Ford Fiesta (1989-1995). Instruction - part 50

drive models, remove the brace from the stud
on the left-hand side of the steering gear.
9 Undo the two bolts securing the support
brackets to the steering gear and move the
brackets and swing the brackets clear.
10 Unhook the steering gear from the
apertures in the bulkhead and remove the
assembly from the right-hand wheel arch.
Ensure that the pressure check valve does not
fall out of the pressure port in the valve body
as the steering gear is removed.

Refitting

11 Centralize the steering gear and steering
wheel, then engage the pinion splined shaft to
the lower steering shaft flexible coupling.
12 Hook the steering gear into the apertures
in the bulkhead then align the support
brackets and refit the two bolts. Tighten the
support bracket upper bolts and support
bracket-to-steering gear bolts to the specified
torque.
13 On left-hand drive models, refit the brace
to the stud on the left-hand side of the
steering gear.
14 Fit new O-ring seals to the pressure and
return hoses, then reconnect the hydraulic
lines to the steering gear. Secure the pipes
with the retaining clips.
15 Refit the pinion splined shaft-to-lower
steering shaft flexible coupling pinch-bolt and
nut and tighten to the specified torque.
16 Refit the track rod end balljoints to the
steering arms, as detailed in Section 28. As
long as the track rod end-to-track rod relative
positions have not been disturbed, it will not
be necessary to reset the front wheel
alignment.
17 Refit the front suspension crossmember
and one-piece undertray, as applicable.
18 Refit the roadwheels, then lower the
vehicle to the ground. Tighten the roadwheel
nuts with the vehicle on its wheels to the
specified torque.
19 On completion, bleed the power steering
hydraulic system as described in Section 27.
Check for any signs of fluid leakage from the
system hoses and connections.

25 Power steering pump -

removal and refitting

4

Removal

HCS engine models

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and Vehicle Support”). Remove
the front roadwheel.
3 Remove the auxiliary drivebelt as described
in Chapter 1.
4 Insert a 9 mm Allen key into the centre of
the pump drive spindle to prevent it from

turning, then unscrew and remove the three
pump pulley retaining bolts. Withdraw the
pulley from the pump.
5 Position a suitable container beneath the
power steering pump, then unscrew and detach
the fluid high pressure pipe and fluid return
hose from the pump. As they are detached from
the pump, allow the fluid to drain from the pipe
and hose (and the pump) into the container.
Plug the exposed ends of the pipe, hose and
the pump connections, to prevent the ingress of
dirt and excessive fluid loss.
6 Unscrew the four retaining bolts (three from
the front and one from the rear) and withdraw
the pump from the vehicle.

PTE engine models

7 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
8 Refer to the relevant Part of Chapter 4 and
remove the air cleaner assembly and air inlet
components as necessary for access to the
pump.
9 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and Vehicle Support”). Remove
the front roadwheel.
10 Refer to Chapter 1 and drain the cooling
system.
11 Refer to Chapter 1 and remove the
auxiliary drivebelt.
12 Insert a 9 mm Allen key into the centre of
the pump drive spindle to prevent it from
turning, then unscrew and remove the three
pump pulley retaining bolts. Refit the
roadwheel, lower the vehicle and withdraw the
pump pulley from above.
13 Disconnect the cooling system hoses as
necessary to gain access to the power
steering pump.
14 Disconnect the pressure switch multi-plug
from the pressure switch located in the fluid
high pressure pipe.
15 Position a suitable container beneath the
power steering pump, then disconnect the
high pressure pipe at the union located part
way along the pipe. Allow the fluid to drain
from the pipe into the container.
16 Disconnect the high pressure pipe clamp
bracket and the fluid return hose from the
pump. Allow the fluid to drain into the
container then plug the exposed ends of the
pipe, hose and the pump connections, to
prevent the ingress of dirt and excessive fluid
loss.
17 Unscrew the pump mounting bolt located
at the rear of the pump and remove the pipe
clamp bracket.
18 Unscrew the three pump mounting bolts
located at the front of the pump and remove
the pump, complete with high pressure pipe,
from the vehicle.
19 If required, the high pressure pipe can be
removed from the pump after unscrewing the
union nut.

