CD changer FORD SIERRA 1982 1.G XR4 Workshop Manual

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. 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.
(for automatic trans)G421RA
(for manual trans.)G421R
pF
Hose- coolant tank to thermostat housingG421HF
pG
Hose- top radiator hose (88-89)G421TH
pG
Hose*- top radiator hose (89 late) has vent air bleed in line
(includes bleed screw).G421TH-9
*for additional info see (diagram B) on page 20
pH Hose- tank (lower) to water pumpG421HH
pI
Water Pump- new Ford water pumpG421
pI
Water Pump- high quality reconditioned water pump on
Ford core.G421A
Hose*- bypass from water pump to inlet mfld.G421HP
*for additional info see (diagram A) on page 20
pJ Hose- lower radiator hose 88-89G421BH
pJ
Hose*- lower radiator hose (89 late) has additional tee off
hose running to overflow tank @ lower bungG421BH-9
*for additional info see (diagram B) on page 20
pK Hose*- to oil cooler pipeG421HK
pL
Hose*- oil cooler pipe to oil coolerG421HL
*for additional info see (diagram A) on page 20
pM Coolant Tank- Cracked and leaking overflow tanks are a
common problem on the Scorpio. Tank pictured above is for early
(1988) type cars.
See page 20 for late style tanks.G421TE
pN
Radiator Cap- cap for Scorpio and XR4's with thread-on
coolant tankG421C
pO
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.AD1000
pP Heater Control Valve- heater control valve, same on
XR4 & ScorpioM421V
pQ
Heater Core- Quality Ford O.E. heater cores.G471
pR
Mechanical Fan Clutch- Quality Ford O.E.G422
pR
Electric Fan- An altermative to the Scorpio mechanical
clutch fan. This highly efficent (1150 cfm) 16" electric "puller" fan
moves more air and frees up a few HP to boot. Wire directly or use
our (optional) adjustable 165-215 degree thermostat/relay wiring kit.
(16" electric fan) A16F-PL
(thermo/relay wiring kit) AFTR1
pS
Heater A/C Blower Motor- New Ford heater blower motor
for Scorpio with 8 wire harness/plug.
G470H
see (diagram A) on page 20
2 2

