Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake10•16 Suspension and steeringdrive models, remove the brace from the studon the left-hand side of the steering gear.9 Undo the two bolts securing the supportbrackets to the steering gear and move thebrackets and swing the brackets clear.10 Unhook the steering gear from theapertures in the bulkhead and remove theassembly from the right-hand wheel arch.Ensure that the pressure check valve does notfall out of the pressure port in the valve bodyas the steering gear is removed.Refitting11 Centralize the steering gear and steeringwheel, then engage the pinion splined shaft tothe lower steering shaft flexible coupling.12 Hook the steering gear into the aperturesin the bulkhead then align the supportbrackets and refit the two bolts. Tighten thesupport bracket upper bolts and supportbracket-to-steering gear bolts to the specifiedtorque.13 On left-hand drive models, refit the braceto the stud on the left-hand side of thesteering gear.14 Fit new O-ring seals to the pressure andreturn hoses, then reconnect the hydrauliclines to the steering gear. Secure the pipeswith the retaining clips.15 Refit the pinion splined shaft-to-lowersteering shaft flexible coupling pinch-bolt andnut and tighten to the specified torque.16 Refit the track rod end balljoints to thesteering arms, as detailed in Section 28. Aslong as the track rod end-to-track rod relativepositions have not been disturbed, it will notbe necessary to reset the front wheelalignment.17 Refit the front suspension crossmemberand one-piece undertray, as applicable.18 Refit the roadwheels, then lower thevehicle to the ground. Tighten the roadwheelnuts with the vehicle on its wheels to thespecified torque.19 On completion, bleed the power steeringhydraulic system as described in Section 27.Check for any signs of fluid leakage from thesystem hoses and connections.25 Power steering pump -removal and refitting4RemovalHCS engine models1 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).2 Chock the rear wheels then jack up thefront of the car and support it on axle stands(see “Jacking and Vehicle Support”). Removethe front roadwheel.3 Remove the auxiliary drivebelt as describedin Chapter 1.4 Insert a 9 mm Allen key into the centre ofthe pump drive spindle to prevent it fromturning, then unscrew and remove the threepump pulley retaining bolts. Withdraw thepulley from the pump.5 Position a suitable container beneath thepower steering pump, then unscrew and detachthe fluid high pressure pipe and fluid returnhose from the pump. As they are detached fromthe pump, allow the fluid to drain from the pipeand hose (and the pump) into the container.Plug the exposed ends of the pipe, hose andthe pump connections, to prevent the ingress ofdirt and excessive fluid loss.6 Unscrew the four retaining bolts (three fromthe front and one from the rear) and withdrawthe pump from the vehicle.PTE engine models7 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).8 Refer to the relevant Part of Chapter 4 andremove the air cleaner assembly and air inletcomponents as necessary for access to thepump.9 Chock the rear wheels then jack up thefront of the car and support it on axle stands(see “Jacking and Vehicle Support”). Removethe front roadwheel.10 Refer to Chapter 1 and drain the coolingsystem.11 Refer to Chapter 1 and remove theauxiliary drivebelt.12 Insert a 9 mm Allen key into the centre ofthe pump drive spindle to prevent it fromturning, then unscrew and remove the threepump pulley retaining bolts. Refit theroadwheel, lower the vehicle and withdraw thepump pulley from above.13 Disconnect the cooling system hoses asnecessary to gain access to the powersteering pump.14 Disconnect the pressure switch multi-plugfrom the pressure switch located in the fluidhigh pressure pipe.15 Position a suitable container beneath thepower steering pump, then disconnect thehigh pressure pipe at the union located partway along the pipe. Allow the fluid to drainfrom the pipe into the container.16 Disconnect the high pressure pipe clampbracket and the fluid return hose from thepump. Allow the fluid to drain into thecontainer then plug the exposed ends of thepipe, hose and the pump connections, toprevent the ingress of dirt and excessive fluidloss.17 Unscrew the pump mounting bolt locatedat the rear of the pump and remove the pipeclamp bracket.18 Unscrew the three pump mounting boltslocated at the front of the pump and removethe pump, complete with high pressure pipe,from the vehicle.19 If required, the high pressure pipe can beremoved from the pump after unscrewing theunion nut.Zetec engine modelsNote: For this operation, the engine will needto be supported from above to allow removalof the right-hand engine mounting, and also toallow the vehicle to be raised for workunderneath, and lowered for work from above.A proprietary engine support bar (or homemadealternative) fitted in the front wing drainchannel each side is ideal for this purpose, butcare must be taken not to damage the wingsor their paintwork.20 Disconnect the battery negative (earth)lead (refer to Chapter 5A, Section 1).21 Suitably support the right-hand side of theengine (see the note at the beginning of thissub-Section) so that all the load is removedfrom the engine mounting.22 Remove the right-hand engine mountingas described in Chapter 2C.23 Refer to Chapter 1 and drain the coolingsystem.24 Chock the rear wheels then jack up thefront of the car and support it on axle stands(see “Jacking and Vehicle Support”). Removethe front roadwheel.25 Undo the retaining screws, and removethe drivebelt lower guard from the underbody.26 Refer to Chapter 11 and remove the wheelarch liner.27 Refer to Chapter 1 and remove theauxiliary drivebelt.28 Insert a 9 mm Allen key into the centre ofthe pump drive spindle to prevent it fromturning, then unscrew and remove the threepump pulley retaining bolts. Refit theroadwheel, lower the vehicle and withdraw thepump pulley from above.29 Refer to Chapter 12 and remove the righthandheadlight unit.30 Refit the roadwheel and lower the vehicleto the ground.31 Position a suitable container beneath thepower steering fluid reservoir, then disconnectthe fluid return hose from the reservoir. Allowthe fluid to drain from the hose and reservoirinto the container.32 Plug the exposed ends of the hose andthe reservoir, to prevent the ingress of dirt andexcessive fluid loss.33 Remove the high pressure pipe clampbrackets from the engine then disconnect thehigh pressure pipe at the union located overthe camshaft cover. Place absorbent ragsunder the union as it is disconnected tocollect any escaping fluid. Plug thedisconnected pipe ends to prevent theingress of dirt and excessive fluid loss.34 Disconnect the cooling system hoses asnecessary to gain access to the powersteering pump.35 Unscrew the two pump mounting boltslocated at the rear of the pump.36 Unscrew the two pump mounting boltslocated at the front of the pump and removethe pump, complete with high pressure pipeand fluid return hose, upwards and out of theengine compartment.37 If required, the high pressure pipe andfluid return hose can be removed from thepump after unscrewing the union nut orslackening the hose clip as applicable.