Zetec engine models

Note: For this operation, the engine will need
to be supported from above to allow removal

of the right-hand engine mounting, and also to
allow the vehicle to be raised for work
underneath, and lowered for work from above.
A proprietary engine support bar (or home-
made alternative) fitted in the front wing drain
channel each side is ideal for this purpose, but
care must be taken not to damage the wings
or their paintwork.
20 Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
21 Suitably support the right-hand side of the
engine (see the note at the beginning of this
sub-Section) so that all the load is removed
from the engine mounting.
22 Remove the right-hand engine mounting
as described in Chapter 2C.
23 Refer to Chapter 1 and drain the cooling
system.
24 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and Vehicle Support”). Remove
the front roadwheel.
25 Undo the retaining screws, and remove
the drivebelt lower guard from the underbody.
26 Refer to Chapter 11 and remove the wheel
arch liner.
27 Refer to Chapter 1 and remove the
auxiliary drivebelt.
28 Insert a 9 mm Allen key into the centre of
the pump drive spindle to prevent it from
turning, then unscrew and remove the three
pump pulley retaining bolts. Refit the
roadwheel, lower the vehicle and withdraw the
pump pulley from above.
29 Refer to Chapter 12 and remove the right-
hand headlight unit.
30 Refit the roadwheel and lower the vehicle
to the ground.
31 Position a suitable container beneath the
power steering fluid reservoir, then disconnect
the fluid return hose from the reservoir. Allow
the fluid to drain from the hose and reservoir
into the container.
32 Plug the exposed ends of the hose and
the reservoir, to prevent the ingress of dirt and
excessive fluid loss.
33 Remove the high pressure pipe clamp
brackets from the engine then disconnect the
high pressure pipe at the union located over
the camshaft cover. Place absorbent rags
under the union as it is disconnected to
collect any escaping fluid. Plug the
disconnected pipe ends to prevent the
ingress of dirt and excessive fluid loss.
34 Disconnect the cooling system hoses as
necessary to gain access to the power
steering pump.
35 Unscrew the two pump mounting bolts
located at the rear of the pump.
36 Unscrew the two pump mounting bolts
located at the front of the pump and remove
the pump, complete with high pressure pipe
and fluid return hose, upwards and out of the
engine compartment.
37 If required, the high pressure pipe and
fluid return hose can be removed from the
pump after unscrewing the union nut or
slackening the hose clip as applicable.

10•16 Suspension and steering

1595Ford Fiesta Remake

Refitting

All models

38 Refitting is a reversal of removal, bearing
in mind the following points:

a) Tighten all nuts and bolts to the specified

torque. Remove the plugs from the
disconnected pipes, hoses and unions
and ensure that the pipes are located
correctly so that they do not foul any
surrounding components.

b) Refit the auxiliary drivebelt as described in

Chapter 1.

c) Where drained, refill the cooling system

as described in Chapter 1.

d) Refit or reconnect any additional

components removed for access as
described in the relevant Sections and
Chapters of this instruction.

e) On completion, bleed the power steering

hydraulic system as described in Section
27. Check for any signs of fluid leakage
from the system hoses and connections.

26 Power steering fluid cooler -

removal and refitting

2

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Position a suitable container beneath the
power steering fluid cooler hose connections,
then disconnect the hoses at the quick-fit
couplings on the fluid cooler. Allow the fluid to
drain from the hose and reservoir into the
container.
3 Plug the exposed ends of the hose and the
reservoir, to prevent the ingress of dirt and
excessive fluid loss.
4 Refer to Chapter 11 and remove the bonnet
lock assembly and the front bumper.
5 Undo the bolts securing the cooler side
support bracket and the bonnet lock stay, and
remove the fluid cooler and bonnet lock stay
as an assembly.
6 Undo the two bolts and remove the stay
from the fluid cooler.

Refitting

7 Refitting is a reversal of removal. On
completion, bleed the power steering
hydraulic system as described in Section 27.

