Central Hydraulic High Pressure Hose - Replacing

88audi09

Applies To: 5000 from 1984 100/200 1989


Subject: Central hydraulic high pressure hose, replacing
Number:

88-07 November 24, 1988
Group:

48
Brakes - Steering



High pressure steering hose (to accumulator), replacing

Before removing a defective high pressure hose, check the routing of the hose to determine if it has been kinked, twisted or installed incorrectly.

^ check if pressure accumulator is twisted out of position
^ check engine mounts and engine rubber stop for damage and replace if necessary
^ check if high pressure hose has been twisted at coupling with damper pipe due to incorrect installation

^ check that metal line at end of high pressure hose contacts stop pin on pressure accumulator
^ check if damper pipe is bent (can be recognized by bent retainer bracket)



Removing

^ on vehicles with cooling fan for injectors, release two retainer straps, separate connector and remove fan motor
^ remove banjo bolt from hydraulic pump at connection to accumulator. Seal connection on damper pipe with a plug

^ remove bolts in damper pipe retaining bracket and seal threaded connection in central hydraulic pump with a plug

^ hold pressure accumulator with an oil filter wrench (arrow) while removing banjo bolt from accumulator


CAUTION

Hydraulic fluid will escape.


Note

The oil filter wrench will keep the accumulator from being turned out of position when loosening the banjo bolt.
^ seal threaded connection on accumulator with a plug
^ remove high pressure hose and damper pipe from top of engine compartment
^ loosen union of high pressure hose and damper pipe

^ remove damper hose from damper pipe



Installing

^ remove plugs from high pressure hose and pressure accumulator
^ clean seal contact surface on pressure accumulator thoroughly
^ feed high pressure hose into engine compartment from underneath


CAUTION

DO NOT interchange banjo bolts 2 and 12.

2 = damper pipe to central hydraulic pump

12 = high pressure hose to accumulator

^ connect high pressure hose to pressure accumulator with new banjo bolt 12 and new seals. Hold accumulator with oil filter wrench when tightening bolt

Note

The metal connection on the damper hose must make contact with the stop pin on the accumulator.

When tightening the connection, the banjo bolt must be in a vertical position.

^ carefully insert new damper hose into new damper pipe
^ thread union together by hand but DO NOT tighten
^ remove plug from central hydraulic pump and clean seal contact surface thoroughly

^ remove plug from damper pipe
CAUTION

DO NOT install O-ring seals in place of metal seals or vice versa.


CAUTION

DO NOT twist high pressure hose when tightening connection.
^ connect damper pipe to central hydraulic pump with new banjo bolt and new seals. Hand tighten only
^ fasten damper pipe to pump with mounting bolts at retaining bracket
^ tighten banjo bolt

^ tighten union while holding 10 mm hexagonal with a wrench
^ clean hydraulic fluid off all parts
Checking

^ check hydraulic fluid level in reservoir; top up with hydraulic fluid G 002 000 if necessary
^ swivel central hydraulic pump towards upper stop on tensioner. Replace V-belt if pump contacts upper stop with belt installed
^ run engine at idle and check for leaks at all connections

^ install injector fan motor