1993 FORD MONDEO steering

(a) Apply petroleum jelly or clean engine oil
to the sensor’s sealing O-ring.
(b) Locate the sensor fully in the cylinder
head, and wipe off any surplus lubricant
before securing it.
(c) Tighten the screw to the specified torque
wrench setting.
Coolant temperature sensor
48Refer to Chapter 3, Section 6.
Intake air temperature sensor
49Remove the air mass meter and resonator
(refer to Chapter 4) to gain access to the
sensor (see illustration).
50Releasing its clip, unplug the sensor’s
electrical connector, then unscrew the sensor
from the resonator.
51Refitting is the reverse of the removal
procedure. Tighten the sensor to the specified
torque wrench setting; if it is overtightened, its
tapered thread may crack the resonator.
Throttle potentiometer
52Remove the plenum chamber (see
Chapter 4). Releasing its wire clip, unplug the
large electrical connector (next to the fuel
pressure regulator).
53Releasing its wire clip, unplug the
potentiometer’s electrical connector. Remove
the retaining screws, and withdraw the unit
from the throttle housing (see illustration). Do
notforce the sensor’s centre to rotate past itsnormal operating sweep; the unit will be
seriously damaged.
54Refitting is the reverse of the removal
procedure, noting the following points:
(a) Ensure that the potentiometer is correctly
orientated, by locating its centre on the D-
shaped throttle shaft (throttle closed), and
aligning the potentiometer body so that
the bolts pass easily into the throttle
housing.
(b) Tighten the screws evenly and securely
(but do not overtighten them, or the
potentiometer body will be cracked).
Vehicle speed sensor
55The sensor is mounted at the base of the
speedometer drive cable, and is removed with
the speedometer drive pinion (see
illustration). Refer to the relevant Section of
Chapter 7, Part A or B, as applicable.
Power steering pressure switch
56Releasing its clip, unplug the switch’s
electrical connector, then unscrew the switch
(see illustration). Place a wad of rag
underneath, to catch any spilt fluid. If a
sealing washer is fitted, renew it if it is worn or
damaged.
57Refitting is the reverse of the removal
procedure; tighten the switch securely, then
top-up the fluid reservoir (see Chapter 1) to
replace any fluid lost from the system, and
bleed out any trapped air (see Chapter 10,
Section 33).
Exhaust gas pressure differential
sensor
Note:See also Section 6, illustration 6.21.
58If better access is required, remove the
resonator (see Chapter 4).
59Releasing its wire clip, unplug the
sensor’s electrical connector. Remove the
two retaining screws, withdraw the unit from
the bulkhead mounting bracket, then
disconnect the two vacuum hoses. Note that
the hoses are of different sizes, to ensure that
they cannot be mixed up on reconnection.
60Check the condition of both hoses, and
renew them if necessary (see Chapter 1).
61Refitting is the reverse of the removal
procedure. Ensure that the hoses are securely
connected to the correct unions.
Oxygen sensor
Note:The sensor is delicate, and will not work
if it is dropped or knocked, if its power supply
is disrupted, or if any cleaning materials are
used on it.
62Release the sensor’s electrical connector
from its bracket on the engine/transmission
front mounting, and unplug it to disconnect
the sensor (see illustration).
63Raising and supporting the front of the
vehicle if required to remove the sensor from
underneath, unscrew the sensor from the
exhaust system front downpipe; collect the
sealing washer (where fitted).
64On refitting, clean the sealing washer
Emissions control systems 6•13
6
4.56 Power steering pressure switch is
screwed into pipe at right-hand rear end of
engine4.62 Oxygen sensor is screwed into
exhaust system front downpipe . . .
4.49 Intake air temperature sensor
(arrowed) is screwed into underside of air
intake resonator4.53 Throttle potentiometer is secured by
two screws (arrowed)
4.55 Vehicle speed sensor “A”, with its
electrical connector “B”
4.45 Camshaft position sensor is located
at left-hand rear end of cylinder head
procarmanuals.com

15Unscrew the two rearmost canister
assembly retaining bolts (see illustration).
16Unplug the two hoses from the canister
assembly, noting which way round they are
fitted (see illustration).
17Unscrew the canister assembly’s front
retaining bolt (see illustration). Withdraw the
canister assembly.
18Release the clip, and drive out the pin to
separate the canister from its bracket (see
illustration).
