Ford Sierra Workshop Manuals
Accessories (books) pA The Sporting Fords- Volume 4: Sierras by Graham Robson. This book has comprehensive information on the development and history of all Sierra, Sierra Cosworth, and Merkur models. Chapters include production street and race versions of the cars, technical information and specifications, buyers and identification guide, performance figures and much more. Hard bound 9 1/2' x 7 1/2', 128 pages, 131 black & white illustrations. M207 pB High Performance Sierras & Merkurs by various authors. Packed with reprints of magazine articles, road tests of production and racing cars, data & comparisons, development, specifications, and tuning.
Cars covered in this publication are Sierra, Sierra Cosworth, RS500, XR 4x4, and Merkur XR4Ti models. Soft bound 8 1/2' x 11', 172 pages, 200 + black & white illustrations. M206 pC Classics in Color - Ford Sierra Cosworth by Dennis Foy & Terry West. A full color profile of the Sierra Cosworth line including R/S Cosworth, RS500, Cosworth 4x4, and Cosworth Sapphire. Great color photographs of both production and racing variants of these unique vehicles. Soft bound 7 1/2' x 10, 96 pages, 130 color illustrations. M203 pD Workshop Manual- Sierra 1982-1992 by Haynes.
(Legate) Cortina – Ford's Bestseller (Robson) Coventry Climax Racing Engines. Shoemark) Mazda MX-5/miata 1.8 Enthusiast's Workshop Manual (Grainger.
Covers the European Sierra & Sapphire 4 cylinder models (except Cosworth). Lots of good information covering repair procedures (light-years ahead of Chiltons).
Most sections, with the exception of the engine, are the same or similar to the US cars. An inexpensive alternative or addition to the American Merkur Manual.
Hard bound 8 1/2' x 11 ', 250 pagesM204 pE Workshop Manual- Sierra XR4i (V6) by Haynes. Similar to above, covers the XR4i & XR4x4 V6 equipped models. Hard bound 8 1/2' x 11 ', 250 pages M204A pF Workshop Manual- Scorpio (V6) by Haynes Covers the European Scorpio/Granada V6 models- very similar to our US spec cars. A handy manual to have. Hard bound 8 1/2' x 11 ', 250 pagesG204 pG Build & Modify Ford V6 Engines by Sven Pruett. A very well done build and tune book covering the V6 Ford 2.6, 2.8, 2.9, 4.0L engines. Soft bound 8 1/2' x 11', 160 pages.G202 pA pC pB pD pFpE pG pH pH How To Prepare The Sierra For Motorsport by Ford Motor Company Competition Department & Graham Robson.
Complete guide to race preparing the European specification Sierra for motorsports competition. Chapters on modifying suspension, body, engine, driveline, brakes, clutch, and differential- including specifications and part number listings. Soft bound 8 1/4' x 11 3/4', 147 pages, 150 black & white illustrations.
M205 Workshop Manual- Sierra & Escort Cosworth origional European Ford shop manuals (2 volume set) for the Cosworth cars.M202 The Complete 2.3L Turbo EEC-IV Handbook a comprehensive view of the engineering, performance characteristics, and troubleshooting for each component of the EEC-IV engine control system.M209 Ford Sierra Cosworth Dennis Foy & Terry West (Not Pictured) 2 0. PJ pI pM pK pV pU continuation pV pG pH pE pC pB pA pL pP pF pN pQ pD pO The cooling system on the XR4Ti is fairly unique. If there is another car with more individual hoses in the cooling system, we have yet to see it. Compound this with the changes throughout the model run and it gets even more complex. We have a good inventory of the hoses and other cooling related components that fit 1985-87 XR4Ti and some (where similar or noted) for 88-1989 cars.
