pressure
hose). Do not perform measurement for longer than 10 sec‐
onds.
Specification for delivery pressure: 120…130 bar
Renew power steering pump if specification is not attained
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
⇒ page 411 . with respect to the correctness of information in this document. Copyright by AUDI AG.

– Switch off engine.

– Remove power steering tester - V.A.G 1402- .
– Install banjo bolt ⇒ Item 2 (page 410) .
– Check hydraulic fluid level ⇒ page 369 .
– Bleed steering system ⇒ page 369 .
– Checking steering system for leaks ⇒ page 370
– Fit noise insulation ⇒ Rep. gr. 50 .
– Lower vehicle onto its wheels.

13.7 Exploded view of power steering pump - vehicles with 6-cyl. 2.4l, 2.8l and
3.0l petrol engine

Note

♦ Renew seals.
♦ Do not re-use hydraulic fluid which has been drained off.
♦ Use only hydraulic fluid .

13. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder petrol engine 409
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Seal
❑ Always renew
2 - Banjo bolt,
❑ 50 Nm
3 - Pressure hose
❑ Note correct installation
position
4 - Power steering pump
❑ Fill with hydraulic fluid
before installing 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
❑ Checking delivery pres‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
sure ⇒ page 407
❑ Removing and installing
⇒ page 411
5 - Seam
❑ For installation position
of suction hose
6 - Hose clip
❑ Tighten using hose clip
pliers - V.A.G 1275- or
locking pliers for steer‐
ing rack - VAS 6199-
❑ Always renew
7 - Suction hose
❑ Pay attention to installa‐
tion position at power
steering pump and suc‐
tion hose pipe
⇒ page 411
❑ Pay attention to installa‐
tion position at reservoir
8 - Nut, 22 Nm
❑ Depending on engine code, may be fitted with stud ⇒ Item 9 (page 410)
9 - Stud
❑ Apply sealant when installing
❑ Depending on engine code, may be fitted with nut ⇒ Item 8 (page 410)
10 - Bolt
❑ 23 Nm
❑ Apply sealant when installing
❑ Depending on engine code, may be fitted instead of stud ⇒ Item 9 (page 410) and nut
⇒ Item 8 (page 410)
11 - Retainer
12 - Bolt
❑ 23 Nm
13 - Bolt
❑ Tightening torque ⇒ Rep. gr. 13
14 - Belt pulley

410 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Installation position of suction hose at power steering pump and

suction hose pipe
– Marking -P- on suction hose -2- must be aligned with seam on
pump -1-.
– The mark at the suction hose pipe -3- must be aligned with the
mark at the suction hose -4- -arrows-.

13.8 Removing and installing power steering

pump - vehicles with 6-cyl. 2.4l, 2.8l and
3.0l petrol 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
Special tools and workshop equipment required with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Pin wrench - 3212-

♦ Hose clip pliers - V.A.G 1275-

13. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder petrol engine 411
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

♦ Torque wrench - V.A.G 1331-

♦ 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.
♦ Used oil collection and extraction unit - V.A.G 1782-

General notes
There is no provision for repairing the power steering pump. If
problems are reported, trace the fault by means of a pressure test
and a leakage test. Renew the power steering pump if there is a
fault.
♦ Always check steering system for leaks if fluid level in reservoir
is low.
♦ If leakage is visible at the pipe connections first tighten con‐
nections and wipe dry, then check for leaks again.
♦ The power steering pump is supplied without fluid filling. Prior
to installation, the pump must therefore always be filled with
hydraulic fluid and turned by hand. Otherwise, there is a pos‐
sibility of pump damage or noise while driving.
Removing
– Extract hydraulic fluid from reservoir using oil extractor -
V.A.G 1358 A- or used oil collection and extraction unit -
V.A.G 1782- .
– Remove poly V-belt ⇒ Rep. gr. 13 .

412 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Vehicle with dual ignition coil

– Unplug connector at ignition coils in direction of -arrow-.
– Unplug three rear connectors -A- from ignition coils.
– Unscrew bolts -arrows-.
– Swivel ignition coil bracket to the rear.

All vehicles (continued)

– Unbolt power steering pump pulley -arrows-. Use pin wrench
- 3212- to counterhold pulley.

– Remove hexagon bolt -arrow- for pressure hose -1-.

– Unscrew rear power steering pump securing bolt using socket

wrench and extension.

Note

The suction pipe may have to be

Protected by detached on for
copyright. Copying vehicles fitted with
private or commercial purposes, in part or in whole, is not
a stud and nut ⇒ Rep. gr. 24 . 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.

13. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder petrol engine 413
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove banjo bolt -1-.

Note

Place a cloth under the unions to catch escaping hydraulic fluid.

– Open clip on suction hose -2-.

– Disconnect suction hose -2-.
– Seal off pressure hose with a plastic bag or similar.
– Unscrew bolts -arrows- and detach power steering pump with
bracket.
Installing
Install in reverse order of removal. Observe the following:

Note

♦ Renew gaskets and seals.

♦ Before fitting a new power steering pump, put in hydraulic fluid
at the inlet and turn pump by hand until fluid flows out at the
pressure outlet.
♦ Secure all hose connections with new hose clips ⇒ Electronic
parts catalogue “ETKA” .

– Turn hub by hand until fluid comes out at pump outlet.

– Fit power steering pump with bracket and tighten front bolts
-arrows- ⇒ Item 12 (page 410) .
– Fit new seals on banjo bolt.
– Tighten banjo bolt -1- ⇒ Item 2 (page 410) .
– Connect suction hose -2- and secure with new hose clip. Note
correct installation position ⇒ page 411 .

