Contents: Continued for all vehicles ⬇ Installation ⬇ Cars with exhaust pipe under…⬇ Continued for all vehicles ⬇ Tightening torques ⬇
Important: Apart from replacing the cuff, tie rod end and tie rod, no other repair work is permitted on the steering gear housing. When working on a power steering system, it is essential to maintain maximum cleanliness. Before starting to disconnect, thoroughly clean the connection points and the areas around them. The removed parts should be placed on a clean surface and, if the repair is not to be carried out immediately, covered. Do not use lint-producing cloths. Remove parts from packaging only immediately before installation. Use only spare parts packed in their original packaging. Drained hydraulic fluid cannot be reused. The O-rings on the hydraulic line should be replaced after each removal. Disposal of the old power steering gear housing. Follow the instructions for reconnecting the battery. The steering wheel should be set to the center position (the wheels are set to move straight) and do not turn it during repairs, otherwise the return ring with the guide coil spring of the Airbag device could become unusable.
With the wheels set to drive straight, secure the steering wheel with "arrow" tape so that the steering wheel cannot turn.
Remove the plastic nuts. Remove cover "2".
Unscrew screw "1". Remove the universal joint with the crosspiece in the direction of the arrow from the input shaft of the power steering gear housing.
Important: Due to the fact that different variants use batteries of different sizes, it may happen that the cover of the hydraulic fluid receiver is blocked by the battery holder. In this case, it is necessary to remove the battery and battery holder.
Disconnect the battery. If necessary, remove the air filter. If necessary, remove the battery and battery holder. Remove the "G250" power steering sensor wire from the "arrow" wire clamp.
Remove the front wheels. Remove the lower engine cover.
Cars with exhaust pipe under suspension mounting beam
Remove the front section of the exhaust pipe with the catalytic converter.
Continued for all vehicles
Unscrew screws "1" and "2" of the rocking support.
Unscrew the nuts of the stabilizer connecting rod "1" to the left and right. Remove the stabilizer connecting rod "3" to the left and right from the stabilizer "2".
The tie rod end nut "1" should be unscrewed to such an extent that the puller rests on the nut. Using a puller, press the transverse tie rod with the transverse tie rod end "2" away from the steering trapezoid lever. Unscrew the nut from the tie rod end on both sides. Remove the tie rod end from the steering linkage arm on both sides.
Unscrew the cover "1" of the working fluid receiver for the hydraulic systems "2" of the power steering pump unit. The hydraulic fluid should be drained through the filling hole using a drain flask.
Important: Some of the hydraulic fluid remains after draining, both in the pump unit and in the return line and in the discharge hose. Drained hydraulic fluid cannot be reused. The discharge hose and return line must not be clamped with any tube clamp or other device. Disconnection may result in damage to the discharge hose and return line. When bending the pressure hose and return line, the bend diameter must not be less than 100 mm to avoid damaging them.
Place a collecting pan under the steering gear housing to catch any leaking hydraulic fluid. Insert a wooden board (490x270x50 mm) "2" in the tip. Support the axle suspension mounting beam with an engine and gearbox removal and installation tool with a tip. Remove screws "1" from the power steering housing.
Important: Follow these steps carefully, making sure to follow the correct sequence. The centering pins may be tightened with a torque not exceeding 20 Nm, otherwise the thread of the centering pin will be damaged.
After unscrewing the left screw "4" of the suspension mounting beam "3", screw on the centering pin and tighten it to 20 Nm.
Unscrew the right screw "4" of the suspension mounting beam (it's not in the picture), screw on the centering pin and tighten to 20 Nm. Remove screws "1" on both sides. After unscrewing the left screw "2", remove the support "5". After screwing in the centering pin "T10096", tighten it to 20 Nm. After unscrewing the right screw "2", remove the support "5". After screwing in the centering pin, tighten it to 20 Nm. The suspension mount beam is secured if all four screws (positions "2" and "4" on both sides of the vehicle) are gradually replaced with centering pins. Release the pressure line from the "arrow" spacer holder.
Caution: When lowering the suspension mount beam, ensure that the pressure line, return line and power steering sensor wire "G250" are not subjected to tensile load.
Lower the suspension mounting beam with the "4" amplifier by approximately 4 cm.
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Unscrew the pressure line "1" and the return line "2" from the power steering gear housing. Cover the pressure line and return line with a plastic bag and secure with tape. Tie the pressure line and return line at the top. The pressure and return line openings and the power steering housing should be sealed with plastic screw plugs.
Remove the Allen head screws "1". Remove the power steering sensor "G250" ("2") with the seal "3" from the power steering gear housing.
Important: When lowering the suspension mount beam, ensure that there is sufficient free space between the drive shafts and the stabilizer.
Slowly lower the suspension mount beam using an engine and transmission removal and installation tool with a tip. Remove the power steering gear housing in a rearward direction.
