1989 FORD FIESTA wheel bolts

9Detach the automatic brake adjuster
cam in a similar manner to that described
in the previous paragraph, noting its
orientation.
10 Clean the adjuster strut and its associated
components.
11 Clean the backplate, then apply a little
high-melting-point grease to the shoe contact
points on the backplate and the lower anchor
plate (see illustration) . On models so
equipped, refit the anti-rattle shims to the
brake shoe lower pivot on the backplate
ensuring that they are securely located.
12 Fit the handbrake operating lever to the
trailing shoe, using a new spring clip.
13 Fit the automatic brake adjuster cam to
the leading shoe, using a new spring clip.
14 Apply a small amount of high-melting-
point grease to the automatic brake adjuster
cam and pawl contact faces, and where
the cam and handbrake operating lever
sweep across their respective brake shoes.
Do not over-apply, as this may result in lining
contamination in use - a thin smear will
suffice. Take care not to allow any grease to
contact the brake linings.
15 Fit the adjuster strut to the trailing shoe,
securing with its spring, then connect the free
end of the strut to the automatic brake
adjuster cam. Fit the upper pull-off spring
between the tops of the two brake shoes.
16 Reconnect the handbrake cable to its
operating lever.
17 Position the brake shoes onto the
backplate so that their upper leading edges
rest against the wheel cylinder pistons, and
their lower leading edges engage either side
of the lower pivot. Fit the lower pull-off spring
into its locating slots at the bottom end of
each brake shoe.
18 Insert the brake shoe locking pins through
the rear of the backplate, then relocate the
springs and cups. Depress and turn the cups
through 90° to secure.
19 Check that the brake shoes and their
associated components are correctly refitted,
then refit the brake drum with reference to
Section 5.
20 Repeat the procedure on the remaining
rear brake.
7 Rear wheel cylinder -
removal, overhaul and refitting
3
Note: Before starting work, refer to the
warning at the beginning of Section 13
concerning the dangers of hydraulic fluid.
Removal
1 Remove the brake drum as described in
Section 5.
2 Using a suitable hose clamp, isolate the
relevant rear brake unit by clamping its
flexible brake hose.
3 Disconnect the brake pipe at the wheel
cylinder union, and fit a blanking plug to the
brake pipe to prevent dirt ingress.
4 On all models except Courier, drill out the
pop-rivets securing the brake backplate to the
axle flange, and withdraw the backplate
assembly with the brake shoes in situ. Note
that it is not possible to remove the backplate
completely as the handbrake cable will still be
attached to the brake shoes.
5 Expand the brake shoes by pulling their
tops away from the wheel cylinder. The
automatic brake adjuster will hold the shoes
clear of the wheel cylinder for ease of
removal.
6 Remove the single bolt securing the wheel
cylinder to the brake backplate, and withdraw
the wheel cylinder (see illustration).
Overhaul
7Clean any heavy dirt or grease deposits
from the external surfaces of the wheel
cylinder, then pull off the dust-excluding
covers (see illustration) .
8 The pistons and seals will probably shake
out. If they do not, apply air pressure from a
foot-operated tyre pump to the brake pipe
connection to eject them.
9 Examine the surfaces of the pistons and the
cylinder bores for scoring or signs of metal-to-
metal rubbing. If evident, renew the complete
cylinder assembly.
10 If the cylinder is to be renewed, note that three sizes are used across the Fiesta range,
dependent on specification. Ensure that the
new cylinder obtained is of the correct size to
maintain the rear braking balance.
11
Where the pistons and cylinder bores are
in good condition, discard the rubber
seals and dust excluders and obtain a repair
kit.
12 Any cleaning of the components should
be done using clean hydraulic fluid or
methylated spirit - nothing else.
13 Reassemble by dipping the first piston in
clean hydraulic fluid, then manipulate its seal
into position using fingers only. Ensure that
the seal is fitted correctly with its raised lip
facing away from the brake shoe bearing face
of the piston.
