3238140 - 4130B40 outlet pipe from pump to power steering case r r

Removing ( Refitting ) Position the vehicle on the rampDrain the power steering fluid from the reservoir using a suitable syringe. Proceed with removal  - 4450B12  front or rear wheels (two) - r+r . Proceed with removal  - 1016A40  ignition coil cover on cylinder head- r+r . 1. Connect the quick-release attachment for the fuel vapour recovery pipe (1a) and move aside after releasing from band (1b) on the power assisted steering fluid reservoir. 2. Release the coolant return pipe to the coolant reservoir from the bands on the modular intake manifold. Proceed with removal  - 1008C10  power unit upper reaction link r r . Proceed with removal  - 1008C16  body link bracket - r r . Release the power steering fluid delivery and return pipes from the connection clip. 1. Undo the bolts (1a) and remove the power assisted steering fluid reservoir (1b). 1. Loosen the bands and disconnect the coolant supply and return pipes from the power steering fluid reservoir.2. Remove the power steering fluid reservoir.3. Unscrew the connector and disconnect the delivery pipe from pump to power steering box, pump side. 1. Position a suitable bracket to support the power unit safely.2. Fit the tool (2a), complete with support blocks (2b) and connect to the bracket fitted previously using link (2c).

	Name	Country
2a	Crossmember	1.820.581.000

	Name	Country
2b	Support mountings	1.870.650.000

Proceed with removal  - 7055B54  under-engine guard - r r . Proceed with removal  - 1076B50  exhaust pipe attachment to engine - r + r . 1. Undo the nut (1a) and the bolt (1b) and remove the rod (1c).2. Undo the bolts (2a) and (2b), then remove the rigid power unit support (2c) complete with flexible mounting (2d). 1. Unscrew the connector (1a), disconnect the outlet hose from the power steering box (1b) and move aside.2. Undo the connector (2a) and disconnect the supply pipe from the pump to the power assisted steering box (2b), power assisted steering box side.3. Undo nut (3a) securing wiring/piping bracket (3b) to the power steering box. 1. Undo the bolts securing the power steering box to the front suspension crossmember. Connect the supply pipe between pump and power steering box to the bands on the power steering box.1. Release the supply pipe from pump to power steering box complete with bracket from the power steering pump. 1. Undo the front nuts securing the mounting for the gear and handbrake levers to the body.2. Recover the plates.3. Undo the front bolts securing the mounting for the gear and handbrake levers to the body. 1. Undo the nuts (1a) and disconnect the front anti-roll bar joints (1b) from the shock absorber fork. 1. Position a hydraulic jack complete with a suitable flange beneath the front suspension beam.2. Unscrew rear bolts (2a) and side bolts (2b) and lower the beam securing the front suspension to the body (2c) as much as necessary. 1. Remove the delivery pipe from pump to power steering box. Refitting ( Removing ) Refit in its seating the delivery pipe from pump to power steering box.1. Refit the front suspension beam (1a) using the hydraulic jack and secure by tightening side bolts (1b) and rear bolts (1c) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Side bolt	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 ÷ 13.2

	Fastening	Component	Ø	Value(daNm)
1c	Rear bolt	ENGINE OR ROD ANCHORAGE BEAM	M10	(Bodyshell side) 8.1 ÷ 9.9

	Fastening	Component	Ø	Value(daNm)
1c	Rear bolts	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 ÷ 13.2

2. Remove the hydraulic jack fitted with a suitable flange for supporting the front suspension crossmember. 1. Connect the front anti-roll bar joints (1a) to the shock absorber fork and tighten the relevant nuts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT ANTI-ROLL BAR JOINTS	M10	3.8 ÷ 4.7

Tighten the front bolts securing the gear and handbrake levers to the body.Refit the plates in their seats and tighten the front nuts securing the gear and handbrake lever mount to the body.Connect the supply pipe between pump and power steering box using the bands on the power steering box.1. Tighten the bolts securing the power steering box to the front suspension crossmember.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	POWER STEERING BOX	M14	(Front suspension crossmember side) 12.4 ÷ 13.7

Tighten the nut securing the wiring/pipe mounting bracket to the power steering box.1. Connect the supply pipe from pump to power steering box (1a), power steering box side, and tighten the connector (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Connector	PIPE BTWN PUMP + POWER STEERING BOX	M14	(Power steering box side) 3.8 - 4.2

2. Connect the outlet pipe from the pump to the power steering box (2a) and tighten the connector (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Connector	POWER STEERING BOX/EXCHANGE RIGID PIPE	M12	(Power steering box side) 2.8 - 3.2

1. Place the power unit rigid rear support (1a), complete with flexible mounting (1b) back in its housing and fasten it by tightening the bolts (1c) and (1d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	POWER UNIT RIGID REAR MOUNT	M12	(Gearbox side) 7.5 ÷ 9.2