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

Price List
PAGE 23 cooling system (Scorpio)
Hose- heater valve (out) to core G421HA 8.90
Hose- heater valve to engine G421HB 17.50
Hose- heater valve (inlet) to core G421HC 13.95
Hose- heater valve to pipe G421HD 18.75
Heater Control Valve- XR4 & Scorpio M421V 60.00
Hose- coolant pipe to oil cooler from heat valve G421HL 9.90
Oil Cooler- oil to water heat exchanger AD1000 110.00
Hose- oil cooler to coolant pipe G421HM 14.40
Hose- coolant pipe from oil cooler to water pump G421HK 17.90
Hose- bypass/ water pump outlet to inlet mfld. G421HP 14.10
Hose- upper radiator (late 89) w/vent G421TH-9 35.00
Hose- coolant tank to thermo housing G421HF-9 16.45
Tank Lever Sender M421LS 40.25
Lever Sender Install Kit M421SK 9.40
Cap/Plug- Rubber G421P 2.50
Hose- lower radiator (late 89) w/tee off hose G421BH-9 35.75
Coolant Tank (6/88>89) Oval TypeG421T 52.00
Coolant Tank (late style 6-88>2-92) rectangular shapeG421TL 46.00
Radiator Cap (thread-on) Scorpio & late XR4 G421C 7.35
PAGE 24 A/C system
Evaporator- (XR4 & Scorpio) M470E 245.75
Expansion Valve - (XR4 & Scorpio) M470EV 46.50
Blower Motor - (XR4)
O.E. FordM470A 198.00
Blower Motor - (Scorpio)
O.E. FordG470A 230.00
Refrigerant Hoses*- (XR4Ti only) M470H 149.00
Refrigerant Hoses*- (Scorpio) G470H 129.00
*this item requires an additional 100.00 charge refundable upon core return
Compressor- (XR4 & Scorpio) includes clutchM470C 429.00
Clutch Assembly*- (XR4 & Scorpio) M470CL 157.50
*this item requires an additional 25.00 charge refundable upon core return
Condenser- (XR4) M470D 335.00
Condenser- (Scorpio) G470D 335.00
Electric Condenser Fan- 16" Pusher (XR4 & Scorpio)A16F-PU 89.00
Fan Mounting Tie Set (for above fan)ABKT1 7.95
Pressure Switch-
(XR4 & Scorpio) O.E. Ford DISCONTINUED
Receiver/Dryer- (XR4 & Scorpio) M470R 108.00
Receiver/Dryer- (XR4 & Scorpio) O.E. Ford M470R-F 131.50
PAGE 25 turbo components
Wastegate Actuator* -Reman. M521WR 95.00
*this item requires an additional 30.00 charge refundable upon core return
Turbo/Reman* (specify auto or 5-speed) M522TR 425.00
Performance Turbo* M522TM 649.00
*this item requires an additional 100.00 charge refundable upon core return
Intercooler Kit M522IC 1195.00
Adjustable Boost Kit M521BV 48.00
Wastegate Actuator (adjustable rod- dual port) M521WA2 119.00
Cockpit Mount Adjustable Boost Kit (remote valve) M521TB 74.50
Turbo Oil Feed Pipe M522P 19.00
Turbo Inlet Hose (45 degree elbow) M22H 44.50
Turbo Base Gasket L521GT 8.75
02/05/023 9
PAGE 26 engine & related
Main Bearing Set (STD) L16A 32.65
Main Bearing Set (+.010") L16B10 32.65
Main Bearing Set (+.020") L16B20 32.65
Main Bearing Set (+.030") L16B30 32.65
Rod Bearing Set (STD) L16H 16.35
Rod Bearing Set (+.010") L16110 16.35
Rod Bearing Set (+.020") L16120 16.35
Rod Bearing Set (+.030") L16130 16.35
Cam Bearing Set L16M 18.50
Cam Bearing Set- grooved L16MA 18.50
Aux. Shaft Bearing L5DC 10.50
Connecting Rod Bolt Set H.D. (standard 2.3 rod) L4FS 44.30
Connecting Rod Bolt Set H.D. (5.7" Chevy rod) L4FSC 35.00
Head Stud Set H.D. L2DS 98.40
Main Stud Set H.D. L2KS 89.20
Full Gasket Set (complete engine) Felpro L15AA 95.00
Top End Gasket Set Felpro L15BA 55.50
Bottom End Gasket Set (block, crank & sump) Felpro L15CA 40.10
Pan Set- sump rails & seals (cork) L15CP 22.05
Head Gasket H.D. (Ford Motorsport turbo style) L15D 16.00
Head Gasket H.D.- Felpro L15DA 19.50
Head Gasket Competition (extreme duty racing gasket)L15DR 29.50
Head Space Shim .020" L15DS 17.85
Valve Cover Gasket (standard cork) L15E 6.75
Valve Cover Gasket H.D. 2300 (hi-temp rubber)L15EA 24.00
Valve Cover Gaskets H.D. 2.9L V6 (hi-temp rubber)G15EA 15.50
Intake Manifold Gasket Set L15FA 11.40
Water Outlet Gasket (thermostat housing) L15N CALL
Water Pump Gasket (pump to block) L15P CALL
Crankshaft Rear Seal L15Q CALL
Camshaft Seal L15R 8.25
Auxiliary Shaft Seal L15S 9.25
Crankshaft Front Seal L15T 16.08
Inlet Hose- Turbo to T.Body (silicone blue) M22H 45.00
Performance Exhaust System 3" (full system) M522 705.00
Performance Exhaust System 2.5" (down pipe w/cat back)M522B 425.00
Exhaust Down Pipe 3" M522DP 159.00
Exhaust Manifold (standard cast Fomoco) M521 185.00
Exhaust Header 2.3 Turbo (tubular stainless steel) L521T 595.00
Gasket- turbocharger to manifold (stainless) L521GT 8.75
Exhaust Hanger (rubber donut) each C522H 5.25
PAGE 27
engine & related
Air Filter- XR4Ti (2.3L Turbo) M22P 35.10
Air Filter- Scorpio (2.9L V-6) G22P 50.00
Mylar Fyre Foil Sleeve -10 (7/8" I.D.) per foot 320510 4.55
Mylar Fyre Foil Sleeve -12 (1" I.D.) per foot 320512 4.90
Mylar Fyre Foil Sleeve -16 (1 1/4" I.D.) per foot 320516 5.64
Mylar Fyre Foil Sleeve -20 (1 1/2" I.D.) per foot 320520 6.32
Motor Mount Insulator (left or right same) XR- each M433 99.50
Motor Mount Insulator (L or R same) Scorpio- each G433 69.45
Transmission Mount/Insulator- Scorpio G433T 39.50
Transmission Mount/Insulator H.D. M433TA 53.00
Trans Crossmember XR (wide) 87-89 manual & auto
DISCONTINUED
Trans Crossmember XR (narrow) 85-86 manual & autoDISCONTINUED
Belt- XR4Ti (1985-89) W. Pump, Alt, P. SteeringM6G 11.90
Belt- XR4Ti (1986-89)
A/C Comp.M6H 9.50
Belt- XR4Ti (1985)
A/C Comp.M6HA 9.50
Belt- Scorpio (1988-89)
Fan & Power SteeringG6G 14.20
Belt- Scorpio (1988-89)
AlternatorG6GA 12.65
Belt- Scorpio (1988-89)
A/C Comp.G6H 10.25
Ignition Wire Set- XR4Ti (8mm ) L9HT 39.95
Ignition Wire Set- XR4Ti (8.5mm KV85 wire) M9HT 69.50
Ignition Wire Set- XR4Ti (10mm R-100 wire) M9HTR 79.00
Ignition Wire Set- Scorpio (8mm) G9HT 50.75
Ignition Wire Set- Scorpio (8.5mm KV85 wire) G9HT9 88.75