19On reassembly, refit the canister to its
bracket and refit the assembly to the vehicle,
tightening the retaining bolts securely, and
ensuring that the two hoses are securely
reconnected to their original unions.
20Offer up the crossmember and refit the
crossmember bolts, tightening them only
lightly at this stage.
21The crossmember must now be aligned
on the underbody. Ford specify the use of
service tool 15-097, which is a pair of tapered
guides, with attachments to hold them in the
crossmember as it is refitted (see
illustration). However, since the working
diameter of these tools is 20.4 mm, and since
the corresponding aligning holes in the
crossmember and underbody are 21 mm and
22 mm in diameter, there is a significant in-
built tolerance possible in the crossmember’s
alignment, even if the correct tools are used. If
these tools are not available, align the
crossmember by eye, centring thecrossmember aligning holes on those of the
underbody, and using the marks made on
removal for assistance. Alternatively, use a
tapered drift such as a clutch-aligning tool, or
a deep socket spanner of suitable size.
22Once the crossmember is aligned as
precisely as possible, tighten its bolts to the
specified torque (see Chapter 10
Specifications) without disturbing its position
(see illustration). Recheck the alignment
once all the bolts are securely tightened.
23The remainder of the refitting procedure is
the reverse of removal.
24Remember that, since the rear suspension
crossmember has been disturbed, the wheel
alignment and steering angles must be
checked fully and carefully as soon as
possible, with any necessary adjustments
being made. This operation is best carried out
by an experienced mechanic using proper
checking equipment; the vehicle should
therefore be taken to a Ford dealer or similar
for attention.
Charcoal canister - Estate models
25Disconnect the battery negative (earth)
lead - see Section 1 of Chapter 5.
26Raise the rear of the vehicle, and support
it securely on axle stands.
Warning: DO NOT place any part
of your body under the vehicle
when it is supported only by a
jack!27Disconnect the two hoses from the
canister assembly, noting which way round
they are fitted.
28Unscrew the canister assembly retaining
bolt and withdraw the assembly, unclipping it
from the front mounting.
29Remove the plastic cover, and drive out
the pin to separate the canister from its
bracket (see illustration).
30On refitting, secure the canister to its
bracket, and refit the assembly to the vehicle.
Tighten the retaining bolt securely, and ensure
that the two hoses are securely reconnected
to their original unions.
General information
1To reduce oxides of nitrogen (NOx)
emissions, some of the exhaust gases are
recirculated through the EGR valve to the inlet
manifold. This has the effect of lowering
combustion temperatures.
2The system consists of the EGR valve, the
EGR exhaust gas pressure differential sensor,
the EGR solenoid valve, the ECU, and various
sensors - see illustration 2.1A. The ECU is
programmed to produce the ideal EGR valve
lift for each operating condition.
Checking
EGR valve
3Start the engine and allow it to idle.
4Detach the vacuum hose from the EGR
valve, and attach a hand vacuum pump in its
place.
5Apply vacuum to the EGR valve. Vacuum
should remain steady, and the engine should
run poorly.
(a) If the vacuum doesn’t remain steady and
the engine doesn’t run poorly, renew the
EGR valve and recheck it.
(b) If the vacuum remains steady but the
engine doesn’t run poorly, remove the
6 Exhaust Gas Recirculation
(EGR) system-
general information, checking
and component renewal
Emissions control systems 6•15
6
5.22 . . . ensure aligned crossmember
does not move - Ford tools used here -
while mounting bolts are tightened5.29 Charcoal canister assembly - Estate
models - showing plastic cover (arrowed)
and pin securing canister to mounting
bracket
5.17 . . . and remove front retaining bolt
(arrowed) to release canister assembly -
Saloon and Hatchback models5.18 Release clip and drive out pin to
separate canister from mounting bracket5.21 Refitting rear suspension crossmember
with Ford service tools (arrowed) in place to
align it with underbody . . .