PA Hose- heater valve to pipe (leads to oil cooler) M421HC pB Hose- heater valve to heater coreM421H (note: pB interchanges with pJ) pC Hose- heater valve to pipe along valve cover (upper) at rear (note: pC interchanges with pF )M421HB pD Heater Valve- heater control valve XR & Scorpio M421V pE Hose- water pipe (lower) to oil coolerM421HE pF Hose- oil cooler to water pipe (from heat valve)M421HB (note: pF interchanges with pC ) pG Hose- oil cooler to intake manifoldM421HD pH Oil Cooler- replacement water to oil heat exchangerAWC1 pI Hose- pipe along valve cover (lower) @ front to water pump. This one is a common problem.M421HA pJ Hose- pipe along valve cover (upper) @ front to thermostat housing (heater supply). Don't hit the road without an extra one of these! (note: pJ interchanges with pB )M421H pK Water Pump- quality replacement pump L6A pK1 Thermostat Housing- H.D. Cast Iron version L2F pL Hose- radiator (lower) 1985-88 (MT & AT)M421BH pL Hose- radiator (lower) 1989 (auto & manual)M421BH9 pM Hose- radiator (upper) 1985-88 (MT & AT)M421TH pM Hose- radiator (upper) 1989 (MT & AT) M421TH9 pS pK1 Cooling System (XR) pW Plumbing Schematic 1985-88 XR4Ti w/5 speed pTpR pN Hose- expansion tank (top fitting) to valve cover pipe (note: shape of hose not accurate in drawing)M421TT pO Expansion Tank- Thread-on cap (similar to Scorpio) Ford tanks, some with, or without, the fluid level sensor port.
Tank caps, fluid level sensors, and sensor mounting parts are also available. (see price list for complete listing) Tank 1985-88 M421E Tank 1989 w/o sensor M421E9 pP Hose- expansion tank (lower fitting) to radiator drain line M421TL pQ Hose- expansion tank (middle fitting) to radiator (upper) M421TM pR Radiator- O.E. Type replacement radiators for 1985-89 manual or 1985-88 auto transmission XR4Ti's.
(1985-88 manual) M421R (1985-88 auto) M421RA (1989 manual) M421R9 (1989 auto) M421R9A Mount/Bushing- @ radiator top mounting locationM421RM pS Electric Fan- An altermative to the sometimes troublesome dual cooling fans on the XR4Ti, this highly efficent (1100 cfm) 16' electric 'puller' fan does the work of both. Wire directly or use our (optional) adjustable 165-215 degree thermostat/relay pack. (16' puller fan) A16F-PL (thermo/relay) AFTR1 pT Blower Motor & Fan A/C & Heater -for heater and A/C, check fuse & relay first before ordering.
M470A pU Heater Core- New O.E. Ford heater cores.
Ford Sierra V6 Workshop Manual Free Download
M471 pV Turbo Water Hose -high temperature CPE silicone hose for turbo (water) inlet/outlet pipes. (1 foot makes 3 hoses) M421WT pW Hose- Lower drain pipe @ radiator lower M421HF 2 1. PA pB pC pD pE pF pG pH pJ pK pL pP pIpN pOpM pS pR pQ Cooling System (Scorpio) In addition to our stock of cooling system components for the XR4Ti we have added the various Scorpio related items to our inventory. The Scorpio's cooling system is only slightly less complicated than the XR4Ti's, it's only saving grace is the parts do not vary all that much from year to year. Again, as with the XR4, components that we offer are from the O.E.
Supplier or Ford originals. PA Hose.- heater valve (outlet) to heater core G421HA pB Hose.- heater valve to engine/inlet mfld.G421HB pC Hose.- heater valve (inlet) to heater coreG421HC pD Hose.- heater valve to pipeG421HD.for additional info see (diagram A) on page 20 pE Radiator- new original equipment Ford radiators at a very attractive prices. Don't be mislead into buying substandard fabricated or fits-all radiators when we can supply new Ford ones for less. Cooling System (Scorpio) supplement pA pF pHpJ Diagram A - heater and oil cooling water system Scorpio 1988-89 (all) pA Hose.- heater valve (outlet) to heater coreG421HA pB Hose- heater valve to engine/inlet mfld.G421HB pC Hose.- heater valve (inlet) to heater coreG421HC pD Hose.- heater valve to oil cooler pipeG421HD pE Heater Control Valve.- heater control valve, same on XR4 & ScorpioM421V pF Hose- connects coolant pipe from heater control valve to oil cooler.G421HL pG Oil Cooler.- replacement water to oil heat exchanger. If water is showing up in your oil it would most likely be either a head gasket or one of these.AWC1 pH Hose.- oil cooler to coolant pipe.G421HM pI Hose.- connects coolant pipe from oil cooler to water pump.G421HK pJ Hose- bypass from water pump to inlet mfld.G421HP.these items are also shown on page 19 diagram Diagram B- Components unique to late 89 Scorpio Scorpio 89 (late) pK Hose.- top radiator hoseG421TH.hose with vent is no longer avalable pL Hose- coolant tank to thermostat housingG421HF-9 pM Tank Level Sender- sender/float assembly. Fits all Scorpio & XR4 over flow tanks.M421LS pN Sender Install Kit- the 3 components (threaded collar, spacer ring, rubber gromett) required to stop a leaking sensor bung. Also a good idea when servicing the tank level sensor (see above part).M421SK pO Cap/Plug- small rubber cap for plugging off the unused waterpump port.G421P pP Hose- lower radiator hose (89 late) has additional tee off hose running to overflow tank @ lower bungG421BH-9 pQ Coolant Tank- oval type tank (use G421TL below) pR Coolant Tank- late style (1990-92) coolant tank.