14 Insert the first piston into the wheel
cylinder from the opposite end of the cylinder
body. With it located in position, fit a dust-
excluding cover to it.
15 Fit the seal to the second piston, as
described in paragraph 13, then insert the
spring to the wheel cylinder, followed by the
second piston. Take care not to damage the
lip of the seal when fitting to the wheel
cylinder - additional lubrication with clean
hydraulic fluid and a slight twisting action
may help. Once again, only fingers should be
used.
16 Fit the dust excluding cover to the second
piston.
Refitting
17 Refitting is the reverse sequence to
removal. When refitting the backplate, locate
it in position and temporarily insert the
hub/drum retaining bolts to ensure correct
alignment. Now secure the brake backplate
using new pop rivets. Release the automatic
brake adjuster so that the brake shoes are
brought into contact with the wheel cylinder,
before refitting the hub/drum assembly as
described in Section 5.
18 On completion, bleed the brake hydraulic
system as described in Section 13 or 14 (as
applicable).
9•6 Braking system
7 .7 Exploded view of rear wheel cylinder
components
A Dust cap E Piston
B Bleed screw F Seal
C Wheel cylinder G Spring
D Dust-excluding cover7.6 Rear view of brake backplate
A Wheel cylinder-to-brake backplate retaining bolt
B Wheel cylinder brake pipe connection
C Bleed screw
6.11 Brake shoe contact points on brake backplate (arrowed)
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8 Rear brake backplate-
removal and refitting
3
Removal
1 Remove the brake drum/hub assembly as
described in Section 5.
2 Remove the rear brake shoes as described
in Section 6.
3 Compress the three retaining lugs, and
release the handbrake cable from the
backplate by pushing it back through the
plate (see illustration) .
4 Using a suitable hose clamp, isolate the
relevant rear brake unit by clamping its
flexible brake hose.
5 Disconnect the brake pipe at the wheel
cylinder union, and fit blanking plugs to
prevent dirt ingress.
6 Drill out the pop-rivets securing the
backplate to the rear axle, and remove the
backplate (see illustration) .
7 Remove the single bolt securing the wheel
cylinder to the brake carrier plate, and
withdraw the wheel cylinder.
8 If required, remove the handbrake
adjustment plunger from the backplate by
gently prising the spring off, over the plunger
abutment, then withdraw the plunger from the
brake shoe side (see illustration) . Remove the
plunger collar from the rear of the backplate.
Refitting
9 Locate the wheel cylinder in positionand
securely tighten the retaining bolt. 10
If removed, refit the handbrake
adjustment plunger to the backplate.
11 Place the backplate in position and
temporarily insert the hub/drum retaining
bolts to ensure correct alignment. Now secure
the brake backplate using new pop rivets
12 Refit the handbrake cable, and ensure
that the retaining lugs are secure.
13 Connect the brake pipe to the wheel
cylinder and remove the brake hose clamp.
14 Refit the rear brake shoes as described in
Section 6.
15 Refit the brake drum/hub as described in
Section 5.
16 On completion, bleed the brake hydraulic
system as described in Section 13 or 14 (as
applicable).
9 Master cylinder - removal,
overhaul and refitting
3
Note: Before starting work, refer to the
warning at the beginning of Section 13
concerning the dangers of hydraulic fluid.
Removal
1 Disconnect the wiring multi-plug from the
fluid level warning indicator in the reservoir
filler cap, then remove the filler cap from the
reservoir. Note that the filler cap must not be
inverted. The brake fluid should now be
removed from the reservoir.
