Ford Fiesta (1989-1995). Manual — part 46

cylinder reservoir filler cap, then remove the
filler cap. Note that the filler cap must not be
inverted. Place a piece of plastic film over the
reservoir and seal it with an elastic band.
2 Raise the vehicle on ramps, or drive it over
an inspection pit, so that working clearance
may be obtained with the full weight of the
vehicle on its roadwheels.
3 Remove the spare wheel and its carrier for
access to the load-apportioning valves (see
illustration).
4 Disconnect the load-apportioning valve
operating links from the rear axle twist beam,
by undoing the nuts securing them.
5 Disconnect the rigid brake pipes from the
load-apportioning valves, and fit blanking plugs
to prevent dirt ingress. Make provision for
escaping fluid as the pipes are disconnected.

6 Remove the bolts securing the valve
assembly mounting bracket to the
vehicle body, then carefully lower from the
vehicle.
7 The valves can now be individually removed
from the mounting bracket, as required, by
undoing the fixings securing them from the
other side of the bracket.
8 Refitting is the reverse sequence to
removal, adjusting the load-apportioning
valves, as described in the previous Section,
before refitting the spare wheel. When fitting a
new valve, the plastic tie must be cut off
before attempting any adjustment, and the
setting tool must be used as described in the
previous Section.
9 Bleed the brake hydraulic system in
accordance with Section 14.

Braking system 9•17

26.3 General view of load-apportioning

valve arrangement (spare wheel and

carrier removed for access)

9

1595Ford Fiesta Remake

10

1595Ford Fiesta Remake

Wheel alignment and steering angles

Front wheel toe setting:

Pre-1990 models:

Tolerance allowed before resetting required . . . . . . . . . . . . . . . . .

3.0 mm toe-out to 3.0 mm toe-in (0°30’ toe-out to 0°30’ toe-in)

Adjustment setting (if required) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parallel ± 1.0 mm (0° ± 0°10’)

1990 models onward:

All models except Turbo:

Tolerance allowed before resetting required . . . . . . . . . . . . . . . .

4.5 mm toe-out to 0.5 mm toe-in (0°45’ toe-out to 0°05’ toe-in)

Adjustment setting (if required) . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 mm toe-out ± 1.0 mm (0°20’ toe-out ± 0°10’)

Turbo models:

Tolerance allowed before resetting required . . . . . . . . . . . . . . . .

4.0 mm toe-out to parallel (0°40’ toe-out to 0°0’)

Adjustment setting (if required) . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 mm toe-out ± 1.0 mm (0°20’ toe-out ± 0°10’)

Chapter 10
Suspension and steering

Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . .See Chapter 1
Front hub bearings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Front spindle carrier - removal and refitting . . . . . . . . . . . . . . . . . . .

2

Front suspension anti-roll bar - removal and refitting . . . . . . . . . . . .

6

Front suspension crossmember - removal and refitting . . . . . . . . . .

7

Front suspension lower arm - removal and refitting . . . . . . . . . . . . .

8

Front suspension strut - dismantling, examination and reassembly . .

5

Front suspension strut - removal and refitting . . . . . . . . . . . . . . . . .

4

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Power steering fluid cooler - removal and refitting . . . . . . . . . . . . . . 26
Power steering fluid level check . . . . . . . . . . . . .See “Weekly Checks”
Power steering hydraulic system - bleeding . . . . . . . . . . . . . . . . . . . 27
Power steering pump - removal and refitting . . . . . . . . . . . . . . . . . . 25
Rear axle (all models except Courier) - removal and refitting . . . . . . 12
Rear axle pivot bushes (all models except Courier) - renewal . . . . . 13
Rear hub bearings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Rear shock absorber (Courier models) - removal, examination

and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Rear strut (all models except Courier) - dismantling, examination

and reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Rear strut (all models except Courier) - removal and refitting . . . . . 10
Rear suspension anti-roll bar (all models except Courier) -

removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Rear suspension assembly (Courier models) - removal and refitting . . 17
Rear suspension components (Courier models) - general . . . . . . . . 15
Rear suspension ride height (Courier models) - adjustment . . . . . . . 18
Steering column (manual steering) - removal and refitting . . . . . . . . 20
Steering column (power steering) - removal and refitting . . . . . . . . . 21
Steering gear (manual steering) - removal and refitting . . . . . . . . . . 23
Steering gear (power steering) - removal and refitting . . . . . . . . . . . 24
Steering gear rubber gaiters - renewal . . . . . . . . . . . . . . . . . . . . . . . 22
Steering wheel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 19
Suspension and steering check . . . . . . . . . . . . . . . . . . .See Chapter 1
Track rod end balljoint - removal and refitting . . . . . . . . . . . . . . . . . 28
Tyre condition and pressure checks . . . . . . . . . .See “Weekly Checks”
Wheel alignment and steering angles - general information . . . . . . . 29