	Fastening	Component	Ø	Value(daNm)
1d	Bolt	INTERM RUBBER MOUNT	M8	(Front suspension crossmember side) 2.7 ÷ 3.4

2. Refit the rod (2a) and tighten the nut (2b) and the bolt (2c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Nut	POWER UNIT RIGID REAR SUPPORT REINFORCEMENT ROD....	M12	2.7 ÷ 3.4

	Fastening	Component	Ø	Value(daNm)
2c	Bolt	POWER UNIT RIGID REAR SUPPORT REINFORCEMENT ROD....	M12	7.2 ÷ 9.2

Proceed with refitting  - 7055B54  under-engine guard - r r . Proceed with refitting  - 1076B50  exhaust pipe attachment to engine - r + r . Remove the safety tools used for supporting the power unit.Connect the supply pipe from the power assisted steering pump to the box, pump side and tighten the connector to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Connector	PIPE BTWN PUMP + POWER STEERING BOX	M16	(Power steering pump side) 3.8 ÷ 4.2

Connect the delivery and return pipes to the power steering reservoir and tighten the bands.Refit in its seating the power steering fluid reservoir and secure it with its bolts. Secure the delivery and return lines from the power steering reservoir using the connection band. Proceed with refitting  - 1008C16  body link bracket - r r . Proceed with refitting  - 1008C10  power unit upper reaction link r r . Secure the rigid return pipe to the coolant reservoir to the modular intake manifold.Place the fuel vapour recovery pipe in its seating, secure it with the band to the power steering fluid reservoir and connect the relevant quick-release fitting. Proceed with removal  - 1016A40  ignition coil cover on cylinder head- r+r . Proceed with removal  - 4450B12  front or rear wheels (two) - r+r . Fill the power steering circuit with the recommended fluid.

	Type	Component	Name	Qty.
-	Fluid	POWER ASSISTED STEERING CIRCUIT	TUTELA GI/A	-

Bleed the power steering system as described belowWith the front wheels raised off the ground, with the engine switched off turn the steering wheel to full lock, left and right, 4-5 times. Check and, if necessary, top up the fluid level in the reservoir. Remove the car from the ramps.Start the engine and carry out 4 - 5 full steering wheel turn cycles (right and left). Top up the fluid level in the reservoir. Removing ( Refitting ) Position the vehicle on the rampEnsure that the ignition key is in the OFF position, then disconnect the negative battery terminal (-).

	Name	Connector
-	Battery	A1B

Proceed with removal  - 4450B12  front or rear wheels (two) - r+r . Proceed with removal  - 1016A40  ignition coil cover on cylinder head- r+r . Drain the power steering fluid from the reservoir using a suitable syringe.1. Connect the quick-release attachment for the fuel vapour recovery pipe (1a) and move aside after releasing from band (1b) on the power assisted steering fluid reservoir. 2. Release the coolant return pipe to the coolant reservoir from the bands on the modular intake manifold. 1. Disconnect the electrical connection from the enablement solenoid of the changeover device actuator.

	Name	Connector
1	Variable geometry control solenoid	L15

2. Disconnect the vacuum intake pipe from the air flow switching device actuator and release it from the fastening. 3. Disconnect the linkage for the air flow switching control actuator. 4. Undo the bolts (4a) and remove the air flow switching control actuator (4b). Release the power steering fluid delivery and return pipes from the connection clip. 1. Undo the bolts (1a) and move the power assisted steering fluid reservoir (1b) aside. 2. Loosen the bands and disconnect the coolant supply and return pipes from the power steering fluid reservoir.3. Remove the power steering fluid reservoir. 1. Unscrew the connector and disconnect the delivery pipe from pump to power steering box, pump side. 1. Position a suitable bracket to support the power unit safely.2. Fit the tool (2a), complete with support blocks (2b) and connect to the bracket fitted previously using link (2c).