2 Identify each brake pipe and its connection
to the master cylinder. Unscrew the fluid pipe to master cylinder union nuts and disconnect
the pipes. On models equipped with anti-lock
brakes, disconnect the modulator return
hoses from the brake fluid reservoir, collecting
fluid spillage from the hoses in a suitable tray
(see illustration)
. The modulator return hose
unions should be disconnected by first
pushing the hose into the reservoir, then
retaining the collar against the reservoir body
whilst withdrawing the hose. Note that the
modulator return hoses are colour coded - the
left-hand modulator has a black return hose
and connector, and should be fitted to the
forward section of the reservoir, whilst the
right-hand modulator has a grey return hose
and connector, and should be fitted to the
rear section of the reservoir.
3 Unscrew the mounting nuts and withdraw
the master cylinder from the servo unit.
Overhaul
4 With the master cylinder removed, empty
any remaining fluid from it, and clean it
externally.
5 Withdraw the brake fluid reservoir from the
top of the master cylinder by pulling and
rocking it free from its retaining seals (see
illustration) .
6 Extract the reservoir seals from the top face
of the master cylinder (see illustration).
Braking system 9•7
8.8 Handbrake adjustment plunger
A Plunger B Spring C Collar8.6 Drilling out a pop-rivet securing the brake backplate to the axle flange8.3 Compress the retaining lugs (arrowed),and release the handbrake cable from the backplate
9.5 Removing the brake fluid reservoirfrom its seals in the master cylinder
9.2 Modulator return hose connections at the brake fluid reservoir
A Return hoses B Collars
9
1595Ford Fiesta Remake 9.6 Brake fluid reservoir seal
An ideal way to remove fluid
from the master cylinder
reservoir is to use a clean
syringe or an old poultry
baster.
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location. Slacken the other two nuts or
remove them, as necessary.
6Remove the four nuts securing the servo
unit to its mounting bracket assembly, then
pull the servo forward to remove the inner
servo support bracket (see illustration).
7 Remove the spring clip and clevis pin
securing the servo pushrod to the cross link,
then lift out the servo unit (see illustration).
8 Note that the servo unit cannot be
dismantled for repair or overhaul and, if faulty,
must be renewed.
Refitting
9 Refitting is a reversal of removal. Refer to
Section 9 for details of refitting the master
cylinder.
16 Vacuum servo unit vacuum
hose and non-return valve -
removal, testing and refitting
1
Removal
1 Depress the brake pedal three or four times
to exhaust any remaining vacuum from the
servo unit.
2 Carefully pull free and detach the servo
vacuum hose from the servo unit. If the hose
is reluctant to move, prise it free with the aid
of a screwdriver, inserting its blade under the
flange of the elbow.
3 Detach the vacuum hose from its inlet
manifold connection. Depending on the fixing,
undo the union nut and withdraw the hose, or
press the hose and its retaining collar
inwards, then holding the collar in, withdraw
the hose.
4 If the hose or the fixings are damaged or in
poor condition, they must be renewed.
Non-return valve testing
5 Examine the non-return valve for damage
and signs of deterioration, and renew it if
necessary. The valve may be tested by
blowing through its connecting hoses in
both directions. It should only be possible
to blow from the servo end to the manifold
end.
Refitting
6 Refitting is a reversal of removal. If fitting a
new non-return valve, ensure that it is fitted
the correct way round.
17 Handbrake lever -
removal and refitting
1
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1), then chock
the wheels to secure the vehicle.
2 Undo the bolts securing the front seats to
the floorpan, and remove both seats from the
vehicle (see Chapter 11). Move the seats on
their slide mechanisms to expose the
mounting bolts, as necessary.
3 Remove the screws securing the rear seat
cushion, then raise the cushion to obtain
access to the carpet retaining screws.
Remove the carpet retaining screws.
4 Undo the bolt securing the seat belt clips to
the centre of the floorpan, then remove the
clip assembly.
5 Remove the seat belt lower anchor bracket
bolt from its location at the base of the B-pillar
behind the driver’s seat.
6 Remove the screws securing the sill scuff
plate to the driver’s side of the vehicle, then
carefully pull the sill scuff plate away from its
location so that the carpet is released. 7
Fold the carpet forwards, at the same time
carefully easing it out from under the sill scuff
plate. Lift the carpet over the handbrake lever.
