Front Delivery Line, Power Steering

Front Delivery Line, Power Steering

Removal
1. Cars without water separator: Remove the grille.
2. Cars without water separator: Undo the air intake bolt and lift the air intake out from its mounting.





3. Raise the car.
4. Remove the forward engine cover.
Diesel: Remove the lower engine cover.
5. Remove the RH engine cover.
6. 4 cyl. petrol: Undo the 2 engine oil cooler bolts and let the cooler hang by its hoses.





7. Cars without water separator: Loosen the clamp holding the air intake hose to the air filter housing and remove the air intake.





8. Undo the nuts which hold the cooling loop to the radiator mount.
9. Remove the clamp from the front delivery line.
10. Place a bowl under the car to collect the power steering fluid. Separate the front and rear delivery pipes at the joint.
11. Lower the car.
12. 4 cyl. petrol: Undo the hose clip which retains the intake hose with the mass air flow sensor and bend the hose to one side.





13. 4 cyl petrol: Relieve the tension in the belt tensioner with tool 83 95 254.
Rotate the power steering pump pulley to gain access to the bolt and detach the front delivery line bracket. Remove the pipe from the pump.





14. 6 cyl. diesel: Undo the bolt which retains the delivery line bracket. Undo the clamp band from the bracket and undo the banjo nipple.





15. 4 cyl. diesel: Undo the banjo nipple on the delivery line from the power steering pump
16. Raise the car.
17. Angle the cooling loop downward on the front delivery line so that all of the front delivery line can be removed.

IMPORTANT: Always observe utmost cleanliness when working with hydraulic components.

Re-Assembly
1. Fit the front delivery line. The pipe must be inserted between the radiator member and the radiator, behind the cable for the A/C compressor.

IMPORTANT: The AC compressor cable can easily catch in the delivery pipe bracket





2. Remove the protection from the front pipe, join the pipes and tighten the coupling as much as possible by hand.
3. Check that the cooling loop is horizontal and tighten the coupling between the front and rear pipes.
4. Fit the rubber suspension onto the radiator unit mounting and then fit the delivery line onto the rubber suspension.





5. Fit the pipe to the clamp.
6. 4 cyl. petrol: Attach the engine oil cooler with 2 bolts.





7. Cars without water separator: Replace the air intake in the air filter housing and bend up the air intake in front of the radiator.





8. Cars without water separator: Tighten the hose clip on the lower air intake mounting on the air filter housing.
9. Wipe of any oil that has spilled onto the subframe.
10. Wipe off any oil from the air deflectors and fit the deflectors.
11. Lower the car.
12. Cars without water separator: Lift up and fit the air intake and tighten the bolt.





13. 4 cyl. petrol: Screw into place the bracket bolts before the delivery line to pump union is tightened. Screw in the delivery line pump union as far as possible by hand, in order to guide the pipe so as to not distort the bracket.
Tighten the delivery line union and the bracket bolts.

IMPORTANT: Make sure that the O-ring is fitted correctly.





14. 6 cyl. diesel: Screw into place the banjo nipple using new seals. Assemble the bolts and clamp band to the bracket.
Tighten the banjo nipple.
Tightening torque 30 Nm (22 ft. lbs.)





15. 4 cyl. diesel, 6 cyl. petrol: Fit the banjo nipple using new seals.
Tightening torque 30 Nm (22 ft. lbs.)
16. 4 cyl. petrol: Fit the intake hose onto the intake pipe of the turbo unit.





17. Cars without water separator: Fit the grille.
18. Fill the system with fluid.
19. Make sure that there are no leaks in the system.