Rectangular (larger volume) tank is a direct fit upgrade to the oval version listed above.G421TL pS Radiator Cap- cap for Scorpio and XR4's with thread- on coolant tankG421C pK pM pN pO pPpQpR see page 19 for radiators see page 19 for water pump Diagram B pC pDpB pE pG pS pLpS Diagram A pI 2 3. PFpG Automotive air conditioning components seem to be difficult to source and expensive to boot. The XR4 and Scorpio are no exception to the rule. Reason being, a functioning A/C system is considered a 'must have' and some will pay almost any price for cold air on a hot day.
BAT understands that comfort is paramount, but on the other hand it should not require a second mortgage to repair your A/C system. You will find we have a selection of high quality, economically priced A/C parts too help keep you cool without breaking the bank. Most A/C Components for XR4 & Scorpio are interchangeable except where noted.
PA pI pJ pB pEpD pH pA Evaporator- The evaporator (alloy fin/tube design) works as a heat exchanger. Air flowing through the core is cooled, cleaned, and dried. It is also one of the major cost portions of the A/C system, with the Ford original costing around $550.00.
Check out our aftermarket alternative for less than half the cost! M470E pB Expansion Valve- Meters the volume of refrigerant to the evaporator. Expansion valve assembly should be replaced with evaporator or if found faulty. M470EV pC Blower Motor- HVAC system blower motor includes motor and fan wheel. (Scorpio) G470A (XR4) M470A pD Refrigerant Hoses.- The complete refrigerant hose manifold assembly. These are specially re-manufactured units that have the hose running to the fire wall extended so it can be routed further away from the turbo's excessive heat. This is a very common failure item.
(XR4ti) extended hose M470H (Scorpio) standard length hose G470H.additional $100.00 core charge on this item- refundable on return pE A/C Compressor- The compressor is one of the major cost portions of the A/C system, with the Ford original costing upwards of $850.00. Check out our brand new Nippondenso A/C compressor units that are complete including the clutch assembly. M470C pC pF Clutch Assembly.- Replacement magnetic clutch assembly. Available separately from compressor. If a clutch is all you need we have it. M470CL.additional $25.00 core charge on this item- refundable on return pG Condenser- The A/C condenser (alloy tube/fin core) is located ahead of the water radiator. Designed to cool the compressed refrigerants air passes over the cooling fins extracting heat to change hot gasses back to liquid refrigerant as it cools.
Again, one of the major cost portions of the A/C system, with the Ford original costing upwards of $600.00. Check out our aftermarket alternative for considerable cost savings! For XR4 M470D for Scorpio G470D pH Electric Fan- An alternative to the expensive original condenser fan ($450.00). This highly efficient (1200 cfm) 16' electric 'pusher' fan moves more air for le$$. A16F-PU pI Pressure Switch- The triple pressure switch assembly engages the condenser fan and switches off the compressor clutch with high/low pressure. Also a common failure item. M470S pJ Receiver/Dryer- Works as a storage/expansion tank for refrigerant as well as a system dehumidifier.
