Skoda Workshop Service and Repair Manuals

Installing the power-assisted steering drive 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. t  Pay attention to the measures after re-connecting the battery → Electrical System; Rep. gr.27. –  Check the centre position of the gear rack of the power-steering gear, if necessary adjust → Chapter.

–  Place the power-steering gear from the rear onto the lowered assembly carrier and 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 with adapter on the fixing bolts of -T10096- and simultaneously 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 seal -3- into the power-steering gear valve housing (if present). –  Insert and tighten screws -1-.

–  Screw pressure line (expansion hose) -1- and return line (return hose) -2- onto the power-steering gear.   Note 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-   Note Pay attention to fitting location of the pressure line → Chapter. –  Raise assembly carrier until the consoles touch both sides of 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. Vehicles up to CW 11 2008

–  Unscrew fixing bolt -1- from -T10096- the left, screw in new bolt and tighten to the recommended tightening torque. 3 -  Assembly carrier –  Unscrew fixing bolt -1- of -T10096- from the right (shown in figure), screw in new bolt and tighten 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. –  Screw in new bolt for left console and support and tighten 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. –  Screw in new bolt for right console and support and tighten to the recommended tightening torque. –  Tighten up the rear right support bolts to the recommended tightening torque. Vehicles as of CW 12 2008

–  Unscrew fixing bolt -1- from -T10096- the left, screw in new bolt and tighten to the recommended tightening torque. –  Unscrew fixing bolt -1- of -T10096- from the right (shown in figure), screw in new bolt and tighten 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. –  Screw in new bolt for assembly carrier and left support and tighten 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. –  Screw in new bolt for assembly carrier and right support and tighten to the recommended tightening torque. –  Tighten up the rear right support bolts to the recommended tightening torque. Continued for all vehicles –  Remove engine/gearbox jack with adapter.

–  Clip pressure line into the spacer holder -arrow-. –  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 wrench at hexagonal socket of stud.

–  Insert left and right coupling rods -3- into the stabilizer -2- and tighten the nuts -1-. –  Screw in the left and right nuts -1- and tighten.

–  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; Rep. gr.26. Continued for all vehicles –  Install front wheels. –  Install the noise insulation → Body Work; Rep. gr.50.

–  Attach cable of power-assisted steering sensor -G250- in the line holder -arrows- (if present).

–  Position the universal joint of the steering column in -direction of arrow- on the shaft of the power-steering gear in the marked location. For vehicles up to MY 2010

–  Fit cover -2- with plastic nuts -1-. Continued for all vehicles –  Remove securing mechanism in opposite direction to the rotation of the steering wheel (adhesive tape). –  If necessary connect removed battery to jumper cables.   Caution Observe the applicable safety instructions for disconnecting the battery with jumper cables! –  Filling and bleeding the power steering system → Chapter. –  Disconnect the Jumper cable.   Note t  If necessary install battery tray and battery → Electrical System; Rep. gr.27. t  Pay attention to the measures after re-connecting the battery → Electrical System; Rep. gr.27. –  Connect battery → Electrical System; Rep. gr.27.   Note Then if necessary install air filter → Engine; Rep. gr.24 (petrol engines) or → Engine; Rep. gr.23 (diesel engines). –  Interrogate fault memory or eliminate fault → Vehicle diagnostic tester. –  Perform chassis alignment → Chapter. –  Perform a test drive. –  Check the steering wheel position during the 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 TRW (M14x1.5) t  Use new hollow screw!	35 Nm
Pipe screw for return line to power steering gear TRW (M16x1.5)	30 Nm
Coupling rod to anti-roll bar	40 Nm
Universal joint of the steering column to power-steering gear t  Use new screw!	20 Nm + 90°
Wheel bolts	→ Chapter