power steering FORD SIERRA 1983 1.G XR4 Workshop Manual

pA Sway Bar Bushings H.D. Urethane sway bar bushings in 25mm for
standard XR4 and 28mm for larger Sierra Cosworth or Scorpio sway bars.
Note: XR4Ti and Scorpio sway bar clamps differ slightly making the bushings
non-interchangeable. XR's that require replacement bar clamps (see below) will
then require Scorpio type bushings to match. (bushings sold each)
Bar Bushing H.D. 25mm- (direct fit) XR4 M407BU
Bar Bushing H.D. 28mm- (direct fit) XR4 M407BAU
Bar Bushing H.D. 25mm- (special) XR4 with G407C clampG407BA
Bar Bushing H.D. 28mm- (direct fit) Scorpio G407BAU
pB
Sway Bar Bushing Clamps The European type sway bar bushing
clamp (used on Scorpio & Cosworth) has a groove to receive a ridge back
type bushing. Clamps are a direct replacement for Scorpio and can also be
used to replace worn or broken clamps on XR4 with correct bushings (see
above).
(2) required- sold each
Sway Bar Bushing Clamp (each)- Scorpio G407C
pC
Steering Rack Complete ZF type rack assemblies include inner tie
rods, boots, and stainless steel inner sleeve.
Steering Rack Assembly- XR4 M434SR
Steering Rack Assembly- Scorpio G434SR
Steering Rack Bushing Standard and H.D. (urethane) rack bushings
(2) required (sold each)
Steering Rack Bushing (each)- XR4 & Scorpio M434B
Steering Rack Bushing H.D (each)- XR4 & Scorpio M434BH
pD
Inner Tie Rod High quality European Ford inner tie rods available
for XR4 and Scorpio.
(sold each)
Inner Tie Rod- XR4Ti M434TK
Inner Tie Rod- Scorpio (left & right same) G434TK
pE
Rack Boot All rubber steering rack bellows (boots). Suitable for both
XR4 and Scorpio.
(left & right rack boots same- sold each)
Steering Rack Boot (each) -XR4 & Scorpio M434RB
pF Outer Tie Rod End High quality European Ford outer tie rod ends
available for XR4 and Scorpio.
(each)
Tie Rod End- XR4 (left) M434L
Tie Rod End- XR4 (right) M434R
Tie Rod End- Scorpio (left & right same) G434
pG
Power Steering Pumps Direct fit, replacement power steering
pumps for XR4 and Scorpio applications.
(core charge required)
Power Steering Pump- XR4Ti (integral reservoir type) M434P
Power Steering Pump- XR4Ti (remote reservoir type) M434PA
Power Steering Pump- Scorpio (all) G434P
pH
P/S Pressure Hose We have these hard to find pressure side hoses
available for all model year XR4Ti's.
P/S Pressure Hose- XR4Ti (all years) M434PH
pI
Strut Boot/Bump Stop These H.D. strut boot/bump stops help
reduce the chance of strut damage due to over-compression and/or strut rod/
seal damage from dirt and corrosion. A specially designed one piece bellows
with integral (NBR),"nitrile butadiene", variable rate bump rubber make these
especially well suited for lowered ride height suspensions.
(sold each)
Strut Boot/Bump Stop (each) -XR4 & Scorpio M405B
Front Strut Rotating Bearings
Upper Rotating Bearing (each) -Scorpio G403
Upper Rotating Bearing (each) -XR4M403
pF pC
pEpD
Suspension & Steering
pA/B
0 4
pI
pH pG

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

Price List
This catalog is viewable and
downloadable from our internet site
(www.batinc.net) you can get
catalog updates there too.