	Name	Country
2a	Crossmember	1.820.581.000

	Name	Country
2b	Support mountings	1.870.650.000

Drain the air conditioner coolant circuit  - 5040A10  Air conditioning refrigerant CIRCUIT - Draining and Refilling . Proceed with removal  - 7055B54  under-engine guard - r r . Proceed with removal  - 5040A20  air conditioner compressor - r+r - includes fluid level check and top up if necessary . Proceed with removal  - 5040A26  compressor mount - r r . Proceed with removal  - 1076A48  catalytic converter heat shield - r r . Proceed with removal  - 1080B62  catalytic converter - r + r . Proceed with removal  - 1008A44  rear rigid mount - r r . 1. Unscrew the connector (1a), disconnect the outlet hose from the power steering box (1b) and move aside.2. Undo the connector (2a) and disconnect the supply pipe from the pump to the power assisted steering box (2b), power assisted steering box side.3. Undo nut (3a) securing wiring/piping bracket (3b) to the power steering box. 1. Undo the bolts securing the power steering box to the front suspension crossmember. Connect the supply pipe between pump and power steering box to the bands on the power steering box.1. Release the supply pipe from pump to power steering box complete with bracket from the power steering pump. 1. Undo the front nuts securing the mounting for the gear and handbrake levers to the body.2. Recover the plates.3. Undo the front bolts securing the mounting for the gear and handbrake levers to the body. 1. Undo the nuts (1a) and disconnect the front anti-roll bar joints (1b) from the shock absorber fork. 1. Position a hydraulic jack fitted with a suitable support under the front suspension crossmember.2. Unscrew rear bolts (2a) and side bolts (2b) and lower the beam securing the front suspension to the body (2c) as much as necessary. 1. Remove the delivery pipe from pump to power steering box. Refitting ( Removing ) Refit in its seating the delivery pipe from pump to power steering box.1. Refit the front suspension beam (1a) using the hydraulic jack and secure by tightening side bolts (1b) and rear bolts (1c) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Side bolt	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 ÷ 13.2

	Fastening	Component	Ø	Value(daNm)
1c	Rear bolt	ENGINE OR ROD ANCHORAGE BEAM	M10	(Bodyshell side) 8.1 ÷ 9.9

	Fastening	Component	Ø	Value(daNm)
1c	Rear bolts	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 ÷ 13.2

2. Remove the hydraulic jack for supporting the front suspension crossmember. 1. Connect the front anti-roll bar joints (1a) to the shock absorber fork and tighten the relevant nuts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT ANTI-ROLL BAR JOINTS	M10	3.8 ÷ 4.7

Tighten the front bolts securing the gear and handbrake levers to the body.Refit the plates in their seats and tighten the front nuts securing the gear and handbrake lever mount to the body.Connect the supply pipe between pump and power steering box using the bands on the power steering box.1. Tighten the bolts securing the power steering box to the front suspension crossmember.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	POWER STEERING BOX	M14	(Front suspension crossmember side) 12.4 ÷ 13.7

Tighten the nut securing the wiring/pipe mounting bracket to the power steering box.1. Connect the supply pipe from pump to power steering box (1a), power steering box side, and tighten the connector (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Connector	PIPE BTWN PUMP + POWER STEERING BOX	M14	(Power steering box side) 3.8 - 4.2

2. Connect the outlet pipe from the pump to the power steering box (2a) and tighten the connector (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Connector	POWER STEERING BOX/EXCHANGE RIGID PIPE	M12	(Power steering box side) 2.8 - 3.2

Proceed with refitting  - 1008A44  rear rigid mount - r r . Proceed with refitting  - 1080B62  catalytic converter - r + r . Proceed with refitting  - 1076A48  catalytic converter heat shield - r r . Proceed with refitting  - 5040A26  compressor mount - r r . Proceed with refitting  - 5040A20  air conditioner compressor - r+r - includes fluid level check and top up if necessary . Proceed with refitting  - 7055B54  under-engine guard - r r . Remove the safety tools used for supporting the power unit.1. Connect the supply pipe from the power assisted steering pump to the box, pump side and tighten the connector to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Connector	PIPE BTWN PUMP + POWER STEERING BOX	M16	(Power steering pump side) 3.8 ÷ 4.2

Connect the delivery and return pipes to the power steering reservoir and tighten the bands.Refit in its seating the power steering fluid reservoir and secure it with its bolts. Fit the air flow switching device actuator in its seating and secure it using the bolts. Connect the linkage for the air flow switching control actuator. Connect the air flow switching control actuator vacuum intake pipe and secure it to the fastening.Connect the electrical connection from the enablement solenoid of the changeover device actuator.Secure the rigid return pipe to the coolant reservoir to the modular intake manifold.Place the fuel vapour recovery pipe in its seating, secure it with the band to the power steering fluid reservoir and connect the relevant quick-release fitting. Proceed with removal  - 1016A40  ignition coil cover on cylinder head- r+r . Proceed with removal  - 4450B12  front or rear wheels (two) - r+r . Connect the negative (-) battery terminal Fill the air conditioner coolant circuit  - 5040A10  Air conditioning refrigerant CIRCUIT - Draining and Refilling . Fill the power steering circuit with the recommended fluid.

	Type	Component	Name	Qty.
-	Fluid	HYDRAULIC POWER ASSISTED STEERING SYSTEM	TUTELA GI/A	1.3

Fluid for Northern European countries: TUTELA CAR GI/E - ATF DEXRON III.

Bleed the power steering system as described belowWith the front wheels raised off the ground, with the engine switched off turn the steering wheel to full lock, left and right, 4-5 times. Check and, if necessary, top up the fluid level in the reservoir. Remove the car from the ramps.Start the engine and carry out 4 - 5 full steering wheel turn cycles (right and left). Top up the fluid level in the reservoir.