procarmanuals.com

Chapter 10 Suspension and steering systems
Front anti-roll bar and links - removal and refitting . . . . . . . . . . . . . . 6
Front hub and bearings - inspection and renewal . . . . . . . . . . . . . . 3
Front suspension lower arm - removal, overhaul and refitting . . . . . 7
Front suspension lower arm balljoint - renewal . . . . . . . . . . . . . . . . 8
Front suspension strut - overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front suspension strut - removal and refitting . . . . . . . . . . . . . . . . . 4
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Power steering fluid level check . . . . . . . . . . . . . . . . . See Chapter 1
Power steering gear (all except left-hand-drive models
with ABS) - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Power steering gear (left-hand-drive models with ABS) -
removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power steering gear rubber gaiters - renewal . . . . . . . . . . . . . . . . . . 32
Power steering hydraulic system - bleeding . . . . . . . . . . . . . . . . . . . 33
Power steering pump - removal and refitting . . . . . . . . . . . . . . . . . . 34
Rear anti-roll bar and links (Estate models) - removal and refitting . 20
Rear anti-roll bar and links (Saloon/Hatchback models) -
removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rear coil spring (Estate models) - removal and refitting . . . . . . . . . . 21
Rear hub and bearings (Estate models) - inspection and renewal . . 17
Rear hub and bearings (Saloon/Hatchback models) -
inspection and renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rear shock absorber (Estate models) - removal, testing and refitting . 19
Rear suspension crossmember (Estate models) - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Rear suspension crossmember (Saloon/Hatchback models) -
removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Rear suspension front lower arm (Estate models) - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Rear suspension knuckle (Estate models) - removal and refitting . . 18
Rear suspension knuckle (Saloon/Hatchback models) - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rear suspension lower arms (Saloon/Hatchback models) -
removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Rear suspension rear lower arm (Estate models) - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Rear suspension strut (Saloon/Hatchback models) - overhaul . . . . . 12
Rear suspension strut (Saloon/Hatchback models) -
removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rear suspension tie-bar (Estate models) - removal and refitting . . . 25
Rear suspension tie-bar (Saloon/Hatchback models) -
removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Rear suspension upper arm (Estate models) - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Steering column - removal, inspection and refitting . . . . . . . . . . . . . 28
Steering column flexible coupling - removal and refitting . . . . . . . . . 29
Steering knuckle and hub assembly - removal and refitting . . . . . . . 2
Steering, suspension and wheel check . . . . . . . . . . . . See Chapter 1
Steering wheel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 27
Track rod end - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Tyre condition and tyre pressure checks . . . . . . . . . . . See Chapter 1
Wheel alignment and steering angles - general information . . . . . . . 36
Front wheel alignment
Toe setting:
Tolerance allowed before resetting required . . . . . . . . . . . . . . . . . . . . 0.5 mm to 3.5 mm toe-out (0°05’ to 0°35’ toe-out)
Adjustment setting (if required) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm ± 1.0 mm toe-out (0°20’ ± 0°10’ toe-out)
Rear wheel alignment
Toe setting:
Tolerance allowed before resetting required:
Saloon/Hatchback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 mm toe-in to 0.1 mm toe-out (0°38’ toe-in to 0°02’ toe-out)
Estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 mm toe-in to 1.3 mm toe-out (0°27’ toe-in to 0°13’ toe-out)
Adjustment setting (if required):
Saloon/Hatchback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 mm ± 1.2 mm toe-in (0°18’ ± 0°12’ toe-in)
Estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 mm ± 1.2 mm toe-in (0°07’ ± 0°12’ toe-in)
Roadwheels and tyres
Wheel sizes:
Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 x 5 1/2
Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 x 5 1/2 or 15 x 6
Tyre sizes:
Wheel size 14 x 5 1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185/65/14 or 195/60VR/14
Wheel size 15 x 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205/55VR/15
Tyre pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Specifications
10•1
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,suitable
for competent DIY
mechanicDifficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
Specifications Contents
10
procarmanuals.com

Torque wrench settingsNm lbf ft
Front suspension
Front subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 to 150 81 to 111
Lower arm balljoint to lower arm (service replacement, bolted on) . . . . 58 43
Lower arm balljoint-to-steering knuckle clamp bolt . . . . . . . . . . . . . . . 48 to 60 35 to 44
Lower arm to subframe:
Stage 1 (used components) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 37
Stage 1 (new components) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 52
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slacken completely
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 37
Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten through further 90°
Anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 18
Anti-roll bar link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 to 58 30 to 43
Suspension strut-to-steering knuckle pinch-bolt . . . . . . . . . . . . . . . . . . 84 62
Suspension strut upper mounting nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 34
Suspension strut thrust bearing retaining nut . . . . . . . . . . . . . . . . . . . . . 59 44
Driveshaft/hub retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 251
Rear suspension (Saloon/Hatchback)
Crossmember mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 to 138 75 to 102
Front lower arm to knuckle and to crossmember . . . . . . . . . . . . . . . . . . 70 to 98 52 to 72
Rear lower arm to knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 to 138 75 to 102
Rear lower arm to crossmember . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 to 98 52 to 72
Anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 to 26 14 to 19
Anti-roll bar link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 to 40 22 to 30
Suspension strut to knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 to 98 52 to 72
Drum brake backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 to 54 33 to 40
Disc brake splash shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 66
Hub nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 181
Tie-bar and tie-bar bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 to 138 75 to 102
Suspension strut upper mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . 23 to 30 17 to 22
Suspension strut upper nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 to 58 30 to 43
Rear suspension (Estate)
Same as for Saloon/Hatchback, except for the following.