27 Power steering hydraulic

system - bleeding

2

1 Following any operation in which the power
steering fluid lines have been disconnected,
the power steering system must be bled to
remove any trapped air.
2 With the front wheel in the straight-ahead
position, check the power steering fluid level
in the reservoir and, if low, top-up with fresh

fluid to the “MAX” or “MAX COLD” level mark.
Pour the fluid slowly to prevent air bubbles
forming, and use only the specified fluid (refer
to “Lubricants, fluids and tyre pressures”).
3 Start the engine and allow it to idle. Check
the hoses and connections for leaks.
4 Stop the engine and recheck the fluid level.
Add more, if necessary, up to the “MAX” or
“MAX COLD” level mark.
5 Start the engine again, allow it to idle, then
bleed the system by slowly moving the
steering from lock-to-lock several times. This
should purge the system of all internal air.
However, if air remains in the system
(indicated by the steering operation being very
noisy), leave the vehicle overnight and repeat
the procedure again the next day.
6 If air still remains in the system, it may be
necessary to resort to the Ford method of
bleeding, which uses a vacuum pump and a
modified reservoir filler cap to which the pump
can be connected. Turn the steering to the
right until it is near the stop, then fit the
vacuum pump to the fluid reservoir, and apply
0.51 bars of vacuum. Maintain the vacuum for
a minimum of 5 minutes, then repeat 
the procedure with the steering turned to the
left.
7 Keep the fluid level topped-up throughout
the bleeding procedure; note that the fluid
temperature increases, the level will rise.
8 On completion, switch the engine off, and
return the wheels to the straight-ahead
position.

28 Track rod end balljoint -

removal and refitting

2

Removal

1 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and Vehicle Support”). Remove
the appropriate front roadwheel.
2 Using a suitable spanner, slacken the track
rod end balljoint locknut on the track rod by a
quarter of a turn only (see illustration). Hold

the balljoint stationary with another spanner
engaged with the flats at its inner end to
prevent it from turning.
3 Extract the split pin, then loosen off the
retaining nut. If the balljoint is to be renewed,
the nut can be fully removed. If the existing
balljoint is to be reconnected, the nut should
be slackened off a couple of turns only at first,
and left in position to protect the joint threads
as the joint is separated from the spindle
carrier. To release the tapered shank of the
joint from the spindle carrier, use a balljoint
separator tool as shown (see illustration). If
the joint is to be re-used, take care not to
damage the rubber dust cover when using a
separator tool.
4 Unscrew the balljoint from the track rod,
counting the number of turns necessary to
remove it.

Refitting

5 Screw the balljoint into the track rod the
number of turns noted during removal until the
balljoint just contacts the locknut. Now tighten
the locknut while holding the balljoint.
6 Engage the shank of the balljoint with the
spindle carrier arm, and refit the retaining nut.
Tighten the nut to the specified torque and
secure with a new split pin.
7 Refit the roadwheel, and lower the vehicle
to the ground.
8 Finally, have the front wheel toe setting
checked (see Section 29).

29 Wheel alignment and

steering angles - general
information

4

General

1 A car’s steering and suspension geometry
is defined in four basic settings - all angles
are expressed in degrees (toe settings are
also expressed as a measurement); the
relevant settings are camber, castor, steering
axis inclination, and toe-setting. With the
exception of front wheel toe-setting, none of
these settings are adjustable.

Suspension and steering  10•17

28.3  Balljoint separator tool in position.

Note that the nut should be left loosely in

position to protect the thread for re-use

28.2  Track rod end balljoint showing the

locknut (A) retaining flats (B) and the

balljoint-to-spindle carrier arm retaining

nut and split pin (C)