It is common to replace the dryer when changing over to newer types refrigerants or whenever the A/C system has been open to atmosphere as the dryer is easily contaminated. M470R Air Conditioning System2 4. Turbocharger pC pG/H/I pF pD pA pB pE pA Standard Wastegate Actuator Since the stock XR wastegate is no longer available new, we supply a high quality re manufactured unit. Internal components (diaphragm) are re- placed and exterior is zinc plated.) M521WR pB Turbochargers We offer both re manufactured stock specification and modified high performance turbos for the XR. High quality re manufactured turbos include; new center cartridge compressor/turbine wheel assembly with recondi- tioned outer compressor/turbine housings, new bearings, seals and O-rings and fasteners. Our high performance turbo adds a few extra tweeks. A GNX compressor wheel machined into the stock comp housing for an additional 30% airflow and a 360 degree thrust bearing is fitted for added durability.
Turbos are fully dressed and include wastegate actuator, base & drain gaskets and sold on a exchange 'core' basis- outright purchase will add an additional $100.00 to the cost. Standard Reman. Turbocharger M522TR High Performance Turbocharger M522TM pC Intercooler Kit If you are looking for a large high flow intercooler kit this is the one to have. Intercooler core mounts ahead of the steering rack in front of the engine facing the ground. Air is ducted up and through the core.
Plumbing is kept short and allows for a larger core than what can usually be fitted in the bumper/grille area. Kit is complete with intercooler core (8' x 20' x 3.5'), mounting brackets, inlet plumbing pipes & connectors, clamps, turbo output elbow, bypass valve and additional hardware and instructions.
M522ICpD Adjustable Boost Valve Kit Replace the troublesome stock boost control solenoid with this easy to adjust under hood boost valve. This kit uses a check valve to accurately control the boost level which allows for faster turbo spool-up (reduced lag) over typical adjustable 'bleed-off' valves. This is a low cost modifi- cation and should be a 'must have' for all XR's. M521BV pE Dual Port Wastegate Actuator These are new actua- tors which feature an adjustable length rod (set boost & pre load) and dual vacuum ports. The dual port feature permits use of a remote mounted boost valve (see below), but can also be used as a replacement for stock actuator. M521WA2 pF Cockpit Mounted Boost Valve Remote cockpit mounted adjustable boost valve for use with dual port wastegate actuators (see above).
Vacuum signal is regulated by the in car mounted valve and recirculated to the dual port actuator for precise adjustment. M521TB pG Turbo Oil Feed Pipe is prone to cracking/leaking and should always be replaced when a new turbo is fitted to assure proper oil flow. Just look inside an old one and you will see what we mean. M522P pH Turbo Inlet Hose we have a version of this (discontin- ued by Ford) hose that links the turbo outlet pipe to the throttle body. Ours is high specification 4-ply Silicone (blue) rated to over 600 degrees, 190 psi burst pressure- better & cheaper than the original! M22H pI Stainless Base Gasket replacement for between the turbo base and exhaust manifold.
Ford Sierra 2.0 Workshop Manual
Engine & Related Items pA pB pC pE pDpA Performance Engine Bearings2.3L At engine rebuild time one item not to skimp on are engine bearings. We supply only the finest ACL/Vandervell heavy duty lead-indium type bearings. All bearings are not alike, regardless of who's name is on the box. Lead-indium bearings, not lesser reticular tin- aluminum, are the only type you will find in quality performance engines. Main Bearing Set- ACL/Vandervell (standard)L16A Main Bearing Set- ACL/Vandervell (+.010' over)L16B10 Main Bearing Set- ACL/Vandervell (+.020' over)L16B20 Main Bearing Set- ACL/Vandervell (+.030' over)L16B30 Rod Bearing Set- ACL/Vandervell (standard)L16H Rod Bearing Set- ACL/Vandervell (+.010')L16110 Rod Bearing Set- ACL/Vandervell (+.020')L16120 Rod Bearing Set- ACL/Vandervell (+.030')L16130 Cam Bearing Set- ACL/VandervellL16M Cam Bearing Set- ACL/Vandervell (360 degree O.D.