Crossmember mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 89
Front lower arm to knuckle and to crossmember . . . . . . . . . . . . . . . . . . 120 89
Upper arm to knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 89
Upper arm to crossmember . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 62
Rear lower arm to knuckle and to crossmember . . . . . . . . . . . . . . . . . . 84 62
Anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 19
Anti-roll bar link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 26
Hub assembly-to-knuckle retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . 65 48
Tie-bar to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 89
Tie-bar bracket to underbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 89
Tie-bar to knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 62
Shock absorber upper mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 62
Shock absorber lower mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 89
Steering
Steering gear mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 to 159 84 to 117
Track rod end to steering knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 to 30 18 to 22
Track rod end locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 to 47 25 to 35
Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 to 55 33 to 41
Flexible coupling-to-pinion shaft clamp bolt . . . . . . . . . . . . . . . . . . . . . 23 to 32 17 to 24
Power steering pipe unions to valve body . . . . . . . . . . . . . . . . . . . . . . . 27 to 35 20 to 26
Steering column-to-coupling clamp bolt . . . . . . . . . . . . . . . . . . . . . . . . 20 to 27 14 to 20
Steering column mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 27 14 to 20
Steering pump mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 to 28 15 to 21
Steering pump pressure line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 to 73 42 to 54
Roadwheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 63
10•2 Suspension and steering systems
procarmanuals.com

The independent front suspension is of
MacPherson strut type, incorporating coil
springs, integral telescopic shock absorbers,
and an anti-roll bar. The struts are attached to
steering knuckles at their lower ends, and the
knuckles are in turn attached to the lower
suspension arm by balljoints. The anti-roll bar
is bolted to the rear of the subframe, and is
connected to the front suspension struts by
links (see illustration).
On Saloon/Hatchback models, the
independent rear suspension is of
“Quadralink” type, having four mounting
points on each side of the vehicle. The two
lower arms are attached to the rear
suspension knuckle at their outer ends, and to
the rear crossmember at their inner ends. A
tie-bar, located between the bottom of the
knuckle and the floor, counteracts braking
and acceleration forces on each side (see
illustration).
On Estate models, the independent rear
suspension is of “SLA” (Short and Long Arm)
type. This allows a larger load area, since
there are no suspension points projecting into
the luggage area. There are three side arms
on each side: one forged upper arm, and two
1 General information
Suspension and steering systems 10•3
10
1.1 Front suspension components
1 MacPherson strut
2 Steering knuckle
3 Lower arm4 Vertical silent bush on
lower arm
5 Anti-roll bar6 Front subframe
7 Front subframe rubber bush
8 Rear subframe rubber bush
1.2 Rear suspension components on
Saloon/Hatchback models
1 Wheel housing
2 Upper mounting bracket and coil spring seat
3 Strut
4 Solenoid valve for adaptive damping
5 Rear suspension crossmember
6 Eccentric bolt for rear toe setting
7 Anti-roll bar
8 Link
9 Front lower arm
10 Rear lower arm
11 Knuckle (drum brake models)
12 ABS wheel sensor
(drum brake models)
13 Tie-bar
14 Backplate
15 Hub and bearing assembly
16 Hub nut
17 Grease cap
18 Brake drum
19 Tie-bar mounting bracket
20 Brake disc
21 Splash shield (disc brake models)
22 Brake caliper (disc brake models)
23 Knuckle (disc brake models)
24 ABS wheel sensor (disc brake models)
procarmanuals.com

10•4 Suspension and steering systems
pressed-steel lower side arms. A tie-bar on
each side supports the rear suspension
knuckles. The coil springs are separate from
the shock absorbers (see illustration).