8 Lift out the noise insulation for access to
the lever mounting bolts and the primary
cable fixing.
9 Fully release the handbrake lever, then
remove the handbrake primary cable clevis
pin securing clip (see illustration).
Remove the clevis pin and withdraw the
primary cable from the handbrake lever
assembly.
10 Remove the cover (see illustration), then
disconnect the handbrake warning light
switch wiring connection, and undo the two
screws securing the switch to the handbrake
lever assembly.
11 Undo the handbrake lever mounting bolts,
then withdraw the handbrake lever assembly
from the vehicle.
Refitting
12 Refitting is the reverse procedure to
removal, ensuring that the handbrake warning
light wiring is routed away from the lever
ratchet. The loom should be secured to the
floorpan with tape.
13 Check the handbrake adjustment as
described in Chapter 1 to complete.
18 Handbrake primary cable -
removal and refitting
1
Removal
1 Release the primary cable from the
handbrake lever, as described in the previous
Section.
2 Chock the front wheels then jack up the
rear of the car and support it on axle stands
(see “Jacking and Vehicle Support” ).
3 Where applicable, detach the exhaust
system and remove the heat shields from the
underside floorpan to allow access to the
primary cable connections underneath the
vehicle (see Chapter 4E).
4 Release the spring clip securing the pin,
and extract the equaliser/cable pin. Detach
9•12 Braking system
17.10 Removing the cover from the
handbrake warning light switch17.9 Removing the handbrake primary cable clevis pin securing clip
15.7 Spring clip (A) and clevis pin (B)
securing servo pushrod to the cross link15.6 Nuts securing servo unit to its
mounting bracket assembly (arrowed)
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needed not to spill the fluid onto the hands -
wear suitable protective gloves. Plug or cap
the disconnected pipes and valve openings,
to prevent dirt ingress and further fluid loss.
4Unbolt the valve from its mounting bracket,
unhook the linkage from the rear axle, then
withdraw the valve (see illustration). The
intermediate bracket may be unbolted if
required.
Refitting
5 Refitting is the reverse of the removal
procedure; adjust the valve as described in
Section 22, then bleed the complete hydraulic
system as described in Section 13. Check the
operation of the brakes before taking the
vehicle out on the road.
22 Light-laden valve (Courier models) - adjustment
2
Note:To adjust the valve accurately, the
vehicle must be at a known rear axle loading -
owners who cannot determine the loading
with sufficient accuracy must have this check
made by a Ford dealer or similar expert.
1 For this operation, the vehicle must be
raised for access underneath at the rear, but
must be standing on its wheels. Suitable
ramps (or an inspection pit) will therefore be
required. If positioning the vehicle on a pair of
ramps, chock the front roadwheels.
2 Measure the distance between the inner
radius of the linkage’s hooked end and the
first shoulder (see illustration) . If the
dimension is not as specified for the axle
loading, adjustment is required.
3 To adjust the setting, slacken the locknut
on the valve linkage, move the rod until the
setting is correct, then tighten the locknut
securely (see illustration) . Check the
operation of the brakes before taking the
vehicle out on the road.
23 Anti-lock braking system (ABS) - general information
A mechanically-driven, two-channel anti-
lock braking system is available as a factory-
fitted option on certain model variants within
the Fiesta range.
The system comprises four main
components; two modulators, one for each
brake circuit, and two rear axle load-
apportioning valves, again, one for each brake
circuit. Apart from the additional hydraulic
piping, the remainder of the braking system is
the same as for conventional models. The modulators are located in the engine
compartment with one mounted on each side
of the transmission, directly above the
driveshaft inner constant velocity joints. Each
modulator contains a shaft which actuates a
flywheel by means of a ball and ramp clutch. A rubber toothed belt is used to drive the
modulator shaft from the driveshaft inner
constant velocity joint.