10•1

Specifications

Contents

Easy, suitable for
novice with little
experience

Fairly easy, suitable
for beginner with
some experience

Fairly difficult,
suitable for competent
DIY mechanic

Difficult, suitable for
experienced DIY
mechanic

Very difficult,
suitable for expert DIY
or professional

Degrees of difficulty

5

4

3

2

1

Roadwheels

Wheel types and sizes (dependent on model):

Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 x 4.5, 13 x 5, 13 x 5.5

Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 x 5.5, 14 x 5.5

Tyres

Tyre sizes (dependent on model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

135 R 13, 145 R 13, 155/70 R 13, 165/55 R 13, 165/65 R 13,
175/60 R 13, 185/55 R 14 or 185/60 R 13

Tyre pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See “Weekly Checks”

Torque wrench settings

Nm

lbf ft

Front suspension

Hub/driveshaft retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

205 to 235

151 to 173

Lower arm balljoint-to-spindle carrier pinch bolt . . . . . . . . . . . . . . . . . .

48 to 60

35 to 44

Front suspension strut to spindle carrier pinch-bolt . . . . . . . . . . . . . . .

80 to 90

59 to 66

Anti-roll bar link to front suspension strut nut . . . . . . . . . . . . . . . . . . . .

41 to 58

30 to 43

Anti-roll bar link to anti-roll bar nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 to 58

30 to 43

Anti-roll bar retaining clamp bolts to lower arm . . . . . . . . . . . . . . . . . . .

20 to 28

15 to 21

Front suspension strut top-mount retaining nut . . . . . . . . . . . . . . . . . . .

40 to 52

30 to 38

Front suspension strut spring retaining nut . . . . . . . . . . . . . . . . . . . . . .

52 to 65

38 to 48

Front suspension crossmember bolts (XR2i only) . . . . . . . . . . . . . . . . .

80 to 90

59 to 66

Lower arm to lower arm mounting bracket bolts (using torque-to-yield
method with vehicle standing on its wheels):

Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

37

Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Slacken completely

Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

37

Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tighten through a further 90°

Rear suspension (all models except Courier)

Rear hub bearing retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

250 to 290

184 to 214

Rear drum/hub to axle flange bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 to 76

41 to 56

Rear axle to body mounting bracket bolts . . . . . . . . . . . . . . . . . . . . . . .

41 to 58

30 to 43

Rear axle trailing arm bush bolt* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 to 79

43 to 58

Rear strut top-mount retaining nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 to 40

20 to 30

Rear strut-to-axle mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 to 138

75 to 102

Rear strut spring retaining through-bolt . . . . . . . . . . . . . . . . . . . . . . . . .

41 to 58

30 to 42

Anti-roll bar front mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 to 58

30 to 42

Anti-roll bar rear mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88 to 113

65 to 83

Load-apportioning valve operating link to axle beam . . . . . . . . . . . . . .

21 to 28

15 to 21

*Torque to be measured from the bolt head (not the nut)

Rear suspension (Courier models)

Rear hub bearing retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

250 to 290

184 to 214

Shock absorber upper mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 to 138

75 to 102

Shock absorber lower mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 to 97

52 to 72

Rear suspension mounting bracket bolts . . . . . . . . . . . . . . . . . . . . . . . .

70 to 97

52 to 72

Manual steering

Steering gear to bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 to 97

57 to 72

Track rod end balljoint to spindle carrier steering arm . . . . . . . . . . . . . .

25 to 30

18 to 22

Track rod locknut to track rod end balljoint . . . . . . . . . . . . . . . . . . . . . .