A rear anti-roll bar is fitted to all models. On
SI models, the front and rear shock absorbers
are gas-filled; on other models, they are filled
with fluid. Self-levelling rear shock absorbers
are fitted as standard to Ghia Estate models.
A variable-ratio type rack-and-pinion
steering gear is fitted, together with a
conventional column and telescopic coupling,
incorporating two universal joints. Power-
assisted steering is fitted to all models. A
power steering system fluid cooler is fitted, in
front of the cooling system radiator on the
crossmember (see illustration). On models
with adaptive damping, a steering position
sensor with sensor disc is located above the
upper universal joint.
On models with adaptive damping, it is
possible to select a hard or soft setting for the
front and rear shock absorbers. The system iscomputer-controlled; a switch is provided
near the handbrake lever for selection of
“Sport” or “Normal” mode. With this system, a
solenoid valve is fitted to each suspension
strut. When the valve is open, the hydraulic oil
inside the shock absorber is routed through a
bypass channel, making the action “softer”.
When the solenoid valve is closed, the shock
absorber action becomes “harder”. The
system takes into consideration the
roadspeed of the vehicle; at high speeds, the
shock absorbers are automatically set to
“hard”. The adaptive damping computer
module is located in the luggage
compartment, behind the rear seat, and
incorporates a self-test function. Adaptive
damping is not available on Estate models
(see illustrations).
When working on the suspension or
steering, you may come across nuts or bolts
which seem impossible to loosen. These nuts
and bolts on the underside of the vehicle are
continually subjected to water, road grime,mud, etc, and can become rusted or seized,
making them extremely difficult to remove. In
order to unscrew these stubborn nuts and
bolts without damaging them (or other
components), use lots of penetrating oil, and
allow it to soak in for a while. Using a wire
brush to clean exposed threads will also ease
removal of the nut or bolt, and will help to
prevent damage to the threads. Sometimes, a
sharp blow with a hammer and punch will
break the bond between a nut and bolt, but
care must be taken to prevent the punch from
slipping off and ruining the threads. Heating
the nut or bolt and surrounding area with a
blow lamp sometimes helps too, but this is
not recommended, because of the obvious
dangers associated with fire. Extension bars
or pipes will increase leverage, but never use
one on a ratchet, as the internal mechanism
could be damaged. Actually tighteningthe nut
or bolt first may help to break it loose. Nuts or
bolts which have required drastic measures to
remove them should always be renewed.
1.5 The power steering system fluid cooler
is located in front of the radiator
1.6A Adaptive damping switch located
near the handbrake lever1.6B Adaptive damping computer module
located in the luggage compartment
1.3 Rear suspension components on
Estate models
1 Tie-bar bracket
2 Short front lower arm
3 Long front upper arm
4 Shock absorber
5 Crossmember
6 Anti-roll bar
7 Coil spring
8 Rear lower arm
9 Stub axle (part of hub and bearing
assembly)
10 Knuckle
11 Brake caliper (disc brake models)
12 Hub nut
13 Brake drum
14 Splash guard (disc brake models)
15 Brake disc
16 Hub and bearing assembly
17 Backplate (drum brake models)
18 ABS wheel sensor
19 Tie-bar
procarmanuals.com

Since most of the procedures dealt with in
this Chapter involve jacking up the vehicle
and working underneath it, a good pair of axle
stands will be needed. A hydraulic trolley jack
is the preferred type of jack to lift the vehicle,
and it can also be used to support certain
components during removal and refitting
operations.
Warning: Never, under any
circumstances, rely on a jack to
support the vehicle while working
beneath it. When jacking up the vehicle, do
not lift or support it beneath the front or
rear subframes.
Removal
1Apply the handbrake. Remove the wheel
cover from the relevant front wheel, and
loosen (but do not remove) the driveshaft/hub
nut. This nut is very tight.
2Loosen the front wheel nuts, jack up the
front of the vehicle and support it on axle
stands. Remove the front wheel.
3Extract the split pin from the track rod end
balljoint nut. Unscrew the nut, and detach the
rod from the arm on the steering knuckle
using a conventional balljoint removal tool.
Take care not to damage the balljoint seal.
4Remove the ABS sensor (when fitted) as
described in Chapter 9.
5Remove the brake caliper and brake disc as
described in Chapter 9, but do not disconnect
the flexible hose from the caliper. Suspend
the caliper from a suitable point under the
wheel arch, taking care not to strain the hose.