PAGE 2 front suspension & steering
Front Sway Bar- Cosworth 28mm M407 185.00
Front Strut- Spax Adjustable (each) XR M401A 165.00
Front Strut- Spax Sport- fixed rate- (each) XR M401V 99.50
Front Strut- Bilstein-Gas- (each) XR M401B 92.50
Front Strut- R/S Adjustable (each) XR M401RS 219.95
Front Strut- Koni Sport (each) Scorpio G401K 199.95
Front Strut- Boge Turbo-Gas (each) XR M401S 97.50
Front Strut- Boge Turbo-Gas (each) Scorpio G401S 101.50
Front Strut- DeCarbon Gas (each) XR M401G 145.00
Front Strut- DeCarbon Gas (each) Scorpio G401G 145.00
Front Strut- KYB GR2 (each) XR M401Y 99.50
Front Strut- KYB GR2 (each) Scorpio G401Y 99.50
Steering Rack Assembly* (XR) M434SR 349.00
Steering Rack Assembly* Scorpio G434SR 349.00
*this item requires an additional 100.00 charge refundable upon core return
Steering Rack Bushing H.D. (set) M434BH 30.00
Steering Rack Boot (left or right) XR & Scorpio M434RB 15.50
Control Arm* (left) XR M428L 75.00
Control Arm* (left) Scorpio G428L 99.50
Control Arm* (right) XR M428R 75.00
Control Arm* (right) Scorpio G428R 99.50
*NEW control arms (ball joints and bushings are installed)
Adjustable Control Arms (pair) w/bushings DISCONTINUED
Adjustable Control Arms- Race (pair) DISCONTINUED
Bushing- H.D. (GPN) Inner Control Arm (each) M428BH-N 16.75
Bushing- H.D. (GPN) Inner Control Arm (each) ScorpioG428BH-N 22.50
Bushings- Urethane Inner Control Arm (set) M428BU 30.00
Bushings- Urethane Inner Control Arm (set) Scoprio G428BU 35.00
Bushing (standard) Inner Control Arm (each) XR C428B 9.50
Bushings*- Urethane Outer Control/Sway (set) M428BK 70.00
Bushings*- H.D. (GPN) Outer Control/Sway (set) M428BK-N 50.00
Bushings*(standard) Outer Control/Sway (1 arm pair) M428B 20.00
*M428B, M428BK & M428BK-N are all suitable for Scorpio
Washer (shallow)- Sway Bar / Outer TCA (each) M407W 2.95
Tie Rod End (left) XR M434L 24.50
Tie Rod End (right) XR M434R 24.50
Tie Rod End (same L or R) Scorpio G434 27.50
Mount/Insulator -H.D. Upper Strut (each) XR M404 24.00
Upper Strut Mount/Insulator- Scorpio (each) G404 24.50
Upper Strut Rotating Bearing- Scorpio (each) G403 7.95
Upper Strut Rotating Bearing- XR4 (each) M403 9.50
PAGE 3 suspension components
Spax Sport Kit -XR M400S 495.00
Spax Sport Kit (adjustable) XR M400A 649.00
Sport Spring Set (4) front/rear (-25mm) XR M414M 189.50
Sport Spring Set (4) front/rear (-40mm) XR M414C 225.00
Sport Spring Set (4) front/rear (standard height) XR M414S 249.00
Sport Spring Set (4) front/rear (-30mm) Scorpio G414M 269.00
Front Spring Scorpio - Standard O.E. Ford (each) G414 63.65
Rear Spring Scorpio - Standard O.E. Ford (each) G415 106.40
Rear Camber Shim Kit -XR M423R 30.00
Front Upper Strut Brace (alloy) XR M403F 149.50
Rear Upper Shock Brace (alloy) XR M403R 142.50
Rear Upper Shock Brace (steel) XR M403RS 78.00
PAGE 4 suspension components
Bar Bushing H.D. 25mm- XR4 w/standard bar M407BU 20.00
Bar Bushing H.D. 28mm- XR4 w/Cosworth barM407BAU 20.00
Bar Bushing H.D. 25mm- XR4 w/ std. bar & G407C clampG407BA 20.00Bar Bushing H.D. 28mm- ScorpioG407BAU 20.00