57 to 68

42 to 50

Steering wheel to column shaft bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 to 55

33 to 40

Steering column mounting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 to 14

7 to 10

Steering column universal joint pinch-bolt . . . . . . . . . . . . . . . . . . . . . . .

45 to 56

33 to 41

Power steering

Steering wheel to column shaft bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

37

Steering gear to bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84

62

Steering gear fluid pipe unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

23

Steering gear flexible coupling pinch-bolt . . . . . . . . . . . . . . . . . . . . . . .

51

38

Track rod end balljoint to spindle carrier steering arm . . . . . . . . . . . . . .

26

19

Track rod locknut to track rod end balljoint . . . . . . . . . . . . . . . . . . . . . .

63

46

Steering pump mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

18

Steering pump pulley bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

18

High pressure fluid pipe to pump union . . . . . . . . . . . . . . . . . . . . . . . . .

65

48

High pressure fluid pipe coupling joint . . . . . . . . . . . . . . . . . . . . . . . . . .

17

13

Steering column mounting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

9

Roadwheel nuts

All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 to 110

52 to 74

10•2 Suspension and steering

1595Ford Fiesta Remake

1

General information

The front suspension is of independent

type, achieved by the use of MacPherson
struts (see illustration). The struts, which
incorporate coil springs and integral shock
absorbers, are located at their upper
mountings by rubber insulators and secured
to the inner wing panels by cup seat
mountings and locknuts. The lower end of
each strut is bolted to the top of a cast spindle
carrier. The spindle carriers house non-
adjustable hub bearings as a variation of a
proven design. The lower mountings of the
spindle carriers are attached, via balljoints, to
a pressed-steel lower arm assembly. The
lower arm assembly consists of two sections.
The lower arm mounting bracket is bolted
securely to the underside of the vehicle, and
has a locating peg and unique outer fixing bolt
to ensure correct location. The A-shaped
lower arm is attached to its mounting bracket
by double vertical bushes and controls both
lateral and fore and aft movement of the front
wheels. The balljoints connecting the lower
mountings of the spindle carriers to the
lower arms are riveted to the lower arms, and
are not available as separate service items. An
anti-roll bar is fitted to high specification
models and, additionally on the XR2i, a front
suspension crossmember is fitted.

On all models except Courier, the rear

suspension is semi-independent, with an
inverted V-section beam welded between
tubular trailing arms (see illustration). This
inverted V-section beam allows a limited
torsional flexibility, giving each rear wheel a
certain degree of independent movement,
whilst maintaining optimum track and wheel
camber control. This type of arrangement is
called a “twist beam” rear axle. The axle is
attached to the body by rubber void bushes,
through brackets bolted to the underside of
the vehicle. Each bracket has a conical
locating peg to ensure accurate alignment of
the axle assembly. The rear suspension struts,
which are similar to the MacPherson struts
used at the front, are mounted at their upper
ends by nut and captive bolt fixings through
the suspension turrets in the luggage
compartment. At their lower ends, the struts
are attached, close to the wheels, by bolts
passed through the trailing arms and lower
strut integral bushes. The rear wheel
hub/brake drum unit and spindle on each side
form an assembly which can be unbolted from
the axle without disturbing the hub bearings.
An anti-roll bar is fitted to the rear suspension
on certain later models.

Courier models are fitted with a modified

version of the twist beam rear axle, using
linked torsion bars as springs and to provide
anti-roll stabilisation (see illustration).
Separate shock absorbers are fitted to control
suspension movement.

Suspension and steering 10•3

1.1 General view of front suspension components

1.3 General view of rear suspension components (Courier models)

1.2 General view of rear suspension components (all models except Courier)

10

1595Ford Fiesta Remake

A Anti-roll bar
B Anti-roll bar connecting link
C Anti-roll bar suspension strut bracket
D Anti-roll bar bush and clamp bracket
E Coil spring and suspension strut

assembly

F Spindle carrier
G Lower suspension arm
H Lower suspension arm mounting bracket
I

Front suspension (bracing) crossmember
(XR2i only)

A Twist beam rear axle
B Coil spring and

suspension strut
assembly

C Mounting bracket
D Void bush
E Brake drum, wheel

hub and spindle
assembly

A Pivot brackets
B Rear axle
C Rear (anti-roll) torsion bars
D Connecting link
E Front (spring) torsion bars