oil FORD SIERRA 1985 1.G XR4 Workshop Manual

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Suspension - (front)0 2
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sway bar bushings
(see page 4)
pF Front Control Arms higher mileage cars exhibiting ball
joint and bushing wear can benefit from our standard control
arms. These arms are brand new, and include ball joints and
bushings installed.
Note: the outboard (sway/control arm) bushing
is an uprated "castellated" design which transmits less vibration
than the original U.S. spec. bushing.
(left) M428L
(right) M428R
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Inner Control Arm Bushing H.D. Made from
increased durometer rubber, these heavy duty (GPN) bushings
offer the desired firming effect while retaining a reasonable
degree of shock and vibration absorption. (each) M428BH-N
Optional urethane version of above bushing(set) M428BU
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Control Arm/Sway Bar Bushing Kit This heavy
duty urethane bushing set really does an excellent job
limiting the amount of "jutter" felt at the steering wheel
which is especially noticeable under braking. The kit includes
bushing halves and center sleeves to do both sides of the
car and is easy to install.
(set) M428BK
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Control Arm/Sway Bar Bushings As an option to
urethane bushings we offer either the "castellated" type
outer TCA bushings are available in standard rubber, or the
new style (better fills the void between the bushing halves)
H.D. GPN bushing kit. Both will dramatically reduce the
vibration under braking common to XR's and Scorpio's.
Outer TCA Bushings Standard (pair) does 1 armM428B
Outer TCA Bushing Set H.D. (set)M428BK-N
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Sway Bar Washer Get the most from your new
"castellated" type outer TCA bushings by using this "shallow"
washer (in front behind the lock nut) for a tighter fit.M407W
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Tie Rod Ends High quality European Ford standard
replacement tie rod ends. (left) M434L (right) M434R
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Front Strut Upper Insulator H.D. Made from increased
durometer rubber, these heavy duty (GPN) Insulators offer the
desired firming effect while retaining a reasonable degree of
shock and vibration absorption. Steering and transitional
response becomes noticeably more direct.(each) M404 pA
Front Sway Bar The larger Cosworth Sierra 28.5mm
factory front sway bar is a direct replacement for the standard
25mm bar.
(H.D. bar clamp bushings are included)M407
NOTE: see price list for sway bar clamp bushings for XR & Scorpio
pB Spring Sets see page 3 (spring section) for listings
pC Front Struts (see below- shocks sold as each)
Spax TA series struts utilize a non pressurized gas over oil design
with 10 positive settings (knob type external adjustment on top) for
tuning the dampening to suit individual applications.M401A
Spax Sport One of the most popular shocks we sell, Spax fixed rate
gas sport shocks are an excellent choice for upgrading the handling
performance on the XR. M401V
Bilstein New for 2000. Bilstein's new sprint series gas shocks
offer the big B's renowned German made performance at a very
attractive price. Bilstein shocks are now available in our
suspension kits see page 3 for details.M401B
Rally/Sport Super-Gas made to European Ford spec. by Koni of
Holland. R/S shocks feature Konis twin-tube low pressure design and
have adjustable settings (knob type external adjustment on top) which
can be tailored to suit individual applications.
M401RS
Boge Turbo-Gas German manufactured twin tube high pressure
gas design utilizing a unique variable valving system that insures
the perfect balance between ride comfort and road holding
capability.M401S
DeCarbon French made mono tube high pressure gas shocks with
fairly sporty valving, similar in design to Bilstein.M401G
KYB GR2 gas struts are high quality, heavy duty units that are
a cost effective performance upgrade for the XR4. Handling is
improved without sacrificing ride quality.M401Y
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Steering Rack complete rack assembly w/inner tie rods,
boots, and stainless steel inner sleeve. M434SR
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Rack Boot* replacement steering rack boot M434RB
*same boot left or right XR4 & Scorpio
Shock Absorbers
GAS SHOCK ABSORBERSSUPER
GAS SHOCK ABSORBERScheck price lists for Scorpio versions of listed items check price lists for Scorpio versions of listed itemscheck price lists for Scorpio versions of listed items check price lists for Scorpio versions of listed items
check price lists for Scorpio versions of listed items

