FORD SIERRA 1985 1.G XR4 Owner's Manual

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. 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

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pV
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continuation
pV
pG
pH
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pC pB
pA
pL
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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
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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
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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
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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. L521GT
2 5

Engine & Related Items
pA
pB
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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. ARP) L2KS 94.55
Full Gasket Set (Felpro)
1985 engineL15AA 95.00
Full Gasket Set (Felpro)
1986-89 engineL15AB 124.50
Top End Gasket Set (Felpro)
specify year when orderingL15BA 55.00
Top End Gasket Set (Felpro)
with hi-temp valve cover setL15BB 79.50
Bottom End Gasket Set (Felpro)
1985 engine (cork pan)L15CA 40.10
Bottom End Gasket Set (Felpro)
1986-89 engine (rubber pan)L15CB 73.85
Oil Pan Gasket (1 piece rubber) 1986-89 L15CP 34.25
Head Gasket (Felpro) L15DA 19.50
Competition Head Gasket (Felpro #1035)
steel wire ring typeL15DF 59.50
Competition Head Gasket (extreme duty racing gasket) L15DR 29.50
Valve Cover Gasket- Cork L15E 6.79
Valve Cover Gasket H.D. (1 piece rubber) includes upper manifoldL15EA 24.00
Intake Manifold Gasket Set L15FA 11.40
Exhaust Manifold to Cylinder Head L15GA 7.50
Turbo Charger to Exhaust Manifold (stainless) L521GT 8.75
Water Outlet Gasket L15N CALL
Water Pump GasketL15P CALL
Camshaft Seal L15R 8.25
Auxiliary Shaft Seal L15S 9.25
Crankshaft Front Seal L15T 16.08
Oil Pump (standard)
MellingL2P 42.90
Oil Pump- (high pressure/ high volume) L2HP 73.20
Water Pump (new) L6A 73.10
Water Pump (recon) L6AA 39.00
Fuel Pump- Electric XR4Ti (in line) M10A 165.00
Fuel Pump- Electric XR4Ti (in tank) M10AT 125.00
Engine Components
Utilizing a design similar to the earlier German
2000 OHC "Pinto" engine the 2300 "Lima" en-
gine eventually replaced the 2000 OHC in most
North American Ford 4 cylinder vehicles from
1974 on. Built for lower maintenance with the
addition of hydraulic lash
adjusters the 2300
was designed to
operate in a lower
RPM range using
its larger displace-
ment and in-
creased torque to
its best advan-
tage. Perfor-
mance turbo-
charged versions
of the 2300 began
to appear in 1979 in
the Mustang/Capri and continued through the
80's in a more refined and powerfull EFI turbo
version. A reduced bore 2000 displacement
"Ranger" truck engine (from 1983-87) was also
produced. Some late production "Lima" engines
are equipped with hydraulic roller cam and valve
train, and other versions use dual spark plug
cylinder heads. The 2300 is a fairly rugged
engine in its stock form, however some compo-
nents will require up-rating with performance
components if high RPM duty is required. The
"Lima" series turbo and normally aspirated en-
gines respond quite well with a bit of perfor-
mance tuning and though lacking in refinement
do give quite a bit of bang for the buck.
Main Bearing Set- ACL/Vandervell (std, .010", .020", .030") L16A 32.65
Connecting Rod Set- (4) Forged H-beam 5.20" length L4ES 549.00
Connecting Rod Set- (4) Forged
I-beam 5.20" length L4ESB 398.00
Connecting Rod Set- (4) Forged H-beam 5.70" length L4ESA 549.00
Rod Bearing Set- ACL/Vandervell (std, .010", .020", .030") L16H 16.35
Con Rod Bolt Set- ARP H.D. (for standard 2.3L rod) L4FS 47.70
Head Stud Set- ARP H.D. L2DS 105.00
Cam Bearing Set- ACL/Vandervell L16M 18.50
Cam Bearing Set- ACL/Vandervell (360 degree O.D. groove) L16MA 18.50
Aux. Shaft Bearing L5DC 20.25
Cam Follower- (standard O.E. type)
eachL5B 7.50
Cam Follower- (roller type)
eachL5BR 16.00
Ring Set- Moly type 1/16", 1/16", 3/16" (std, .020", .030", .040", .060")

*for above "performance pistons" - specify sizeL4R 85.90
Ring Set*- Gapless Moly type 1/16", 1/16", 3/16" (std, .020", .030", .040", .060")

*for above "performance pistons" - specify sizeL4TF 98.00
Ring Set*- Gapless Moly type 1/16", 1/16", 3/16" (std, .025", .035", .045", .065")

*for above "performance pistons" - file fit top ringL4T1 127.50
Ring Set*- Gapless Moly type 2mm, 2mm, 4.75mm (std, .020", .030", .040", .060")
*for standard OE type pistons - specify sizeL4TFA 98.00
Performance Piston- Power Forged #250F (std, +.020", +.030", +.040", +.060 sizes)
exact replacement for standard 2.3 turbo piston, light weight "power forged"
design, 1.589" comperssion height for 8.0:1 compression, 2mm 2mm 4.75mm
ring land, supplied with wrist pins and locks.
L4-250F 62.20
Performance Piston- Forged (custom)
BAT can supply custom forged pistons to your specifications. Information regarding
bore size, ring land sizes & locations, compression height, and wrist pin bore size
is required for ordering. Pricing is on request
2 8