6Unscrew and remove the driveshaft/hub
nut. Note that the nut is of special laminated
design, and should only be re-used a
maximum of 5 times. (It is a good idea to file a
small notch on the nut every time it is
removed.) Obtain a new nut if necessary.
7Note which way round the lower arm
balljoint clamp bolt is fitted, then unscrew and
remove it from the knuckle assembly. Lever
the balljoint down from the knuckle; if it is
tight, prise the clamp open using a large flat-
bladed tool. Take care not to damage the
balljoint seal during the separation procedure.
8Unscrew and remove the pinch-bolt
securing the steering knuckle assembly to the
front suspension strut, noting which way
round it is fitted. Prise open the clamp using a
wedge-shaped tool, and release the knuckle
from the strut. If necessary, tap the knuckle
downwards with a soft-headed mallet to
separate the two components. Support the
knuckle on an axle stand.
9Pull the steering knuckle and hub assembly
from the driveshaft splines. If it is tight,
connect a universal puller to the hub flange,
and withdraw it from the driveshaft. When the
driveshaft is free, support it on an axle stand,
or suspend it from a suitable point under thewheel arch, making sure that the inner
constant velocity joint is not turned through
more than 18°. (Damage may occur if the joint
is turned through too great an angle.)
Refitting
10Lift the steering knuckle and hub
assembly onto the driveshaft splines, and
support the assembly on an axle stand.
11Locate the assembly on the front
suspension strut. Insert the pinch-bolt with its
head facing forwards. Fit the nut and tighten it
to the specified torque.
12Refit the lower arm balljoint to the knuckle
assembly, and insert the clamp bolt with its
head facing forwards. Refit the nut and tighten
it to the specified torque.
13Refit the driveshaft/hub nut, and tighten it
moderately at this stage. Final tightening of
the nut is made with the vehicle lowered to the
ground.
14Refit the brake caliper and brake disc as
described in Chapter 9.
15Where fitted, refit the ABS sensor as
described in Chapter 9.
16Reconnect the track rod end balljoint to
the steering arm, and tighten the nut to the
specified torque. Check that the split pin
holes are aligned; if necessary, turn the nut to
the nearest alignment, making sure that the
torque wrench setting is still within the
specified range. Insert a new split pin, and
bend it back to secure.
17Refit the front wheel, and lower the
vehicle to the ground. Tighten the wheel nuts
to the specified torque.
18Tighten the driveshaft/hub nut to the
specified torque, and refit the wheel cover.
Inspection
1The front hub bearings are non-adjustable,
and are supplied already greased.
2To check the bearings for excessive wear,
apply the handbrake, jack up the front of the
vehicle and support it on axle stands.
3Grip the front wheel at top and bottom, and
attempt to rock it. If excessive movement is
noted, it may be that the hub bearings are
worn. Do not confuse wear in the driveshaft
outer joint or front suspension lower arm
balljoint with wear in the bearings. Hub
bearing wear will show up as roughness or
vibration when the wheel is spun; it will also
be noticeable as a rumbling or growling noise
when driving.
Renewal
4Remove the steering knuckle and hub
assembly as described in Section 2.
5The hub must now be removed from the
bearing inner races. It is preferable to use a
press to do this, but it is possible to drive outthe hub using a length of metal tube of
suitable diameter (see illustration).
6Part of the inner race will remain on the hub,
and this should be removed using a puller.
7Note that if this procedure is being used to
renew the hub only (ie it is not intended to
renew the bearings), then it is important to
check the condition of the bearing balls and
races, to see if they are fit for re-use. It is
difficult to be sure that no damage has
occurred, especially if makeshift methods
have been used during removal; in practice, it
is probably false economy not to renew the
bearings in any case, having got this far.
8Using circlip pliers, extract the inner and
outer circlips securing the hub bearing in the
steering knuckle (see illustration).
9Press or drive out the bearing, using a
length of metal tubing of diameter slightly less
than the bearing outer race.
10Clean the bearing seating faces in the
steering knuckle.
3 Front hub and bearings -
inspection and renewal
2 Steering knuckle and hub
assembly -
removal and refitting
Suspension and steering systems 10•5
10
3.5 Front hub and bearing
1 Hub 4 Stub axle
2 Double-row ball-bearing 5 Steering knuckle
3 Circlips 6 ABS sensor
3.8 Front wheel bearing retaining circlips
(arrowed)
procarmanuals.com

11Locate one of the circlips in the outer
groove of the knuckle.