– Tighten rear securing bolt ⇒ Item 10 (page 410) or nut

⇒ Item 8 (page 410) .
– Clean off fluid in engine compartment where necessary.
– BoltProtected
on power steering
by copyright. pump
Copying pulley
for private ⇒ Rep.
or commercial gr. 13
purposes, . or in whole, is not
in part
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Fit poly
withV-belt ⇒theRep.
respect to gr. of13
correctness .
information in this document. Copyright by AUDI AG.

– Check hydraulic fluid level ⇒ page 369 .

– Bleed steering system ⇒ page 369 .
– Checking steering system for leaks ⇒ page 370

414 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Install poly-V-belt and make sure that belt runs straight ⇒ Rep.
gr. 13 .

Note

Ensure that the belt is properly seated in the pulleys when instal‐
ling.

1- Alternator
2- Poly V-belt
3- Power steering pump
4- Air conditioner compressor
5 -Protected
Crankshaft
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- Tensioning
with roller of information in this document. Copyright by AUDI AG.
respect to the correctness

13. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder petrol engine 415
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

14 Power steering pump, hydraulic

pipes and hoses, fluid reservoir - ve‐
hicles with 6-cylinder petrol engine,
biturbo
⇒ “14.1 Exploded view - vehicles with 6-cyl. petrol engine, bitur‐
bo”, page 416
⇒ “14.2 Checking delivery pressure of power steering pump - ve‐
hicles with 6-cyl. petrol engine, biturbo”, page 419
⇒ “14.3 Exploded view of power steering pump - vehicles with 6-
cyl. petrol engine, biturbo”, page 420
⇒ “14.4 Removing and installing power steering pump - vehicles
with 6-cyl. petrol engine, biturbo”, page 422

14.1 Exploded view - vehicles with 6-cyl. pet‐

rol engine, biturbo
General notes
There is no provision for repairing the power steering pump. If
problems are reported, trace the fault by means of a pressure test
and a leakage test. Renew the power steering pump if there is a
fault.
The hydraulic fluid circuit on right-hand drive vehicles is the same
as on left-hand drive vehicles, except that the hydraulic pipes are
extended from left to right on the steering rack.
♦ Always check steering system for leaks in the event of a lack
of fluid in the reservoir. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

♦ If leakage is visible at the pipe connections with

firstrespect
tighten
to thecon‐
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
correctness of information in this document. Copyright by AUDI AG.
nections and wipe dry, then check for leaks again.
♦ Replacement pumps are not filled with fluid. Prior to installa‐
tion they are therefore to be filled with hydraulic fluid -
G 002 000- and cranked by hand to avoid the possibility of
noise whilst driving or pump damage.
♦ Fluid type: Hydraulic fluid - G 002 000-

416 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Power steering rack

❑ Exploded view:
❑ Left-hand drive vehicles
⇒ page 328
❑ Right-hand drive vehi‐
cles ⇒ page 337
❑ Servicing ⇒ page 359
2 - Return hose
3 - Expansion hose
❑ Section with pipe, leads
to steering rack
4 - Heat shield
5 - Cap with dipstick
❑ Checking fluid level
⇒ page 369
6 - Hexagon bolt, 9 Nm
7 - Reservoir
❑ Capacity approx. 0.85 l
8 - Rubber mounting
9 - Return hose
Between reservoir and cooling
pipe

10 - Suction hose
❑ Installation position
⇒ page 418
❑ Marks must align
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

11 - Hose clip
with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Tighten using hose clip

pliers - V.A.G 1275-
12 - Hose clip
❑ Tighten using hose clip pliers - V.A.G 1275-
13 - Rubber buffer
14 - Hexagon nut, 9 Nm
❑ M6
15 - Cooling pipe
16 - Sleeve
17 - Bolt with washer, 9 Nm
18 - Torx bolts (T 25)
❑ 5 Nm
❑ M5×12
19 - Pipe
❑ Mark must coincide with suction hose mark
20 - Suction hose
❑ Mark -P- must coincide with parting line at pump
21 - Power steering pump
❑ Fill with fluid before installing ⇒ page 416
❑ Checking delivery pressure ⇒ page 419

14. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder petrol engine, biturbo 417
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

❑ Exploded view ⇒ page 420

22 - Seal, 16 x 22 mm
❑ Always renew
23 - Banjo bolt, 47 Nm
❑ M16×1.5
24 - Expansion hose
❑ Section with pipe, leads to steering rack
25 - Hexagon bolt, 7.5 Nm
❑ M8×15
26 - Union nut
❑ Tighten to 40 Nm whilst providing support at hexagon
❑ Marks must coincide
27 - Self-tapping combi bolt
❑ 2 Nm
28 - Heat shield
29 - Speed nut
❑ 1.3 Nm

Installation position of suction hose to reservoir (all engines)

– The mark at the suction hose -1- must be aligned with the
seam at 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.

418 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

14.2 Checking delivery pressure of power steering pump - vehicles with 6-cyl.
petrol engine, biturbo

Special tools and workshop

equipment required
♦ Spring-type clip pliers -
V.A.G 1921-
♦ 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.

– Unfasten the hose clamps -arrows- and take out the intake
hose -1-.
– Unscrew union nut -2- whilst providing support at hexagon of
pressure pipe.
– Close off the pipe leading to the steering rack with a blanking
plug.

14. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder petrol engine, biturbo 419
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Screw the adapter - V.A.G 1402/3- into the pipe to the power
steering pump.
– Screw the hose of the pressure gauge - V.A.G 1402- onto the
adapter - V.A.G 1402/3- .
– Close cut-off valve on pressure gauge (lever pointing to the
left).
– Re-install intake hose.
– Top up fluid in reservoir if necessary.
Checking pressure
To avoid damaging the pump, please note the following points:
♦ Do not run the engine for more than 10 seconds when per‐
forming this check.
♦ Start engine without pressing accelerator and leave it running
at idling speed.
♦ Take pump pressure reading at idling speed immediately after
starting engine (have second mechanic take reading).
♦ The pressure will drop during the test; the highest pressure
reading is therefore the required test value.
Specification for Audi A6: 120 - 130 bar.
Specification for Audi allroad: 120 - 130 bar.
– Renew power steering pump if specification is not attained
⇒ page 422 .
– Switch off engine.
– Check hydraulic fluid level ⇒ page 369 .
– Bleed steering system ⇒ page 369 .
– Checking steering system for leaks ⇒ page 370

14.3 Exploded view of power steering pump - vehicles with 6-cyl. petrol engine,
biturbo

Note

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

♦ Do not re-use hydraulic fluid which has been drained off. to the correctness of information in this document. Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect

♦ Hydraulic fluid - G 002 000-

420 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Expansion hose
❑ Section with pipe, leads
to steering rack
2 - Hexagon bolt, 7.5 Nm
❑ M8×15
3 - Power steering pump
❑ Fill with fluid before in‐
stalling ⇒ page 416
❑ Check delivery pressure
❑ Removing and installing
⇒ page 422
4 - Hose clip
❑ Tighten using hose clip
pliers - V.A.G 1275-
5 - Suction hose
❑ Mark -P- must coincide
with parting line at pump
6 - Pipe
7 - Protected
Hexagon socketCopying
by copyright. headforbolt,
private or commercial purposes, in part or in whole, is not
22 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.
❑ Attachment of power
steering pump to holder
at rear
8 - Slotted bushing
❑ For tolerance compen‐
sation
9 - Bracket for power steering
pump
10 - Hexagon socket head bolt,
22 Nm
❑ For attaching power
steering pump bracket to crankcase
11 - Hexagon socket head bolt, 22 Nm
❑ Attachment of power steering pump to holder at front
12 - Hexagon bolt, 22 Nm
❑ For attaching power steering pump bracket to crankcase
13 - Hexagon socket head bolt, 22 Nm
❑ Counterhold with pin wrench - 3212- when slackening off and tightening
14 - Belt pulley
15 - Seal
❑ Always renew
16 - Banjo bolt, 47 Nm

14. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder petrol engine, biturbo 421
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

14.4 Removing and installing power steering pump - vehicles with 6-cyl. petrol
engine, biturbo

Special tools and workshop

equipment required
♦ Hose clamp - 3094-
♦ Locking pin - 3204-
♦ Pin wrench - 3212-
♦ Open-end spanner - 3312-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-

♦ Hose clip pliers - V.A.G 1275-

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
– Remove the bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Front bumper .

422 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Move the lock carrier to the service position ⇒ General body

repairs, exterior; Rep. gr. 50 ; Body - front .
– Unfasten the bolted joints -arrows- and detach the front cover.

Note

The viscous fan has a left-hand thread. Turn in -arrow direction-

to unscrew.

– Provide support for the viscous fan pulley with the pin wrench
- 3212- and unscrew the viscous fan with the open-ended
wrench - 3312- (left-hand thread).
– Lift out the viscous fan.

Note

Before removing the poly V-belt, mark the direction of rotation. A

used belt can break if it runs in the opposite direction. Ensure that
the belt is properly seated in the pulleys when installing.
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
– To slacken off, turn the poly V-belt clockwise with
with respect a 17
to the mm ring
correctness of information in this document. Copyright by AUDI AG.
spanner until both holes coincide -arrow- and secure with a
locking pin - 3204- .
– Remove poly V-belt from belt pulley.

– Remove the pressure pipes -1-.

Note

Pay attention to retainers -2-.

14. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder petrol engine, biturbo 423
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unbolt power steering pump pulley. Use a pin wrench - 3212-

to provide support.

– Clamp off suction pipe with hose clamp - 3094- .

– Unplug the connector at the charge air pressure sender - G31-

-arrow-.
– Detach rubber elbow -1-.

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 -arrow- and detach the suction hose from
the pump.
– Unscrew pressure pipe -1-.
– Unscrew the holder of the power steering pump (-2-, -3- and
-4-).
– Remove bracket with pump.
– Then screw power steering pump off bracket.
Installing
– Before fitting a new pump, put in hydraulic fluid at the inlet and
turn pump by hand until fluid flows out at the pressure outlet.
– Clean off fluid in engine compartment where necessary.
– Screw the pump to the holder.
– Tighten two front bolts first and then the rear bolt, 22 Nm.

424 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Insert pump with bracket.

– Fit new seals on banjo bolt.
– Tighten banjo bolt for pressure pipe -1- to 50 Nm.
– Fit suction hose; mark “P” must be aligned with parting line at
pump.
– Remove hose clamps - 3094- .
– Tighten hexagon socket head bolts for power steering pump
belt pulley to 22 Nm.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Tightening torque for viscous fan ⇒ Rep. gr. 19 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.
Tightening torque for viscous fan
Torque wrench - V.A.G 1331- and open-ended 37 Nm
wrench - 3312-
Torque wrench - V.A.G 1331- without open-ended 70 Nm
wrench - 3312-
– Attach the bumper ⇒ General body repairs, exterior; Rep. gr.
63 ; Front bumper .
– Attach the lock carrier ⇒ General body repairs, exterior; Rep.
gr. 50 ; Body - front .
– Check hydraulic fluid level ⇒ page 369 .
– Bleed steering system ⇒ page 369 .
– Checking steering system for leaks ⇒ page 370

14. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 6-cylinder petrol engine, biturbo 425
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