During driving and under normal braking
the modulator shaft and the flywheel rotate
together and at the same speed through the
engagement of a ball and ramp clutch. In this
condition hydraulic pressure from the master
cylinder passes to the modulators and then to
each brake in the conventional way. In the
event of a front wheel locking the modulator
shaft rotation will be less than that of the
flywheel and the flywheel will overrun the ball
and ramp clutch. This causes the flywheel to
slide on the modulator shaft, move inward and
operate a lever which in turn opens a dump
valve. Hydraulic pressure to the locked brake
is released via a de-boost piston allowing the
wheel to once again revolve. Fluid passed
through the dump valve is returned to the
master cylinder reservoir via the modulator
return hoses. At the same time hydraulic
pressure from the master cylinder causes a
pump piston to contact an eccentric cam on
the modulator shaft. The flywheel is then
decelerated at a controlled rate by the
flywheel friction clutch. When the speed of the
modulator shaft and flywheel are once again
equal the dump valve closes and the cycle
repeats. This complete operation takes place
many times a second until the vehicle stops or
the brakes are released. The load-apportioning valves are mounted
on a common bracket attached to the rear
body, just above the rear axle twist beam
location, and are actuated by linkages
attached to the axle beam. The valves
regulate hydraulic pressure to the rear brakes,
in accordance with vehicle load and attitude,
so that the braking force available at the rear
brakes will always be lower than that available
at the front. A belt-break warning switch is fitted to the
cover which surrounds each modulator
drivebelt. The switch contains an arm which is
in contact with the drivebelt at all times. If the
belt should break, or if the adjustment of
the belt is too slack, the arm will move out
closing the switch contacts and informing the
driver via an instrument panel warning light.
24 Anti-lock braking system (ABS) components - removal
and refitting
3
Modulator
Note: Before starting work, refer to the
warning at the beginning of Section 13
concerning the dangers of hydraulic fluid.
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Minimise hydraulic fluid loss by
disconnecting the wiring multi-plug from the
fluid level warning indicator in the master
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.
3 Disconnect the modulator return hoses
from the master cylinder reservoir, collecting
any fluid spillage from the hoses in a suitable
tray. The modulator return hose unions should
be disconnected by first pushing the hose
into the reservoir, then retaining the collar
against the reservoir body whilst withdrawing
the hose. Note that the hoses are colour
coded - the left-hand modulator has a black
return hose and connector, and should be
fitted to the forward section of the reservoir,
whilst the right-hand modulator has a grey
return hose and connector, and should be
fitted to the rear section of the reservoir.
9•14 Braking system
22.3 Light-laden valve linkage adjustment locknut (arrowed)
22.2 Light-laden valve adjustment details
With rear axle load at 400 kg, “X” should be 147 mm
With rear axle load at 850 kg,
“X” should be 166 mm
21.4 Light-laden valve mounting bolts (arrowed)
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Right-hand side
4Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and Vehicle Support” ).
5 Remove the one-piece undertray where
fitted, by turning the bayonet type fasteners,
and on XR2i models, remove the front
suspension crossmember (see Chapter 10).
6 From underneath, remove the belt-break
switch from the right-hand drivebelt cover by
squeezing its release lever towards the main
body of the switch (see illustration), then
carefully withdraw, ensuring that the belt
contact arm does not catch on the drivebelt
cover.
7 Remove the two bolts securing the
modulator drivebelt cover to the modulator
mounting bracket, and withdraw the cover
(see illustration) .
8 Disconnect the rigid brake pipes from the
modulator, fitting blanking plugs to prevent
excessive fluid loss and dirt ingress.
9 Remove the modulator pivot bolt and
adjuster bolt (see illustration) , then slip the
drivebelt from its pulley, and withdraw the
modulator unit from the vehicle. Ensure that
the modulator return hose does not become
kinked as the modulator unit is withdrawn.
