Front Delivery Line, Power Steering.: Re-assembly

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

Fig 1: Illustration For Step 1
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Remove the protection from the front pipe, join the pipes and tighten the coupling as much as possible by hand.
Check that the cooling loop is horizontal and tighten the coupling between the front and rear pipes.
Fit the rubber suspension onto the radiator unit mounting and then fit the delivery line onto the rubber suspension.

Fig 2: Illustration For Steps 3-5
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Fit the pipe to the clamp.
4 cyl. petrol: Attach the engine oil cooler with 2 bolts.

Fig 3: Illustration For Step 6
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Cars without water separator: Replace the air intake in the air filter housing and bend up the air intake in front of the radiator.

Fig 4: Illustration For Steps 7-8
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Cars without water separator: Tighten the hose clip on the lower air intake mounting on the air filter housing.
Wipe of any oil that has spilled onto the subframe.
Wipe off any oil from the air deflectors and fit the deflectors.
Lower the car.
Cars without water separator: Lift up and fit the air intake and tighten the bolt.

Fig 5: Illustration For Step 12
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4-cylinder petrol:

Fig 6: Illustration For Step 13
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IMPORTANT: Make sure that the O-ring is fitted correctly.

? Insert the delivery line into the power steering pump as far as possible by hand to give it some support.

? Mount the bolt in the bracket.

? Tighten the delivery line.

? Tighten the bolt on the bracket.
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 lbf ft)

Fig 7: Illustration For Step 14
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4 cyl. diesel, 6 cyl. petrol: Fit the banjo nipple using new seals.
Tightening torque 30 Nm (22 lbf ft)
4 cyl. petrol: Fit the intake hose onto the intake pipe of the turbo unit.

Fig 8: Illustration For Step 16
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Cars without water separator: Fit the grille.
Fill the system with fluid. Refer to BLEEDING THE POWER STEERING SYSTEM .
Make sure that there are no leaks in the system.