15 Power steering pump, hydraulic

pipes and hoses, fluid reservoir - ve‐
hicles with 8-cylinder petrol engine
⇒ “15.1 Exploded view - vehicles with 8-cyl. petrol engine”, page
426
⇒ “15.2 Checking delivery pressure of power steering pump - ve‐
hicles with 8-cyl. petrol engine”, page 429
⇒ “15.3 Exploded view of power steering pump - vehicles with 8-
cyl. petrol engine”, page 431
⇒ “15.4 Removing and installing power steering pump - vehicles
with 8-cyl. petrol engine”, page 433
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.
15.1 Exploded view - vehicles with 8-cyl. pet‐
rol engine
General notes
There is no provision for repairing the power steering pump. If
problems are reported, trace the fault by means of a pressure test
and a leakage test. Renew the power steering pump if there is a
fault.
The hydraulic fluid circuit on right-hand drive vehicles is the same
as on left-hand drive vehicles, except that the hydraulic pipes are
extended from left to right on the steering rack.
♦ Always check steering system for leaks in the event of a lack
of fluid in the reservoir.
♦ If leakage is visible at the pipe connections first tighten con‐
nections and wipe dry, then check for leaks again.
♦ Replacement pumps are not filled with fluid. Prior to installa‐
tion they are therefore to be filled with hydraulic fluid -
G 002 000- and cranked by hand to avoid the possibility of
noise whilst driving or pump damage.
♦ Fluid type: Hydraulic fluid - G 002 000-

426 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Power steering rack

❑ Exploded view:
❑ Left-hand drive vehicles
⇒ page 328
❑ Right-hand drive vehi‐
cles ⇒ page 337
❑ Servicing ⇒ page 359
2 - Return hose
❑ Steering rack - fluid
cooler
3 - Pressure pipe
❑ Tighten union nut to 40
Nm at
⇒ Item 4 (page 427)
whilst providing support
at hexagon
❑ Note correct installation
position:
❑ At steering rack
⇒ page 428
4 - Expansion hose
❑ Power steering pump -
steering rack
❑ Note correct installation
position:
❑ At power steering pump
⇒ page 428
5 - Cap with dipstick
❑ Checking fluid level
⇒ page 369
6 - Hexagon bolt, 9 Nm
7 - Reservoir
❑ Capacity approx. 0.85 l
8 - Rubber mounting
9 - Return hose
Between reservoir and cooling pipe
❑ Installation position: Restrictor -arrow- facing
Protected reservoir
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 - Banjo bolt, 47 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ M16×1.5
11 - Seals
❑ Always renew
12 - Suction hose
❑ Power steering pump - reservoir
❑ Note correct installation position:
❑ At power steering pump ⇒ page 428
❑ At reservoir ⇒ page 429
13 - Banjo bolt, 50 Nm
❑ M18×1.5
14 - Seals
❑ Always renew

15. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder petrol engine 427
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

15 - Hose clip
❑ Tighten using hose clip pliers - V.A.G 1275-
16 - Fluid radiator
17 - Cross-head bolt
❑ 1.3 Nm
❑ On four-wheel drive vehicles, bolt with washer 9 Nm
18 - Power steering pump
❑ Fill with fluid before installing ⇒ page 426
❑ Checking delivery pressure ⇒ page 429
❑ Exploded view ⇒ page 431
19 - Speed nut
❑ 1.3 Nm
20 - Self-tapping combi bolt
❑ 2 Nm
21 - Heat shield
❑ Different types at vehicles with auxiliary heater
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
22 - Heat shield with respect to the correctness of information in this document. Copyright by AUDI AG.

Installation position of suction and expansion hose at power

steering pump
Angle -a- for expansion hose: Approx. 57°
Angle -b- for suction pipe: Approx. 90°

Installation position of return pipe and pressure pipe at steering

rack (left-hand drive vehicles)
Angle -a- for pressure pipe: Approx. 45°
Angle -b- for return hose: Approx. 116°

428 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Installation position of suction hose to reservoir (all engines)

– The mark at the suction hose -1- must be aligned with the
seam at the reservoir.

15.2 Checking delivery pressure of power steering pump - vehicles with 8-cyl.
petrol engine

Special tools and workshop

equipment required
♦ Hose clamps - 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.

15. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder petrol engine 429
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Detach the cover from the reservoir.

– Clamp off suction pipe with hose clamp - 3094- .

– Unscrew the expansion hose from the power steering pump.

– Screw the adapter - V.A.G 1402/3- into the power steering

pump in place of the banjo bolt.
– Protected
Screw by the hose of the pressure gauge - V.A.G 1402- onto the
copyright. Copying for private or commercial purposes, in part or in whole, is not
adapter - V.A.G 1402/3-
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.

430 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Close cut-off valve on pressure gauge (lever pointing to the

left).
– Detach the hose clamps - 3094- and top up the fluid level in
the reservoir if necessary.
Checking pressure
To avoid damaging the pump, please note the following points:
♦ Do not run the engine for more than 10 seconds when per‐
forming this check.
♦ Start engine without pressing accelerator and leave it running
at idling speed.
♦ Take pump pressure reading at idling speed immediately after
starting engine (have second mechanic take reading).
♦ The pressure will drop during the test; the highest pressure
reading is therefore the required test value.
Specification: 120 - 130 bar.
– Renew power steering pump if specification is not attained
⇒ page 433 .
– Switch off engine.
– Check hydraulic fluid level ⇒ page 369 .
– Bleed steering system ⇒ page 369 .
– Checking steering system for leaks ⇒ page 370

15.3 Exploded view of power steering pump - vehicles with 8-cyl. petrol engine

Note

♦ Renew seals.
♦ Do not re-use hydraulic fluid which has been drained off.
♦ Hydraulic fluid - G 002 000-
♦ When replacing the power steering pump, always check that the pulleys on the air conditioner compressor
and power steering pump are aligned.

