Skoda Workshop Service and Repair Manuals

Installing the power-assisted steering gear TRW - RHD version t  Pay attention to fitting position when attaching pressure line (flexible hose) to the power steering gear → Chapter. t  When tensioning and while driving the pressure line (expansion hose) and the return line (return hose) must not touch or chafe. t  To connect the pressure line use new gasket rings. t  Use new hollow screw for the connection of the pressure line to the power steering gear (TRW). t  To connect the return line use new O-rings. t  Coat the seal on the power-steering gear with lubricant before installing the power-steering gear, e.g. lubricating soap. t  Make sure all sealing surfaces are clean. t  After positioning the power-steering gear on the drive shaft of the steering column make sure the seal on the power-steering gear is not bent on the assembly plate and correctly seals the footwell opening. Otherwise this could cause water penetration and/or noise. t  Before fitting the power-steering gear check the centre position of the gear rack → Chapter. t  Only position the universal joint of the steering column on the input shaft of the steering gear, if the vehicle is on the ground and all wheels are pointing straight ahead. –  Check the centre position of the gear rack of the power-steering gear, if necessary adjust → Chapter.

–  Position the power-assisted steering gear from the rear on the lowered assembly carrier. l  The pressure line and return line must be fixed with clip -1- before positioning the steering gear on the assembly carrier.

–  Tighten new screws -1- by hand. –  Check correct fit of the seal on the power-steering gear valve housing. –  Align the assembly carrier with the fixing bolts of -T10096- screwed into the body.   Note Raise the assembly carrier until a distance of approx. 4 cm is between the console and body. –  Slowly raise the assembly carrier with engine/gearbox jack and adapter, and while doing so insert the input shaft of the power-steering gear in the opening in the vehicle floor. 2 -  Wooden insert (490 x 270 x 50 mm)

–  Insert the power-assisted steering sensor -G250- (-2-) with new seal -3- into the power-steering gear valve housing. –  Insert and tighten screws -1-. The installation of the power-assisted steering sensor -G250- with adapter cable is illustrated in the ilustration. The installation of the power-assisted steering sensor -G250- with fixed connection line occurs in the same way.

–  Mount pressure line (expansion hose) -1- and return line (return hose) -2- at the power-steering gear. –  A new hollow screw must be used to connect the pressure line (expansion hose) -1- to the power-steering gear (TRW). 3 -  for power-assisted steering sensor - G250- with fixed connecting line 4 -  Assembly carrier 5 -  Fixing bolt of -T10096-    Pay attention to fitting location of the pressure line → Chapter. –  Raise assembly carrier until the console touches the body.   Note t  Note the following work steps and absolutely ensure that you follow the sequence. t  Unscrew the fixing bolts of -T10096- one at a time. It should be subsequently replaced by a new bolt tightened to the recommended torque.

–  Unscrew fixing bolt -1- of -T10096- from the left and screw in new bolt to the recommended tightening torque. 3 -  Assembly carrier –  Unscrew fixing bolt -1- of -T10096- from the right (shown in figure) and screw in new bolt to the recommended tightening torque. –  Unscrew fixing bolt -2- of -T10096- from the left. –  Install left support. –  Screw in new bolts for the left support and tighten at the rear by hand. –  Tighten new bolts for left console and support to the recommended tightening torque. –  Tighten the rear left support bolts to the recommended tightening torque. –  Unscrew right fixing bolts -2- of -T10096- (shown in figure). –  Install right support. –  Screw in new bolts for the right support and tighten at the rear by hand. –  Tighten new bolts for the console and screw in to the recommended tightening torque. –  Tighten up the rear right support bolts to the recommended tightening torque. –  Remove engine/gearbox jack with adapter. –  Tighten screws for fixing the steering gear to the assembly carrier to the recommended tightening torque. –  Insert track rod end/track rod into steering arm and tighten new nut → Chapter.    If the joint stub rotates when tightening, counterhold it with hexagon socket wrench –  Hook the coupling rod joint stub in the stabilizer and tighten nut.

–  Mount pendulum support on the gearbox and tighten new screws -1- and -2-.   Note Position the screws -1- and -2- in the elongated holes of the pendulum support in such a way that there is maximum distance between the gearbox and the assembly carrier. Vehicles with the exhaust system below the assembly carrier –  Install front exhaust pipe → Engine, Mechanics; Rep. gr.26. Continued for all vehicles –  Install front wheels. –  Install the noise insulation → Body Work; Rep. gr.50.

–  Attach line of power-steering sensor -G250- with the line holders -arrows-.

–  Slide the universal joint of the steering column in the -direction of the arrow- onto the input shaft of the power steering and tighten with a new screw -1-. –  Fit cover for universal joint.   Caution Observe the applicable safety instructions for disconnecting the battery with jumper cables! –  Connect the removed battery with jumper cables. –  Filling and bleeding the power steering system → Chapter. –  Disconnect the Jumper cable. –  If necessary install the battery and battery tray → Electrical System; Rep. gr.27. –  Connect battery → Electrical System; Rep. gr.27. –  If necessary install air filter → Engine, Fuel Injection; Rep. gr.24 (petrol engines) or → Engine, Fuel Injection; Rep. gr.23 (diesel engines). –  Performing self-diagnosis → Chapter. If faults are stored in the fault memory: –  Remove fault → Chapter. –  Erasing fault memory → Chapter. –  Perform chassis alignment → Chapter. –  Perform a test drive.   Caution If after the test drive and with the front wheels pointing straight ahead the steering wheel is off straight, perform a chassis alignment → Chapter.

Tightening torques:

Power-steering gear to assembly carrier t  Use new screws!	50 Nm + 90°
Assembly carrier to body t  Use new screws!	70 Nm + 90°
Support to body t  Use new screws!	20 Nm + 90°
Pendulum support to gearbox t  Use new screws!	30 Nm + 90°
Track rod end/track rod to steering arm t  Use new nuts!	20 Nm + 90°
power-assisted steering sensor -G250 - to power-assisted steering gear (TRW)	6 Nm
Hollow screw for pressure line to power steering gear (M14x1.5) - TRW t  Use new hollow screw!	35 Nm
Pipe screw for return line to power steering gear (M16x1.5)	30 Nm
Coupling rod to anti-roll bar	40 Nm
Universal joint to power-steering gear t  Use new screw!	20 Nm + 90°
Wheel bolts	120 Nm