Groove)L16MA Auxiliary Shaft BearingL5DC pB Performance Engine Fasteners As with engine bearings, skimping on fasteners is false economy. As a minimum install a set of H.D. Rod bolts and nuts for an added degree of reliability. Con Rod Bolt Set (H.D. SPS type) for standard 2.3 rodL4FS Con Rod Bolt Set (H.D.
SPS type) for 5.7 Chevy I-6 rodsL4FSC Head Stud Set (H.D. SPS type)L2DS Main Cap Stud Set (H.D. SPS type)L2KS pC Engine Gaskets (2.3L Turbo) We have a wide range of performance and speciality gaskets available for the 2.3L turbo engine from full sets to individual pieces. Full Gasket Set (complete engine) FelproL15AA Top End Gasket Set (cylinder head, valve train, inlet/exhaust) FelproL15BA Bottom End Gasket Set (block, crank & sump) FelproL15CA Pan Set- sump rails & seals (cork)L15CP Head Gasket H.D.
(Ford Motorsport turbo style)L15D Head Gasket H.D.- FelproL15DA Head Gasket Competition- Felpro #1035 (steel wire ring type)L15DF Head Gasket Competition (extreme duty racing gasket)L15DR Head Space Shim.020'L15DS Valve Cover Gasket (standard cork)L15E Valve Cover Gasket H.D. (hi-temp rubber / includes- upper inlet gasket)L15EA Intake Manifold Gasket Set (upper & lower inlet manifold)L15F Water Outlet Gasket (thermostat housing)L15N Water Pump Gasket (pump to block)L15P Crankshaft Rear SealL15Q Camshaft SealL15R Auxiliary Shaft SealL15S Crankshaft Front SealL15T pD 2.3 Turbo Inlet Hose We have a version of this (recently discontinued by Ford) hose that links the turbo outlet pipe to the throttle body on XR4Ti, T-Bird & SVO. Ours is higher specification 4-ply Silicone (blue) rated to over 600 degrees, 190 psi burst pressure- better & cheaper than the original! M22H pE,F Exhaust Components We offer the Modern Performance line of exhaust related items for the XR4Ti including full systems (hi-flow down pipe, converter and muffler) as well as cat back systems (excludes converter). Exhaust piping and mufflers are constructed in heavy 14 gauge aluminized tubing, converters and mufflers are straight through design for minimum restriction. These systems are unparalleled for performance and sound great too.
The 3' down pipe can be added to standard or Borla systems for increased performance. We also stock the standard Ford cast iron exhaust manifolds (which are prone to cracking) or alternate stainless tubular exhaust headers. Exhaust System 3' (full system) S.S. Muffler & converterM522 Performance Exhaust System 2.5' (down pipe w/cat back)M522B Exhaust Down Pipe 3'M522DP Exhaust Manifold (standard cast Fomoco)M521 Exhaust Header 2.3 Turbo (tubular stainless steel)L521T Gasket (stainless)- Turbo to Exhaust ManafoldL521GT Exhaust Hanger (rubber donut)C522H pF 2 6. Engine & Related Items 2.5mm metallic inductance EMI suppressed conductor: with stainless steel windings spaced over ferrimagnetic core substrate serves as strength member for cable assembly ignition cables have a non-layered high strenght insulating jacket made entirely of aerospace grade silicone rubber to prevent swelling and splitting at extreme trmperatures KV85 & R-100 metallic inductance EMI suppressed conductor pA Performance Air Filters A quick and easy performance modification is to replace the standard air filter with a direct fit KN high performance air filter.
Merkur XR4Ti (2.3L Turbo)M22P Merkur Scorpio (2.9L V-6)G22P pB High Temp Fyre Sleeve The under hood temperatures on the XR4Ti can be quite severe. Slipping a length of fyre sleeve over critical wiring or rubber water & A/C hoses will add an extra degree of protection.
Fyre Sleeve provides radiant heat protection up to 800 degrees. Sleeve is sold per foot and is sized by internal diameter. Hoses or wiring can be disconnected at one or both ends then slipped through fyre sleeve or sleeve can be un-stitched at the seam and wire tied in place. Mylar Fyre Foil Sleeve -10 (7/8' I.D.) per foot320510 Mylar Fyre Foil Sleeve -12 (1' I.D.) per foot320512 Mylar Fyre Foil Sleeve -16 (1 1/4' I.D.) per foot320516 Mylar Fyre Foil Sleeve -20 (1 1/2' I.D.) per foot320520 pC Engine Mount Insulators BAT has an alternative to the recently discontinued original equipment Ford motor mounts on the XR4Ti.