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. type)
eachL31 25.75
Exhaust Valve- 1.510" (oversized stainless steel hi-flow)
eachL31A 13.25
Exhaust Valve- 1.590" (oversized stainless steel hi-flow)
eachL31B 15.00
Valve Spring Retainers (various)-
call with specific application------CALL
Valve Spring Set- (sport spring set for hydro cams to .480" lift) L3F 73.75
Valve Springs Racing-
call with specific application------CALL
Electric Fan Switch -XRM450FS 24.50
Knock Sensor-XRM450KS 52.70
Engine Coolant Temp Sensor (ECT)-XR M450EC 28.45
Idle Speed (Air Bypass Valve) XR/Scorpio
M450IS 79.90
Throttle Position Sensor (TPS)-XR M450TP 47.60
Oxygen Sensor (OS)-XRM450OS 60.50
Oil Pressure Switch-XRM450P 6.40
Water Temp Gauge Sender- XR (purple band)M450F 39.75
Adjustable Cam Sprocket (key way type) L5F 34.95
Adjustable Cam Sprocket (vernier type) L5FA 95.75
Cam Belt- (H.D. Ford Motorsport) L5G 29.95
Cam Belt- (H.D. Pirelli type)L5GA 15.00
Fuel Injector 2.3L Turbo (35pph -disk type) each L7G 68.50
Fuel Injector 2.3L Turbo- Remanufactured (35pph -brown top) each M7G 49.50
Intake Hose- Turbo Outlet to Throttle Body (Hi-Temp 4-Ply Silicone "Blue") XR4Ti, T-Bird & SVO M22H 47.00
Air Vane Meter* 50mm (T-Bird)
reconditionedL7V 164.50
Air Vane Meter* 65mm (SVO)
reconditionedL7VA 175.00
*can also be used for performance upgrade on XR4Ti with "PE" programed chip (call for information)
Distributor- 2.3L Turbo (reman) w/o cap, rotor, module (35.00 core) L9AB 119.00
Distributor Cap H.D. (hi-temp epoxy w/brass terminals) L9B 16.98
Distributor Rotor H.D. (hi-temp epoxy)
85-86 screw down typeL9F 7.50
Distributor Rotor H.D. (hi-temp epoxy)
87-89 push-on typeL9FA 8.90
Ignition Module TFI (on distributor) L9M 80.75
Ignition Wire Set- (8mm custom length w/silicone jacket and boots)L9HT 39.00
Ignition Wire Set- (8.5mm custom length w/silicone jacket and boots) M9HT69.50
Ignition Wire Set- (10mm custom length w/silicone jacket and boots)M9HTR 79.50
Performance Air Filter KN (2.3L Turbo) XR4Ti M22P 32.50
*durations quoted gross & .050" - timing events are @.050"
Grind#
Pricing $DescriptionPower
BandCam Lift
inlet/exhst.Valve Lift
inlet/exhst.Duration
inlet/exhTim ing
FiguresTiming
Inlet @
Full LiftValve
Clearance
inlet/exhst.Com m ents
2300 Turbo Camshafts (Hydraulic)
H260
$169.00Hydraulic2500-6000.252"/.252".416"/.416"272/272
220/2200/40 40/01100 / 0smooth idle, strong low and mid performance,
turbo suitable, auto & manual trans.
H283
$169.00Hydraulic3500-6500.274"/.274".453"/.453"276/276
224/2242/42 42/21100 / 0good idle, strong low and mid performance,
turbo suitable, manual transmission only
2300 Turbo Camshafts (Hydraulic Roller*) *for cars origionally equipped or kit available below
HR220
$385.00Hydro-roller2700-6500.305"/.305".505"/.505"272/222
221/231------1110 / 0H.P. roller cam for cars origionally roller cam equipped,
or see kit below- manual transmission only
HR225
$399.00Hydro-roller3000-6800.314"/.314".520"/.520"280/280
226/226------1110 / 0H.P. roller cam for cars origionally roller cam equipped,
or see kit below- manual transmission only
HR310
$375.00Hydro-roller3000-7000.317"/.317".535"/.535"284/284
224/2240/44 44/01120 / 0H.P. roller cam for cars origionally equipped.
turbos use 112 centerline, manual transmission only
2300 Turbo Camshaft Kits (Hydraulic Roller)
HR220K
$680.00Hydro-roller
cam kit2700-6500.305"/.305".505"/.505"272/222
221/231------1110 / 0Kit Includes: camshaft, roller followers, valve springs,
valve keepers & retainers, lash caps & cam oil seal
HR225K
$715.00Hydro-roller
cam kit3000-6800.314"/.314".520"/.520"280/280
226/226------1110 / 0Kit Includes: camshaft, roller followers, valve springs,
valve keepers & retainers, lash caps & cam oil seal
2 9