10 Disconnect the modulator return hose
from the modulator unit, and fit a blanking
plug to prevent dirt ingress. Allow for residual
fluid spillage as the hose is disconnected.
11 If a new modulator is to be fitted, note that
these units are not interchangeable from side
to side, and the correct replacement must be
obtained. The modulator units are colour-
coded, and must be fitted with the arrows on
top of the casings pointing towards the front
of the vehicle.
12 To refit, first connect the modulator return
hose to the return outlet on the modulator
unit.
13 Locate the modulator unit to its bracket
and fit the pivot bolt, having applied a thin
smear of anti-seize compound to the bolt, but
do not fully tighten at this stage. Take care not
to damage the modulator return hose as it is
manoeuvred into position.
14 Fit the drivebelt to its modulator pulley
location, ensuring that it sits correctly over the driveshaft pulley, then refit the adjuster bolt
but do not fully tighten at this stage.
15
Adjust the tension of the drivebelt by
moving the modulator unit, until a belt
deflection of 5.0 mm is obtained under firm
finger pressure. Check this using a ruler at a
point midway between the two pulleys.
16 With the drivebelt tensioned correctly,
tighten the pivot and adjuster bolts to the
specified torque. Re-check the tension of the
drivebelt after tightening the bolts.
17 Reconnect the rigid brake pipes to the
modulator, tightening the unions securely.
18 Refit the modulator drivebelt cover to the
modulator mounting bracket, and secure with
its two retaining bolts.
19 Refit the belt-break switch to the
modulator drivebelt cover, taking care not to
damage the belt contact arm as it passes
through the cover.
20 Reconnect the modulator return hose by
pushing the hose firmly into its brake fluid
reservoir location, then lever out the collar to
retain it.
21 Refit the front suspension crossmember
and the one-piece undertray, as applicable.
22 Lower the vehicle to the ground.
23 Top-up the brake fluid reservoir using
fresh fluid of the specified type (see “ Weekly
checks ”), then bleed the brake hydraulic
system in accordance with Section 14. Refit
the reservoir filler cap and warning indicator
wiring multi-plug on completion.
24 Reconnect the battery negative lead.
Left-hand side
25Repeat the procedures given in
paragraphs 1 to 3.
26 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 roadwheels.
27 Remove the one-piece undertray where
fitted, by turning the bayonet type fasteners,
and on XR2i models, remove the front
suspension crossmember (see Chapter 10).
28 Remove the belt-break switch from the
left-hand drivebelt cover in a similar manner to
that described in paragraph 6, this time from
the engine compartment. 29
Remove the two bolts securing the
modulator drivebelt cover to the modulator
mounting bracket, then ease the lower portion
of the cover over the driveshaft taking care
not to damage the driveshaft CV joint gaiter.
Withdraw the cover through the engine
compartment, manoeuvring it to clear
obstructions.
30 Disconnect the rigid brake pipes from the
modulator, fitting blanking plugs to prevent
excessive fluid loss and dirt ingress.
31 Slacken the modulator pivot and adjuster
bolts, then swing the modulator downwards
to release the drivebelt tension before slipping
the drivebelt from its modulator pulley
location.
32 Remove the modulator pivot and adjuster
bolts, withdraw the modulator upwards
through the engine compartment. Ensure that
the modulator return hose does not become
kinked as the modulator unit is withdrawn.
33 Disconnect the modulator return hose
from the modulator unit, and fit a blanking
plug to prevent dirt ingress. Allow for residual
fluid spillage as the hose is disconnected.
34 If a new modulator is to be fitted, note that
these units are not interchangeable from side
to side, and the correct replacement must be
obtained. The modulator units are colour-
coded, and must be fitted with the arrows on
top of the casings pointing towards the front
of the vehicle.
35 To refit, first connect the modulator return
hose to the return outlet on the modulator
unit.