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. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder petrol engine 431
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Bolt with washer, 22 Nm

2 - Retainer
3 - Hexagon socket head bolt,
22 Nm
❑ Attachment of power
steering pump to holder
at rear
4 - Slotted bushing
❑ For tolerance compen‐
sation
5 - Expansion hose
❑ Power steering pump -
steering rack
❑ Note correct installation
position:
❑permitted
Angle -a-:authorised
Approx. 57° 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
unless by AUDI

6 - Banjo bolt, 47 Nm
with respect to the correctness of information in this document. Copyright by AUDI AG.

7 - Seals
❑ Always renew
8 - Suction hose
❑ Power steering pump -
reservoir
❑ Note correct installation
position:
❑ Angle -b-: Approx. 90°
9 - Banjo bolt, 50 Nm
10 - Power steering pump
❑ Fill with fluid before in‐
stalling ⇒ page 426
❑ Checking delivery pres‐
sure ⇒ page 429
❑ Removing and installing ⇒ page 433
11 - Shims
❑ Select such that pulleys of air conditioner compressor and power steering pump are mutually aligned.
❑ Check alignment of poly V-belt ⇒ page 437 .
12 - Belt pulley
13 - Hexagon socket head bolt, 22 Nm
❑ Counterhold with pin wrench - 3212- when slackening off and tightening

432 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

15.4 Removing and installing power steering pump - vehicles with 8-cyl. petrol
engine

Special tools and workshop

equipment required
♦ Hose clamps - 3094-
♦ Aligning gauge - 3201-
♦ Pin wrench - 3212-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-

Removing 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

– Unfasten the bolted joints -arrows- and detach the engine cov‐
with respect to the correctness of information in this document. Copyright by AUDI AG.

ers -A- and -B-.

– Detach the cover -C- from the reservoir.

15. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder petrol engine 433
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Detach green plug for solenoid clutch/air conditioning com‐

pressor and detach bottom part of connector from retainer.
– Move wiring to compressor clear. To do so, unfasten the cable
tie at the bottom -arrow-.
– Detach the right toothed belt guard.

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

– Cover sharp edges with adhesive strip.

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.

– Remove the electric fan. To do so, screw out the bolt -arrow-.
– Detach the sealing lip slightly from the front end in the area of
the electric fan.
– To remove, turn the electric fan slightly in -arrow direction-.
– Set down the electric fan to the side.

– Clamp off suction pipe with hose clamp - 3094- .

434 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove noise insulation panel.

Note

Before removing the poly V-belt, mark the direction of rotation. A

used belt can break if it runs in the opposite direction. Ensure that
the belt is properly seated in the pulleys when installing.

– Unscrew the clamp of the coolant central line.

– To slacken off the poly V-belt, swivel the tensioner in
-arrow direction-.
– Remove poly V-belt and again unload tensioning roller.

– Pinch off the return pipes with hose clamps - 3094- .

– Place a drip tray underneath to catch hydraulic fluid.
– Unscrew the expansion hose -1- and suction hose -2- from the
pump.
– Seal off connections with plugs.
– Unscrew the power steering pump/holder bolt -3-.

– Unbolt power steering pump pulley. Use a pin wrench - 3212-

to provide 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.

15. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder petrol engine 435
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unscrew the pump from the holder and take out from under‐
neath.
Installing
– Before fitting a new pump, put in hydraulic fluid at the inlet and
turn pump by hand until fluid flows out at the pressure outlet.
– Clean off fluid in engine compartment where necessary.
Installation position of expansion hose ⇒ page 437
Installation position of suction hose ⇒ page 438
– Insert pump in bracket from below and screw in all three bolts
by hand.
– Attach expansion and suction hose with new seals but do not
tighten.

– Tighten both front 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.

Note

The front side of the pulley is labelled “Front”.

436 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Screw on the power steering pump pulley. Use a pin wrench

- 3212- to provide support.
Checking and adjusting pulley alignment

– Position aligning gauge - 3201- on pulley of air conditioner

compressor.
– Pulleys on pump and air conditioner compressor must be
aligned.
If the two pulleys are not in alignment:
– Unbolt pump pulley.

– Use the shims listed in ⇒ Electronic parts catalogue “ETKA”

to adjust the gap so the two pulleys are aligned.

Installation position of expansion hose:

Angle -a-: Approx. 57°
– Align expansion hose and tighten.
– Fit the electric fan.

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. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder petrol engine 437
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Route wiring for solenoid clutch/air conditioner and connect.

– Remove adhesive tape.

– Fit the toothed belt, reservoir and engine covers.

– Tighten rear bolt of power steering pump.

Installation position of suction

Protected pipe:
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
Angle -b-: Approx. 90°
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Align suction hose and tighten.

– Remove hose clamps - 3094- .
Installation position poly V-belt

438 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Installation position of poly V-belt ⇒ Rep. gr. 13

Note

When installing the poly V-belt ensure correct running direction

and correct seating of the belt in the pulley.

– Swivel the tensioner -arrow direction-.

– Attach poly V-belt and again unload tensioning roller.
– Bolt on clamp or coolant line.
– Check hydraulic fluid level ⇒ page 369 .
– Bleed steering system ⇒ page 369 .
– Checking steering system for leaks ⇒ page 370

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 the noise insulation.

15. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder petrol engine 439
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

16 Power steering pump, hydraulic

pipes and hoses, fluid reservoir - ve‐
hicles with 8-cylinder petrol engine
with chain drive
⇒ “16.1 General notes”, page 440
⇒ “16.2 Removing and installing power steering pump”,
page 440

16.1 General notes

There is no provision for repairing the power steering pump. If
problems are reported, trace the fault by means of a pressure test
and a leakage test. Renew the power steering pump if there is a
fault.
The hydraulic fluid circuit on right-hand drive vehicles is the same
as on left-hand drive vehicles, except that the hydraulic pipes are
extended from left to right on the steering rack.
♦ Always check steering system for leaks in the event of a lack
of fluid in the reservoir.
♦ If leakage is visible at the pipe connections first tighten con‐
nections and wipe dry, then check for leaks again.
♦ Replacement pumps are not filled with fluid. Prior to installa‐
tion they are therefore to be filled with hydraulic fluid and
cranked by hand to avoid the possibility of noise whilst driving
or pump damage.
♦ Fluid type: Hydraulic fluid , for assignment refer to ⇒ Electronic
parts catalogue “ETKA” .

16.2 Removing and installing power steering pump

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.

440 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

Special tools and workshop

equipment required
♦ Support bracket - 10-222/
A-
♦ Link plate - 2024 A/2-
♦ Used oil collector and ex‐
tractor - V.A.G 1358 A- or -
V.A.G 1782-
♦ Wing supports - T40045-
(6.5 mm for wing edges)
♦ Bolt M10 x 15 mm

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
– Pull off rear engine cover panel -arrows-.
– Use the extractor - V.A.G 1358 A- or the extractor -
V.A.G 1782- to draw off the power steering hydraulic fluid from
the reservoir.

16. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder petrol engine with chain drive 441
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Attach the link plate - 2024 A/2- to the rear left engine lifting
eye. To do so, screw out the bolt at the link plate and replace
it with a bolt M10 x 15 mm with washer.
– Remove the rubber sealing strip from the edges of the wing
mounting flanges.

– So as not to damage the edges of the wing with the support

bar, insert the wing supports - T40045- between the wing
mounting flange and the fillet plate beneath it on both sides.

– Position the support bar - 10-222/A- on the wing mounting

flanges.
– Engage the link plate - 2024 A/2- at the spindle of the support
bracket.
– Take up weight of engine with spindle of support bracket, but
do not lift engine.
– Remove front left wheel.

– On vehicles with auxiliary heater, remove bolts -arrows- for

exhaust pipe of auxiliary/additional heater at 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.

442 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unfasten the quick-release fasteners -1- ... -3- and detach the
noise insulation (2-part).

– Remove the heat shield -1- for the left drive shaft.
– Remove the left drive shaft ⇒ Running gear, front-wheel drive
and four-wheel drive; Rep. gr. 40 .

– Remove nuts -1-…-4- for anti-roll bar mountings (left and

right).

– Unscrew nut -3-.

– Screw out the bolts -1- and -2- and detach the engine bracket.

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.

16. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder petrol engine with chain drive 443
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unplug electrical connector -1- on engine mounting (left-side).

– Unscrew nut -2- and detach engine mounting.

Note

Illustration shows engine removed.

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 bolts -1- and -2-.
– Detach return pipe from power steering pump -arrow-.

– Disconnect hydraulic pressure pipe from power steering pump

-arrow-.
– Move hydraulic pressure pipe to the side.

– Remove engine support (left-side) -arrows-.

444 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Unplug the connector -2- at the speedometer sender - G22- .

Note

-1- can be ignored.

– Slacken off the lock nut -3- by a few turns.

– Screw out the stud bolt -4- as far as possible.
– Unscrew bolts -1- and -2- and take off power steering pump.
Installing
– Clean off fluid in engine compartment where necessary.
– Before fitting a new pump, put in hydraulic fluid at the inlet and
turn pump by hand until fluid flows out at the pressure outlet.
– Renew O-ring on drive shaft of power steering pump.
– On re-installation, grease splines of drive shaft and power
steering pump all round. For correct version refer to ⇒ ETKA
- Electronic parts catalogue
– Renew seals.
– Secure all hose connections with the correct type of hose clips
(same as original equipment): ⇒ Electronic parts catalogue
“ETKA” .
– Install engine console and tighten subframe bolts ⇒ page 10 .
– Install anti-roll bar ⇒ page 81 .
– Install drive shaft ⇒ page 87 .
– Check hydraulic fluid level ⇒ page 369 .
– Bleed steering system ⇒ page 369 .
– Checking steering system for leaks ⇒ page 370
Tightening torques
Component Nm
Power steering pump to engine 22
Stud bolt to pump 40
Lock nut to stud bolt 65
Engine support to cylinder block 42
Hydraulic pressure line to power steering pump 47
Return pipe to Engine support 10
Coolant pipe 10
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Engine mounting Engine support
permitted unless authorised by AUDI AG. AUDI23 AG does not guarantee or accept any liability
to with respect to the correctness of information in this document. Copyright by AUDI AG.
Engine console 23
Heat shield for drive shaft to gearbox 23

16. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder petrol engine with chain drive 445
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

17 Power steering pump, hydraulic

pipes and hoses, fluid reservoir - ve‐
hicles with 8-cylinder petrol engine,
biturbo
⇒ “17.1 Exploded view - vehicles with 8-cyl. petrol engine, bitur‐
bo”, page 446
⇒ “17.2 Checking delivery pressure of power steering pump - ve‐
hicles with 8-cyl. petrol engine, biturbo”, page 449
⇒ “17.3 Exploded view of power steering pump - vehicles with 8-
cyl. petrol engine, biturbo”, page 451
⇒ “17.4 Removing and installing power steering pump - vehicles
with 8-cyl. petrol engine, biturbo”, page 453

