Refit

Refit

1. Clean steering pump and mating faces.
2. Position steering pump and support bracket.
3. Fit but do not tighten long bolts, support bracket to steering pump.
4. Fit but do not tighten short bolt, support bracket to steering pump.
5. Align steering pump to coolant pump drive lugs.
6. Fit 2 short bolts and spacers, tighten long and short bolts to 25 Nm.
7. Clean steering pump pulley and mating faces.
8. Position pulley to steering pump, fit and tighten bolts to 25 Nm.
9. Connect feed hose to steering pump, tighten clip.
10. Connect high pressure hose to steering pump, use new sealing washers.
11. Fit high pressure hose banjo bolt and tighten to 20 Nm.
12. Position engine mounting bracket to engine, fit bolts and tighten to 55 Nm.
13. Position engine RH mounting to bracket, fit nut and tighten to 83 Nm.
14. Remove trolley jack.
15. Fit alternator, see ELECTRICAL – Repairs.
16. Turbo: Fit intercooler, see MODULAR ENGINE MANAGEMENT SYSTEM – MPi – Repairs.
17. Naturally aspirated: Fit air cleaner, see MODULAR ENGINE MANAGEMENT SYSTEM – MPi – Repairs.
18. Refill cooling system, see MAINTENANCE.
19. Remove stand(s) and lower vehicle.
20. Bleed power steering system.

POWER STEERING OIL COOLER – 1.4

Service Repair No. 57.15.11

Remove

1. Remove headlamp assembly, see ELECTRICAL – Repairs.

2. Mark position of bonnet catch and release bonnet release cable clip from bonnet platform support bracket.
3. Remove 3 bolts securing bonnet catch and move catch aside.

4. Slacken clips securing oil cooler hoses to reservoir and return pipe, disconnect hoses.
5. Remove 3 bolts securing oil cooler brackets and release cooler pipes from between bumper and bonnet platform support bracket.
6. Remove oil cooler and clips.

Refit

1. Remove plugs from new cooler and fit to old.
2. Position oil cooler.
3. Feed pipes down between bumper and bonnet locking platform support bracket and align pipe brackets.
4. Fit and tighten cooler support bolts to 9 Nm.
5. Fit hose clips and connect hoses, tighten hose clips.
6. Position and align bonnet catch, fit and tighten bolts to 9 Nm.
7. Secure bonnet release cable clip.