36 Locate the modulator unit to its mounting
bracket and fit the pivot bolt, having applied a
thin smear of anti-seize compound to the bolt,
but do not fully tighten at this stage. Take care
not to damage the modulator return hose as it
is manoeuvred into position.
37 Fit the drivebelt to its modulator pulley
location, ensuring that it sits correctly over the
driveshaft pulley, then refit the adjuster bolt
but do not fully tighten at this stage.
38 Adjust the tension of the drivebelt by
moving the modulator unit, until a belt
deflection of 5.0 mm is obtained under firm
finger pressure. Check this using a ruler at a
point midway between the two pulleys.
Braking system 9•15
24.9 Modulator pivot bolt (A) and adjuster bolt (B)24.7 Modulator drivebelt cover to
mounting bracket securing bolts (arrowed)24.6 Belt-break switch in drivebelt cover
A Main switch body B Release lever
9
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39With the drivebelt tensioned correctly,
tighten the pivot and adjuster bolts to the
specified torque. Re-check the tension of the
drivebelt after tightening the bolts.
40 Reconnect the rigid brake pipes to the
modulator, tightening the unions to seal the
system.
41 Refit the modulator drivebelt cover and
secure with its two retaining bolts. Take care
not to damage the driveshaft CV joint gaiter as
the cover is eased into position.
42 Refit the belt-break switch to the
modulator drivebelt cover, taking care not to
damage the belt contact arm as it passes
through the cover.
43 Reconnect the modulator return hose by
pushing the hose firmly into its brake fluid
reservoir location, then lever out the collar to
retain it.
44 Refit the front suspension crossmember
and the one-piece undertray, as applicable.
45 Refit the roadwheels, then remove the
axle stands and lower the vehicle to the
ground. Tighten the wheel nuts to the
specified torque.
46 Top-up the brake fluid reservoir using
fresh fluid of the specified type (see “ Weekly
checks ”), then bleed the brake hydraulic
system in accordance with Section 14. Refit
the reservoir filler cap and the warning
indicator wiring multi-plug on completion.
47 Reconnect the battery negative lead.
Modulator drivebelt
48Disconnect the battery negative (earth)
lead (refer to Chapter 5A, Section 1).
49 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 relevant front roadwheel.
50 Remove the one-piece undertray where
fitted, by turning its bayonet-type fasteners,
and on XR2i models, remove the front
suspension crossmember (see Chapter 10).
51 Remove the belt-break switch from the
relevant drivebelt cover, then remove the
drivebelt cover, as described in the previous
sub-Section.
52 Slacken the modulator pivot and adjuster
bolts to release drivebelt tension, then slip the
drivebelt from the modulator.
53 Remove the track rod end balljoint from
the steering arm on the spindle carrier (see
Chapter 10).
54 Disconnect the anti-roll bar connecting
link (where applicable) and release the brake
hose from their locations on the suspension
strut.
55 Remove the pinch bolt and nut securing
the lower suspension arm balljoint to the
spindle carrier, and separate the balljoint from
the spindle carrier assembly.
56 To release the driveshaft inner CV joint
from the differential, have an assistant pull the
spindle carrier away from the centre of the
vehicle whilst you insert a lever between the
inner CV joint and the transmission casing,
then firmly strike the lever with the flat of the hand, but be careful not to damage adjacent
components. Make provision for escaping
transmission oil, if possible plugging the
opening to prevent excessive loss. Do not
allow the CV joints to bend more than 20°
from the horizontal or internal damage may
occur. If both driveshafts are to be removed,
immobilise the differential by inserting an old
joint or suitable shaft, before the other
driveshaft is removed.
57
Slide the drivebelt off the driveshaft.
58 Remove the snap-ring from the groove in
the splines of the inner CV joint. This snap-
ring must be renewed every time the
driveshaft is withdrawn from the differential.