17.1 Exploded view - vehicles with 8-cyl. pet‐

rol engine, biturbo
General notes
There is no provision for repairing the power steering pump. If
problems are reported, trace the fault by means of a pressure test
and a leakage test. Renew the power steering pump if there is a
fault.
The hydraulic fluid circuit on right-hand drive vehicles is the same
as on left-hand drive vehicles, except that the hydraulic pipes are
extended from left to right on the steering rack.
♦ Always check steering system for leaks in the event of a lack
of fluid in the reservoir.
♦ If leakage is visible at the pipe connections first tighten con‐
nections and wipe dry, then check for leaks again.
♦ Replacement pumps are not filled with fluid. Prior to installa‐
tion they are therefore to be filled with hydraulic fluid -
G 002 000- and cranked by hand to avoid the possibility of
noise whilst driving or pump damage.
♦ Fluid type: Hydraulic fluid - G 002 000-

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.

446 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Power steering rack

❑ Exploded view:
❑ Left-hand drive vehicles
⇒ page 328
❑ Right-hand drive vehi‐
cles ⇒ page 337
❑ Servicing ⇒ page 359
2 - Return hose
❑ Steering rack - fluid
cooler
3 - Pressure pipe
❑ Tighten union nut to 40
Nm whilst providing
support at hexagon
❑ Note correct installation
position:
❑ At steering rack
⇒ page 448
4 - Expansion hose
❑ Power steering pump -
steering rack
❑ Note correct installation
position:
❑ At power steering pump
⇒ page 448
5 - Cap with dipstick
❑ Checking fluid level
⇒ page 369
6 - Hexagon bolt, 9 Nm
7 - Reservoir
8 - Rubber mounting
9 - Return hose
Between reservoir and cooling pipe
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Installation position:
permittedRestrictor -arrow-
unless authorised by AUDIfacing
AG. AUDIreservoir
AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
10 - Banjo bolt, 47 Nm
❑ M16×1.5
11 - Seals
❑ Always renew
12 - Suction hose
❑ Power steering pump - reservoir
❑ Note correct installation position:
❑ At power steering pump ⇒ page 448
❑ At reservoir ⇒ page 448
13 - Banjo bolt, 50 Nm
❑ M18×1.5
14 - Seals
❑ Always renew
15 - Hose clip
❑ Tighten using hose clip pliers - V.A.G 1275-

17. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder petrol engine, biturbo 447
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

16 - Fluid radiator
17 - Bolt
❑ 1.5 Nm
18 - Power steering pump
❑ Fill with fluid before installing ⇒ page 446
❑ Checking delivery pressure ⇒ page 449
❑ Exploded view ⇒ page 451
19 - Speed nut
❑ 1.3 Nm
20 - Self-tapping combi bolt
❑ 2 Nm
21 - Heat shield
❑ Different types at vehicles with auxiliary heater
22 - Heat shield

Installation position of suction and expansion hose at power

steering pump
Angle -a- for expansion hose: Approx. 74°
Angle -b- for suction pipe: Approx. 90°

Installation position of return pipe and pressure pipe at steering

rack (left-hand drive vehicles)
Angle -a- for pressure pipe: Approx. 45°
Angle -b- for return hose: Approx. 116°

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 suction hose to reservoir (all engines)

– The mark at the suction hose -1- must be aligned with the
seam at the reservoir.

448 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

17.2 Checking delivery pressure of power steering pump - vehicles with 8-cyl.
petrol engine, biturbo

Special tools and workshop

equipment required
♦ Hose clamps - 3094-
♦ Power steering tester -
V.A.G 1402-
♦ Adapter - V.A.G 1402/3-

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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.

– Remove the underseal.

– Detach the cover from the reservoir.
– Unclip the connector unit -arrow-.

17. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder petrol engine, biturbo 449
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Lift off the connector unit.

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 two hose clamps and remove the air hose
-arrow-.

– Unfasten the two hose clamps -arrows- and remove the air
hose.

– Screw the adapter - V.A.G 1402/3- into the power steering

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- .

450 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Close cut-off valve on pressure gauge (lever pointing to the

left).
– Detach the hose clamps - 3094- and top up the fluid level in
the reservoir if necessary.

– Re-attach the lower air hose.

Note

So as not to damage the turbocharger, the engine is not to be

started with the lower air hose detached.

Checking pressure
To avoid damaging the pump, please note the following points:
♦ Do not run the engine for more than 10 seconds when per‐
forming this check.
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Start engine without pressing accelerator and leave it running
with respect to the correctness of information in this document. Copyright by AUDI AG.

at idling speed.
♦ Take pump pressure reading at idling speed immediately after
starting engine (have second mechanic take reading).
♦ The pressure will drop during the test; the highest pressure
reading is therefore the required test value.
Specification: 120 - 130 bar.
– Renew power steering pump if specification is not attained
⇒ page 433 .
– Switch off engine.
– Check hydraulic fluid level ⇒ page 369 .
– Bleed steering system ⇒ page 369 .
– Checking steering system for leaks ⇒ page 370

17.3 Exploded view of power steering pump - vehicles with 8-cyl. petrol engine,
biturbo

Note

♦ Renew seals.
♦ Do not re-use hydraulic fluid which has been drained off.
♦ Hydraulic fluid - G 002 000-
♦ When replacing the power steering pump, always check that the pulleys on the air conditioner compressor
and power steering pump are aligned.

17. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder petrol engine, biturbo 451
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

1 - Bolt with washer, 22 Nm

2 - Retainer
3 - Hexagon socket head bolt,
22 Nm
❑ Attachment of power
steering pump to holder
at rear
4 - Slotted bushing
❑ For tolerance compen‐
sation
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - Expansion hose permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Power steering pump -
with respect to the correctness of information in this document. Copyright by AUDI AG.

steering rack
❑ Note correct installation
position:
❑ Angle -a-: Approx. 75°
6 - Banjo bolt, 47 Nm
7 - Seals
❑ Always renew
8 - Suction hose
❑ Power steering pump -
reservoir
❑ Note correct installation
position:
❑ Angle -b-: Approx. 90°
9 - Banjo bolt, 50 Nm
10 - Power steering pump
❑ Fill with fluid before in‐
stalling ⇒ page 446
❑ Checking delivery pres‐
sure ⇒ page 449
❑ Removing and installing ⇒ page 453
11 - Shims
❑ Select such that pulleys of air conditioner compressor and power steering pump are mutually aligned.
❑ Check alignment of poly V-belt ⇒ page 437 .
12 - Belt pulley
13 - Hexagon socket head bolt, 22 Nm
❑ Counterhold with pin wrench - 3212- when slackening off and tightening

452 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

17.4 Removing and installing power steering pump - vehicles with 8-cyl. petrol
engine, biturbo

Special tools and workshop

equipment required
♦ Hose clamps - 3094-
♦ Aligning gauge - 3201-
♦ Locking pin - 3204-
♦ Pin wrench - 3212-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-

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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
– Remove the bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Front bumper .
– Move the lock carrier to the service position ⇒ General body
repairs, exterior; Rep. gr. 50 ; Body - front .
– Unplug the connector -5- at the charge air pressure sender -
G31- .
– Unfasten hose clamps -3- and -4-.
– Detach the hoses from the air recirculation valves.
– Screw out the bolts -1- and -2- and detach the air pipe.

17. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder petrol engine, biturbo 453
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Remove the air hose to the charge air cooler on the left
-arrows-.

Note

Before removing the poly V-belt, mark the direction of rotation. A

used belt can break if it runs in the opposite direction. Ensure that
the belt is properly seated in the pulleys when installing.

– To slacken off the poly V-belt, swivel the belt tensioner inor accept any liability
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
-arrow direction-.
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Lock the tensioner in position by inserting the locking pin -

3204- in the locating holes -arrow-.
– Detach the poly V-belt from the power steering pump pulley.

– Screw out the bolts -arrows- of the power steering pump poly
V-belt pulley.
– When slackening off and tightening the bolts -arrows-, provide
support with the pin wrench - 3212- .

454 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Take the connectors -arrows- out of the holder.

– Remove holder for connectors.

– Use hose clamps - 3094- to pinch off the hydraulic hoses.

Note

Place a cloth under the unions to catch escaping hydraulic fluid.

– Detach the suction hose -1- and expansion hose -2- at the
power steering pump.

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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 bolts -arrows-.

– Take out the power steering pump.
Installing
– Before fitting a new pump, put in hydraulic fluid at the inlet and
turn pump by hand until fluid flows out at the pressure outlet.
– Clean off fluid in engine compartment where necessary.
– Renew seals and O-rings.
– Secure all hose connections with the correct type of hose clips
(same as original equipment): ⇒ Electronic parts catalogue
“ETKA” .
Installation position of expansion hose ⇒ page 457
Installation position of suction hose ⇒ page 457

17. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder petrol engine, biturbo 455
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Insert the pump in the holder and screw in all 3 bolts

-arrows-.
– Attach expansion and suction hose with new seals but do not
tighten.

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 front side of the pulley is labelled “Front”.

♦ Screw on the power steering pump pulley. Use a pin wrench
- 3212- to provide support.

Checking and adjusting pulley alignment

– Position aligning gauge - 3201- on pulley of air conditioner

compressor.
♦ The poly V-belt pulley of the power steering pump must be
aligned with that of the air conditioner compressor.
If the two pulleys are not aligned:

456 Rep. gr.48 - Steering

 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Use shims of 0.5, 1.0 and 1.5 mm thickness to even out the
distance between the poly V-belt pulleys for the power steering
pump and the air conditioner compressor. For part no., refer
to ⇒ Electronic parts catalogue “ETKA” .

– Then check the alignment of the poly V-belt pulleys again us‐
ing the alignment gauge - 3201- . Repeat adjustment if nec‐
essary.
Installation position of expansion hose:
Angle -a-: Approx. 75°
– Align expansion hose and tighten.
Installation position of suction pipe:
Angle -b-: Approx. 90°
– Align suction hose and tighten.
– Remove hose clamps - 3094- .
Installation position poly V-belt

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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.

17. Power steering pump, hydraulic pipes and hoses, fluid reservoir - vehicles with 8-cylinder petrol engine, biturbo 457
 Audi A6 1998 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 10.2013

– Installation position of poly V-belt ⇒ Rep. gr. 13

Note

Pay attention to correct positioning on pulleys when fitting the poly

V-belt.

– Attach poly V-belt and again unload tensioning roller.

– Replace the front air pipe O-ring.
Hose connections and hoses for charge air system must be free
of oil and grease before fitting. Never use lubricant.
– Check hydraulic fluid level ⇒ page 369 .
– Bleed steering system ⇒ page 369 .
– Checking steering system for leaks ⇒ page 370
– Start engine and check that belt runs properly.
– Attach the bumper ⇒ General body repairs, exterior; Rep. gr.
63 ; Front bumper .
– Attach the lock carrier ⇒ General body repairs, exterior; Rep.
gr. 50 ; Body - front .
Tightening torques
Component Nm
Power steering pump to bracket 22
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Pulley to power steering pump permitted unless22authorised 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.
Hydraulic pipe M16 50
On power steering pump M18 47
Front air pipe to cylinder block 9
Clamps for air hoses 5

458 Rep. gr.48 - Steering