10

1595Ford Fiesta Remake

Front wheel toe setting -
checking and adjustment

2 Due to the special measuring equipment
necessary to accurately check the wheel
alignment, and the skill required to use it
properly, checking and adjustment is best left
to a Ford dealer or similar expert. Note that
most tyre-fitting shops now possess
sophisticated checking equipment. The
following is provided as a guide, should the
owner decide to carry out a DIY check.
3 The front wheel toe setting is checked by
measuring the distance between the front and
rear inside edges of the roadwheel rims.
Proprietary toe measurement gauges are
available from motor accessory shops.
Adjustment is made by screwing the track
rods in or out of their track rod end balljoints,
to alter the effective length of the track rod
assemblies.
4 For accurate checking, the vehicle must
be at the kerb weight, ie unladen and with a
full tank of fuel.
5 Before starting work, check the tyre
pressures and tread wear, the condition of the
hub bearings, the steering wheel free play,
and the condition of the front suspension
components (see Chapter 1). Correct any
faults found.
6 Park the vehicle on level ground, check that
the front roadwheels are in the straight-ahead
position, then rock the rear and front ends to

settle the suspension. Release the handbrake,
and roll the vehicle backwards 1 metre, then
forwards again, to relieve any stresses in the
steering and suspension components.
7 Measure the distance between the front
edges of the wheel rims and the rear edges of
the rims. Subtract the smallest measurement
from the largest, and check that the result is
within the specified range.
8 If adjustment is necessary, apply the
handbrake, then jack up the front of the
vehicle and support it securely on axle stands
(see “Jacking and Vehicle Support”). Turn the
steering wheel onto full-left lock, and record
the number of exposed threads on the right-
hand track rod. Now turn the steering onto
full-right lock, and record the number of
threads on the left-hand side. If there are the
same number of threads visible on both sides,
then subsequent adjustment should be made
equally on both sides. If there are more
threads visible on one side than the other, it
will be necessary to compensate for this
during adjustment. Note: It is most important
that after adjustment, the same number of
threads are visible on each track rod.
9 First clean the track rod end; if they are
corroded, apply penetrating fluid before
starting adjustment. Release the rubber gaiter
outboard clips (where necessary), and peel
back the gaiter; apply a smear of grease to
the inside of the gaiter, so that both are free,

and will not be twisted or strained as their
respective track rods are rotated.
10 Use a straight-edge and a scriber or
similar to mark the relationship of each track
rod to its track rod end balljoint, then, holding
each track rod in turn, unscrew its locknut
fully.
11 Alter the length of the track rods, bearing
in mind the note made in paragraph 8. Screw
them into or out of the track rod end balljoints,
rotating the track rods using a self-grip
wrench. Shortening the track rods (screwing
them into their track rod end balljoints) will
reduce toe-in/increase toe-out.
12 When the setting is correct, hold the track
rods and securely tighten the track rod end
balljoint locknuts. Count the exposed threads
to check the length of both track rods. If they
are not the same, then the adjustment has not
been made equally, and problems will be
encountered with tyre scrubbing in turns;
also, the steering wheel spokes will no longer
be horizontal when the wheels are in the
straight-ahead position.
13 If the track rod lengths are the same, lower
the vehicle to the ground and re-check the 
toe setting; re-adjust if necessary. When the
setting is correct, securely tighten the track rod
end balljoint locknuts. Ensure that the rubber
gaiters are seated correctly, and are not
twisted or strained, and secure them in position
with new retaining clips (where necessary).

10•18 Suspension and steering

1595Ford Fiesta Remake

11

1595Ford Fiesta Remake

Torque wrench settings

Nm

lbf ft

Front seat slide mechanism-to-floor mounting bolts  . . . . . . . . . . . . . . .

25 to 32

18 to 24

Rear seat backrest hinge to backrest . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 to 4.6

2.7 to 3.4

Rear seat backrest hinge to body  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 to 25

15 to 18

Rear seat belt anchors and stalks to body  . . . . . . . . . . . . . . . . . . . . . . .

25 to 45

18 to 34

Rear seat belt retractor assembly to body  . . . . . . . . . . . . . . . . . . . . . . .

25 to 45

18 to 34

Front seat belt stalks to floorpan  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 to 45

18 to 34

Front seat belt lower anchor bolt to body  . . . . . . . . . . . . . . . . . . . . . . .

25 to 45

18 to 34

Front seat belt lower anchor slide bar bolt to body  . . . . . . . . . . . . . . . .