59 With the drivebelt removed, closely
examine the condition of the belt over its
entire length. Renew the belt if any cracks are
noticed in the fabric at the roots of the teeth, if
there is any abrasion of the fabric facing
material, or if there are any tears starting from
the edge of the belt.
60 If, since the drivebelts were last renewed,
a vehicle has covered more than 30 000 miles
(48 000 km) or a period of more than two
years has elapsed, the drivebelts should be
renewed as a matter of course.
61 Prior to refitting the drivebelt, thoroughly
clean its CV joint pulley location.
62 Fit the drivebelt over the driveshaft then,
with a new snap-ring fitted to the inner CV
joint splines, lubricate the splines with
transmission oil. Remove the temporary plug
and insert the inner CV joint to its
transmission casing location. Press against
the spindle carrier so that the snap-ring
engages fully to hold the CV joint splines in
the differential.
63 Refitting is now a reversal of the removal
procedure, tensioning the drivebelt as
described in the previous sub-Section. Ensure
that the pinch-bolt securing the lower
suspension arm balljoint to the spindle carrier
locates in the annular groove on the balljoint
spindle. Secure the track rod and balljoint,
using a new split pin. Tighten the suspension
components to their specified torque (see
Chapter 10).
64 Check the level of the transmission oil,
and top-up as required (see Chapter 1).
Modulator belt-break switch
65 Modulator belt-break switches are fitted
to each of the two drivebelt covers, and clip
into position. To remove, gently squeeze the
protruding lever on the switch towards the
main switch body and lift out, ensuring that
the belt contact arm does not catch on the
drivebelt cover.
25 Load-apportioning valve (ABS models) - adjustment
3
1Before attempting to adjust the load-
apportioning valves, the vehicle must be at its
kerb weight, ie with approximately half a tank
of fuel and carrying no load. Note that a
special setting tool will be required to adjust
the valves - this can be fabricated, to the
dimensions shown (see illustration).
2 Raise the vehicle on ramps or drive it over
an inspection pit, so that working clearance is
obtained with the full weight of the vehicle
resting on its roadwheels. Remove the spare
wheel and its carrier.
3 To check adjustment, insert the load-
apportioning valve setting tool into the nylon
sleeve without pre-loading the valve. If unable
to insert the tool, carry out the following
adjustment procedure.
4 Slacken the operating link adjustment fixing
screw then insert the setting tool into the
nylon sleeve, applying light pressure to the
operating link upper arm, so that the setting
tool fully locates. With the setting tool just
resting up against the adjustment post,
tighten the operating link adjustment fixing
screw to the specified torque (see
illustration) .
5 Repeat the procedure on the other valve.
6 Refit the spare wheel on completion.
26 Load-apportioning valve
(ABS models) - removal and
refitting
3
1 Minimise hydraulic fluid loss by
disconnecting the wiring multi-plug from the
fluid level warning indicator in the master
9•16 Braking system
25.4 Load-apportioning valve adjustment
A Setting tool
B Operating link adjustment fixing screw
C Adjustment post
25.1 Load-apportioning valve adjustment tool (dimensions given in mm)
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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.
2Raise 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
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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 settingsNmlbf 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 5037
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . Slacken completely
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 5037
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5037
Steering gear to bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8462
Steering gear fluid pipe unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3123
Steering gear flexible coupling pinch-bolt . . . . . . . . . . . . . . . . . . . . . . . 5138
Track rod end balljoint to spindle carrier steering arm . . . . . . . . . . . . . . 2619
Track rod locknut to track rod end balljoint . . . . . . . . . . . . . . . . . . . . . . 6346
Steering pump mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2518
Steering pump pulley bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2518
High pressure fluid pipe to pump union . . . . . . . . . . . . . . . . . . . . . . . . . 6548
High pressure fluid pipe coupling joint . . . . . . . . . . . . . . . . . . . . . . . . . . 1713
Steering column mounting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Roadwheel nuts
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 70 to 110 52 to 74
10•2 Suspension and steering
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