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 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  - 7055B54  under-engine guard - r r . Proceed with the removal  - 1076B52  exhaust pipe (one) leaving l/h or r/h exhaust manifold - r + r (Right and left sides). 1. Undo nuts (1a) and remove the protective heat shield (1b) from the power steering box. 1. Undo the nut (1a) and disconnect the front anti-roll bar joints (1b) from the lower suspension forks. 1. Position a hydraulic jack under the differential.2. Undo the bolts (2a), (2b) and remove the power unit rigid rear mounting (2c) complete with flexible block (2d).3. Recover the rigid support for the exhaust pipe. 1. Undo the bolts (1a) and nuts (1b) of the gearlever and handbrake lever mount (1c).2. Undo the bolts securing the power steering box to the front suspension crossmember. 3. Position a hydraulic jack fitted with a suitable flange and secure it to the front suspension crossmember.4. Undo rear bolts (1a) and side bolts (4b) securing the front suspension crossmember (4c) to the body. 1. Release the power assisted steering system pipes from the band on the front suspension crossmember. Lower the front suspension beam using the hydraulic jack as necessary.1. Undo the connectors (1a) and disconnect the fluid inlet and outlet pipes from power steering box (1b). 1. Undo the nut (1a) fixing the gear selector and engagement cables mounting bracket (1b) to the power assisted steering box.2. Open the bands securing the supply pipe from the pump to power steering box, power steering box side. 1. Undo the bolts (1a) and nut (1b), then remove the power steering pipe rear mount (1c). 1. Undo the bolts (1a), then remove the power steering pipe front mount (1b). 1. Undo the fastenings and remove the left cylinder head exhaust manifold heat shield. 1. Undo the connector (1a) and disconnect the delivery pipe from pump to power steering box (1b), pump side, then remove. Refitting ( Removing ) Place the supply pipe from the pump to the power assisted steering box back in its housing, connect it to the pump and tighten the connector to the recommended torque.Place the heat shield for the left cylinder head exhaust manifold back in its housing and secure using the fastenings.Refit the power steering system pipe front support and secure with bolts.Refit the rear power steering system pipe mount and secure with the bolts and nut.Tighten the bands securing the supply pipe from the pump to power steering box, power steering box side.Tighten the nut securing the gear selector and engagement cables mounting bracket to the power assisted 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 rubber return hose from power steering box to rigid pipe (2a), power steering box side, and tighten the connector (2b) to the recommended torque.

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

Replace the front suspension crossmember using the hydraulic jack.Secure the power assisted steering system pipes using the band on the front suspension crossmember.1. Tighten the rear bolts (1a) and the side bolts (1b) fixing the front suspension crossmember to the bodyshell to the recommended torque.

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

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

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

2. Remove the hydraulic jack, complete with flange for supporting the front suspension crossmember.3. Tighten the bolts securing the power steering box to the front suspension crossmember to the specified torque.

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

4. Tighten the bolts (4a) and nuts (4b) of the gear and handbrake lever mount. 1. Position a hydraulic jack under the differential.2. Refit power unit rear mount (2a) complete with flexible block (2b) and rigid exhaust pipe mount (2c) and secure by tightening bolts (2d) and (2e) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2d	Bolt	POWER UNIT RIGID REAR MOUNT	M12	7.5 ÷ 9.2

	Fastening	Component	Ø	Value(daNm)
2e	Bolt	INTERM RUBBER MOUNT	M12	7.5 ÷ 9.2

1. Connect the front anti-roll bar joints (1a) to the lower suspension forks and tighten the relevant nut (1b) to the specified torque.

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

Refit the power steering box heat shield in its seat and tighten its nuts. Proceed with the refitting  - 1076B52  exhaust pipe (one) leaving l/h or r/h exhaust manifold - r + r (Right and left sides). Proceed with refitting  - 7055B54  under-engine guard - r r . Proceed with refitting  - 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.