25 to 45

18 to 34

Front seat belt retractor to B-pillar bolt  . . . . . . . . . . . . . . . . . . . . . . . . .

25 to 45

18 to 34

Front seat belt upper anchor bolt to B-pillar (non-adjustable type)  . . . .

25 to 45

18 to 34

Front seat belt upper anchor adjuster plate-to-B-pillar bolts . . . . . . . . .

19 to 28

14 to 22

Front seat belt upper anchor bolt to adjuster slide  . . . . . . . . . . . . . . . .

25 to 45

18 to 34

Bonnet hinge-to-bonnet bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5 to 12

6.5 to 9

Bonnet latch retaining bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 to 12

6 to 9

Tailgate hinge-to-tailgate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5 to 12

6.5 to 9

Tailgate latch retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 to 12

6 to 9

Rear door lower hinge cap bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5 to 12

6.5 to 9

Rear door latch retaining bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5 to 12

6.5 to 9

Front and rear bumper retaining nuts . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 to 12

6 to 9

Chapter 11
Bodywork and fittings

Body adhesive emblems - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Body trim mouldings - removal and refitting . . . . . . . . . . . . . . . . . . . 10
Bodywork, paint and exterior trim check  . . . . . . . . . . . .See Chapter 1
Bonnet - removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . .

6

Bonnet latch - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Bonnet release mechanism - removal and refitting  . . . . . . . . . . . . .

7

Bumper and rear quarter mouldings - renewal  . . . . . . . . . . . . . . . . . 17
Bumpers - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Centre console - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . 45
Door aperture weatherstrip - removal and refitting  . . . . . . . . . . . . . . 11
Door window glass - removal and refitting  . . . . . . . . . . . . . . . . . . . . 32
Door window regulator - removal and refitting  . . . . . . . . . . . . . . . . . 31
Door, tailgate and bonnet check and lubrication  . . . . . .See Chapter 1
Exterior mirror and glass - removal and refitting . . . . . . . . . . . . . . . . 18
Facia - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Front seat and slide assembly - removal and refitting  . . . . . . . . . . . 39
Full-length sunroof - general information  . . . . . . . . . . . . . . . . . . . . . 38
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Interior mirror - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . 19
Interior trim panels - removal and refitting  . . . . . . . . . . . . . . . . . . . . 42
Maintenance - bodywork and underframe  . . . . . . . . . . . . . . . . . . . .

2

Maintenance - upholstery and carpets  . . . . . . . . . . . . . . . . . . . . . . .

3

Major body damage - repair  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Minor body damage - repair  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Parcel shelf support/loudspeaker housing - removal and refitting  . . 43

Passenger grab handle - removal and refitting  . . . . . . . . . . . . . . . . . 44
Rear door inner trim panels (Courier models) - removal and refitting  . . 29
Rear door lock, catches and handles (Courier models) - 

removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Rear doors (Courier models) - removal and refitting  . . . . . . . . . . . . . 28
Rear seat - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Seat belt check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Seat belts - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Side door inner trim panel - removal and refitting . . . . . . . . . . . . . . . 21
Side door lock, lock cylinder and handles - removal and refitting  . . 22
Side doors - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Side window glass - removal and refitting  . . . . . . . . . . . . . . . . . . . . 33
Sill extension moulding - removal and refitting  . . . . . . . . . . . . . . . . . 12
Sunroof panel - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . 35
Sunroof panel seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Sunroof weatherseal - removal and refitting  . . . . . . . . . . . . . . . . . . . 37
Tailgate - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tailgate inner trim panel - removal and refitting  . . . . . . . . . . . . . . . . 26
Tailgate lock components - removal and refitting . . . . . . . . . . . . . . . 27
Tailgate spoiler - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . 25
Tailgate support strut - removal and refitting  . . . . . . . . . . . . . . . . . . 23
Wheelarch liners - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . 13
Wheelarch mouldings - removal and refitting  . . . . . . . . . . . . . . . . . . 14
Wind deflector/radiator grille slat - removal and refitting  . . . . . . . . . 15
Windscreen and tailgate window glass - removal and refitting  . . . . 34

11•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