Simply remove the old motor mount assemblies, discard the worn-out rubber portion, and reuse the top and bottom metal plates with our replacement insulators. Note: slight modification requires 10mm holes in plates to be increased to 12mm. Scorpio mounts are Ford mfg. Direct replacements. Engine Mount Insulator (left & right same) XR4TiM433 Engine Mount Insulator (left & right same) Scorpio- new FordG433 pD Transmission Mount /Insulator Rear transmission mount/insulator- direct fit for automatic & manual Scorpio. A heavy duty version also available.
Note: this 'square' type mount can be fitted to the XR4 with special crossmember, (see below) as the standard 'round' trans. Mount used on our XR4Ti's is no longer available. Transmission Mount Insulator.- (automatic & manual) G433T Transmission Mount Insulator H.D.- (automatic & manual) M433TA.can be fitted to XR4 with additional x-member (see below) pE Transmission Crossmember Wide and narrow type transmission tunnel crossmenbers allow the above 'square' mount/insulators to be installed in the XR4Ti. Fitting the XR with this crossmember/mount combination is a consider- able upgrade (strength, noise, vibration) over the USA supplied 'round' mount. Crossmember. XR4 (wide) 1987-89- manual & auto M433XL Crossmember.
XR4 (narrow) 1985-86- manual & autoM433X.for use in combination with above G433, M433 'square' type mount pF Engine Belts H.D. Our search for the ultimate heavy duty engine accessory v-belts lead us to the top cog 'Gold Series' by Dayco. Top cog v- belts are built to last up to 20% longer than conventional belts. A unique cogged design increases flexibility and airflow around the belt for reduced friction and heat. Laminated design with high temperature rated polyester cords provide maximum tension holding (reduced slip) over the life of the belt. Belt- XR4Ti (1985-89) W.
Pump, Alt, P. Steering (2 required)M6G Belt- XR4Ti (1986-89) A/C CompressorM6H Belt- XR4Ti (1985) A/C CompressorM6HA Belt- Scorpio (1988-89) Fan & Power Steering (2 required)G6G Belt- Scorpio (1988-89) AlternatorG6GA Belt- Scorpio (1988-89) A/C CompressorG6H pG Performance Ignition Wire Sets We have tried a number of different ignition wire options on the 2.3 Turbo and 2.9L V6 engines and have found the Magnecor brand to offer superior quality, performance, and durability.
Cables are red in color with 8mm, 8.5mm and 10mm cable diameters. Merkur XR4Ti (2.3L Turbo) Ignition Wire Set- (8mm w/silicone jacket and boots)L9HT Ignition Wire Set- (8.5mm KV85 wire w/silicone jacket and boots)M9HT Ignition Wire Set- (10mm R-100 wire w/silicone jacket and boots)M9HTR Merkur Scorpio (2.9L V6) Ignition Wire Set- (8mm w/silicone jacket and boots)G9HT Ignition Wire Set- (8.5mm KV85 wire w/silicone jacket and boots)G9HT9 pG pF pA Aluminized Mylar Fyre Sleeve pB pC pD pE 2 7. L4-218 L2G L4ES L15D L15DS L604A L15E L2KS L4FS 2300 Turbo Engine Components Cylinder Block Bare (H.D.
'Turbo' Block) L2G 475.00 Main Cap Stud Set (H.D. Engine Components Camshafts- see chart below Hydraulic Lash Adjuster Set- (standard O.E. Type) L5BA 43.00 Hydraulic Lash Adjuster Set- (high rev. Anti pump-up) L5BH 49.95 Intake Valve- (standard O.E. Type) L3H 8.25 Intake Valve- 1.740' (oversized stainless steel hi-flow) eachL3HA 13.25 Intake Valve- 1.890' (oversized stainless steel hi-flow) eachL3HB 15.00 Exhaust Valve- (standard O.E.
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