Installation
When installing a pressure line (stretchable hose) on the power steering gear housing, ensure that the correct position is maintained for assembly. When tightening the pressure and return lines, it is necessary to ensure that the hoses do not touch anything during installation or while the vehicle is moving, so that they cannot become worn out. New seals must be used for pressure line connections. To connect the pressure line to the TRW power steering housing, use a new hollow screw. New O-ring seals must be used for return line connections. Before installing the power steering gear housing, lubricate the lip seal of the power steering gear housing with a lubricant to ease assembly, e.g., soap paste. Ensure that the sealing surfaces are clean. After installing the power steering housing onto the steering column driveshaft, ensure that the lip seal on the power steering housing fits against the mounting plate without breakage and that the opening leading to the footwell is properly sealed. Otherwise, moisture penetration or noise may occur. Before installing the power steering housing, check the center position of the rack. Only fit the universal joint with the steering shaft crosspiece onto the input shaft of the steering gear housing when the vehicle is on the ground and the wheels are positioned for straight-ahead driving. Follow the instructions for reconnecting the battery. Check the center position of the power steering gear rack and adjust it if necessary. After placing the power steering gear housing on the lowered axle suspension mounting beam from the rear, tighten the new screws by hand. Check that the oil seal is installed correctly on the power steering gear housing. Fit the suspension mounting beam to the body with the centering pins screwed in.
Important: Raise the suspension mount beam so that the distance between the bracket and the body is approx. 4 cm.
Slowly raise the axle suspension beam using an engine/gearbox lifter with a centering pin attachment while inserting the power steering gear housing input shaft into the opening in the vehicle base. Insert the power steering sensor "G250" ("2") with the seal "3" into the power steering gear housing. After screwing in screws "1", tighten them. Screw the pressure line "1" and return line "2" onto the power steering gear housing.
Important: A new hollow screw must be used to connect pressure line "1" to the TRW power steering housing.
- 3 - Power steering sensor "G250" with non-removable wire connection
- 4 - Suspension mounting beam (bracket for mounted units)
- 5 - Centering pin
Important: Observe the position for assembling the pressure line.
Raise the suspension mount beam so that the brackets on both sides are flush with the body.
Important: Follow these steps carefully, making sure to follow the correct sequence. Only one centering pin should ever be unscrewed. Then you should replace it with a new screw and tighten it to the specified torque.
After unscrewing the left centering pin "1", screw in a new screw and tighten it to the specified tightening torque.
Having unscrewed the right centering pin "1" (it is not shown in the picture), screw in a new screw and tighten to the specified tightening torque. Unscrew the left centering pin "2". Install the left support. After installing the new left support screws, tighten them at the rear by hand. After installing the new screw for the bracket and left support, tighten it to the specified tightening torque. Tighten the left support screws at the rear to the specified tightening torques. Unscrew the right centering pin "2" (it's not in the picture). Install the right support. After screwing in the new screws for the right support, tighten them at the rear by hand. After installing the new screw for the bracket and left support, tighten it to the specified tightening torque. Tighten the right support screws at the rear to the specified tightening torques. Remove the engine and gearbox removal and installation tool with the tip. Secure the pressure line to the "arrow" spacer holder. Tighten the screws securing the steering gear housing to the axle suspension beam to the specified torque. After installing the tie rod end together with the tie rod into the steering linkage arm, tighten it with a new nut. If the journal rotates when tightened, it is necessary to hold it with a wrench by the internal hexagon of the journal.
Insert the stabilizer connecting rods "3" to the left and right into the stabilizer "2" and tighten the nuts "1". After screwing the nuts "1" to the left and right, tighten.
After installing the rocker support on the gearbox, tighten it with new screws "1" and "2".
Important: Place bolts "1" and "2" into the slots of the rocker support so that there is maximum distance between the gearbox and the axle suspension mounting beam.
Cars with exhaust pipe under suspension mounting beam
Install the front section of the exhaust pipe with the catalytic converter.
Continued for all vehicles
Install the front wheels. Install the lower engine cover. Attach the wire of the power steering sensor "G250" to the "arrow" wire clamp.
Having thrust (in the direction of the arrow) universal joint with steering column crosspiece to the input shaft of the power steering gear housing, tighten with a new screw.
Install cover "2" using plastic nuts "1". Remove the device preventing the steering wheel from turning (adhesive tape).
The removed battery should be connected using auxiliary wires to connect the starter to the auxiliary battery. After filling the power steering system, bleed the air from it. Disconnect the starter wires from the auxiliary battery. If necessary, install the battery holder and battery.
Important: Follow the instructions for reconnecting the battery.
Connect the battery. If necessary, an air filter should be installed. Implement automatic control. If faults are loaded into the fault memory: Eliminate faults. Reset the contents of the fault memory. Conduct a test run.
Caution: If after a test run and with the front wheels set to drive straight, the steering wheel is not in the correct position, the vehicle must be measured.
Take measurements of the vehicle.
Tightening torques
| Power steering housing on the suspension mounting beam | 50 Nm + 90° |
| Suspension mounting beam on the body | 70 Nm + 90° |
| Support on the body | 20 Nm + 90° |
| Rocker support on the gearbox | 30 Nm + 90° |
| Tie rod end with tie rod on steering link arm | 20 Nm + 90° |
| Power steering sensor "G250" on the TRW power steering gear housing | 6 Nm |
| TRW Power Steering Gear Housing Pressure Line Hollow Screw (M14 x 1.5) | 35 Nm |
| Pressure line pipe screw on the power steering gear housing (M16 x 1.5) | 30 Nm |
| Stabilizer connecting rod on the stabilizer | 40 Nm |
| Cardan shaft with steering column crosspiece on the power steering gear housing | 20 Nm + 90° |
| Wheel mounting bolts | 120 Nm |