Front Sway Bar Clamp- Scorpio (each) M407C 7.50
Steering Rack Assembly* XR M434SR 349.00
Steering Rack Assembly* Scorpio G434SR 349.00
*this item requires an additional 100.00 charge refundable upon core return
Steering Rack Bushing (each) M434B 8.70
Steering Rack Bushing H.D. (each) M434BH 20.00
Inner Tie Rod -XR4 M434TK 51.00
Inner Tie Rod -Scorpio G434TK 51.00Steering Rack Boot (left or right) XR & Scorpio M434RB 16.75
Outer Tie Rod End (left) XR M434L 24.50
Outer Tie Rod End (right) XR M434R 24.50
Outer Tie Rod End (same L or R) Scorpio G434 27.50
Power Steering Pump XR4Ti* (integral reservoir) M434P 135.00
Power Steering Pump XR4Ti* (remote reservoir) M434PA 136.00
Power Steering Pump Scorpio* G434P 136.00
*this item requires an additional 25.00 charge refundable upon core return
P/S Pressure Hose XR4Ti M434PH 58.33
Strut Boot/Bump Stop (each) XR & Scorpio M405B 19.00
Strut Insulator/Bearing Kit XR4 (does 1 side) M403K 7.00
Upper Rotating Bearing XR4 (each) M403 8.50
Upper Rotating Bearing Scorpio (each) G403 7.95
PAGE 5
Pricing is listed with part numbers on this pages
PAGE 6
rear suspension
Rear Sway Bar w/bush- Cosworth 16mm (XR4) M408 99.50Rear Sway Bar w/bush- Cosworth 18mm (Scorpio only)G408 89.95
Rear Bar End Shackle (each) -XR M408S 15.00
Rear Bar End Shackle (each) -Scorpio G408S 15.00
Rear Bar Bush(12mm) urethane (each) stock XR4 M408BU 6.00
Rear Bar Bush (16mm) urethane (each) Cosworth M408BAU 6.00
Rear Bar Bush (16mm) urethane (each) Scorpio G408BU 6.00
Rear Control Arm Set -H.D. Competition M424 675.00
Bushing*- Urethane Outer Control Arm (each) M424BO 29.75
Bushing*- GPN Outer Control Arm (each) M424BO-N 30.50
Bushing*- GPN Body Beam Mount (each) M429B 36.75
Bushing*- Urethane H.D. Body Beam Mount (each) M429BU 54.50
Bushing*- Urethane Inner Control Arm (each) M424BI 29.75
*above bushings also Scorpio suitable
Beam/Subframe Assembly -H.D. CompetitionDISCONTINUED
Rear Shock- Spax Adjustable (each) XR M402A 89.00
Rear Shock- Spax Adjustable (each) Scorpio G402A 105.50
Rear Shock- Spax Sport- fixed rate- (each) XR M402V 75.00
Rear Shock- Bilstein- Gas (each) XR M402B 73.00
Rear Shock- Koni R/S Adjustable (each) XR M402RS 99.50
Rear Shock- Koni Sport (each) Scorpio G402K 122.85Rear Shock- Boge Turbo-Gas (each) XR M402S 75.50
Rear Shock- Boge Turbo-Gas (each) Scorpio G402S 62.50
Rear Shock- DeCarbon-Gas (each) XR M402G 63.00Rear Shock- DeCarbon-Gas (each) Scorpio G402G 87.00
Rear Shock- KYB (each) XR M402Y 46.50
Rear Shock -KYB (each) Scorpio G402Y 46.50
IMPORTANT PRICE LIST NOTES:
(1) Scorpio versions of listed XR4 parts will generally
appear below XR4 item in
italics.
(2) Items that apply for both XR4 & Scorpio are noted.
(3) Fitment notes, and core charge information is also
italicized.
(4) Additional items that do not appear in the literature
can be found in with the corresponding category /
page number reference. These listings are also
italicized.
3 503/11/02

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