12Press or drive the new bearing into the
knuckle until it contacts the circlip, using a
length of metal tube of diameter slightly less
than the outer race. Do not apply any
pressure to the inner race.
13Locate the remaining circlip in the inner
groove of the knuckle.
14Support the inner race on a length of
metal tube, then press or drive the hub fully
into the bearing.
15Refit the steering knuckle and hub
assembly as described in Section 2.
Removal
1Apply the handbrake, then jack up the front
of the vehicle and support it on axle stands.
Remove the appropriate front wheel.
2Unbolt the brake hose support bracket from
the front of the suspension strut (see
illustration).
3Remove the brake caliper as described in
Chapter 9, but do not disconnect the flexible
hydraulic hose from the caliper. Suspend the
caliper from a suitable point under the wheel
arch, taking care not to strain the hose.
4Extract the split pin from the track rod end
balljoint nut. Unscrew the nut, and detach the
rod from the arm on the steering knuckleusing a conventional balljoint removal tool.
Take care not to damage the balljoint seal.
5Remove the ABS sensor (when fitted) from
the steering knuckle, as described in Chapter 9.
6Remove the clip securing the driveshaft
inner gaiter to the inner CV joint. Disconnect
the gaiter from the CV joint housing.
7Remove the nut and disconnect the anti-roll
bar link from the strut. Note that, on models
fitted with ABS, the ABS wheel sensor wiring
support bracket is located beneath the nut
(see illustration).
8Note which way round the lower arm
balljoint clamp bolt is fitted, then unscrew and
remove it from the knuckle assembly. Lever
the balljoint down from the knuckle; if it is
tight, prise the clamp open carefully using a
large flat-bladed tool. Take care not to
damage the balljoint seal during the
separation procedure.
9Where applicable, disconnect the adaptive
damping wiring multi-plug at the strut, and
unclip the wire.
10Support the strut and steering knuckle on
an axle stand. Working inside the engine
compartment, remove the strut cap (if fitted).
Unscrew and remove the front suspension
strut upper mounting nut, holding the piston
rod stationary with an 8 mm Allen key (see
illustration).
11Lower the suspension strut, together with
the driveshaft and steering knuckle, from
under the wheel arch, withdrawing the tripod
on the inner end of the driveshaft from the CV
joint housing.12Unscrew and remove the pinch-bolt
securing the steering knuckle assembly to the
front suspension strut, noting which way
round it is fitted. Prise open the clamp using a
wedge-shaped tool, and release the knuckle
from the strut (see illustrations).
Refitting
13With the clamp prised open, locate the
front suspension strut on the steering knuckle,
and refit the pinch-bolt with its head facing
forwards. Tighten the bolt to the specified
torque.
14Locate the suspension strut (together with
the driveshaft and steering knuckle) in its
upper mounting, and loosely screw on the
nut.
15Locate the tripod on the inner end of the
driveshaft in the CV joint housing, then
manipulate the gaiter onto the housing, and fit
a new clip.
16Where applicable, reconnect the adaptive
damping multi-plug, and fit the wire in the clip.
17Locate the lower arm balljoint fully in the
bottom of the steering knuckle. Refit the
clamp bolt and tighten it to the specified
torque.
18Reconnect the anti-roll bar link to the
strut, and tighten the nut to the specified
torque. On models fitted with ABS, do not
forget to locate the sensor wiring support
bracket beneath the nut.
19Where fitted, refit the ABS sensor as
described in Chapter 9.
20Refit the track rod end balljoint to the
steering knuckle, and tighten the nut to the
specified torque. Check that the split pin
holes are aligned; if necessary, turn the nut to
the nearest alignment, making sure that the
torque wrench setting is still within the
specified range. Insert a new split pin, and
bend it back to secure.
21Refit the brake caliper as described in
Chapter 9.
22Refit the brake hose support bracket to
the strut, and tighten the bolt.
23Refit the wheel, and lower the vehicle to
the ground. Tighten the wheel nuts to the
specified torque.
24Tighten the suspension strut upper
mounting nut to the specified torque, while
4 Front suspension strut -
removal and refitting
10•6 Suspension and steering systems
4.2 Removing the brake hose support
bracket from the front of the front
suspension strut4.7 Removing the anti-roll bar link and
ABS sensor wiring bracket4.10 Front suspension strut upper
mounting nut
4.12A Steering knuckle-to-strut pinch-bolt4.12B Releasing the knuckle from the strut
procarmanuals.com