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GAS SHOCK ABSORBERS
pA Rear Sway Bar The larger Cosworth Sierra 16mm rear
sway bar is a direct replacement for standard U.S. spec. rear
bar.
(bar includes urethane bar clamp bushings)M408
Cosworth Bar 18mm w/bush for Scorpio G408
Rear Sway Bar Shackle Worn sway bar end link shackles
can reduce the rollbars effectiveness and should be
inspected and replaced if needed. (each)M408S
Rear Sway Bar Shackle for Scorpio G408S
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Rear Bar Bushings H.D. urethane bushings for either
standard 12mm or Cosworth 16mm bars. (sold each)
(12mm size) M408BU (16mm size) M408BAU
pC Spring Sets See page 3 for spring selection.
pD Rear Wishbone Set H.D. Race prepared rear arms are
fully strengthened with bracing tubes and capped to give a smooth
lower surface. The shock absorber mounts are gusseted for added
reliability. Inner and outer bushings are replaced with race quality
spherical bearings. Wishbones are supplied in a durable shot
blasted, powder coated finish.
M424
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Outer Rear Arm Bushing H.D. Made from specalized
aircraft urethane, these heavy duty bushings offer the desired
firming effect while retaining a reasonable degree of shock and
vibration absorption. (each-
2 halves w/sleeve) M424BO
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Body Beam Mount Bushing H.D. This heavy duty
rubber (GP N) bushing/mounts will reduce the for/aft movement
at the rear axle beam mounting points and really does a great job
in firming up the rear end. (each)M429B
optional urethane version of above bushingM429BU
note M429BU is specially designed for easy installation
pG Inner Rear Arm Bushing H.D. Made from specalized
aircraft urethane, these heavy duty bushings offer the desired
firming effect while retaining a reasonable degree of shock and
vibration absorption. (each-
2 halves w/sleeve) M424BI
Shock Absorbers
GAS SHOCK ABSORBERSSUPERpB
Differential Mount
See Page 32
pH Complete Beam Assembly H.D. Fully race
prepared beam/subframe assembly has capped and
braced tubes and double skinned wishbone and
differential mounting plates, supplied in a durable shot
blasted, powder coated finish.M429
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Rear Shock Absorbers (see below - sold as each)
Spax TA series shocks utilize a non pressurized gas over oil
design with external adjustment valve (external screw in bottom)
for fine tuning the dampening to suit individual applications.
Spax is England's largest and best known manufacturer of
performance shock absorbers.M402A
Spax Sport One of the most popular shocks we sell, Spax fixed
rate gas sport shocks are an excellent choice for upgrading the
handling performance on the XR.M402V
Bilstein New for 2000. Bilstein's new sprint series gas shocks
offer the big B's renowned German made performance at a
very attractive price. Bilstein shocks are now available in our
suspension kits see page 3 for details.M402B
Rally Sport Super-Gas made to European Ford spec. by Koni
of Holland. R/S shocks feature mono-tube high pressure design and
have 4 adjustable rebound (STD., +20%, +50%, +100%) settings
which can be tailored to suit individual applications.
M402RS
Boge Turbo-Gas shocks are a German manufactured twin
tube high pressure gas design utilizing a unique variable
valving system that insures the perfect balance between
ride comfort and road holding capability.M402S
DeCarbon French made mono tube high pressure gas shocks
with fairly sporty valving, similar in design to Bilstein. M402G
KYB Gas-Adjust shocks are well made, heavy duty
dampeners that are the least expensive performance shock
upgrade for the XR4. Handling is improved without
sacrificing ride quality.M402Y
NEW
0 6Suspension (rear)
check price lists for Scorpio versions of listed items check price lists for Scorpio versions of listed itemscheck price lists for Scorpio versions of listed items check price lists for Scorpio versions of listed items
check price lists for Scorpio versions of listed items

Brake (related)
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Racing Brake Fluid Not all brake fluid is created equally. High
operating temperatures at the caliper transfers extreme heat through the piston
causing lesser quality brake fluid to boil. This in turn allows the fluid to become
compressed and reduces overall braking performance. The best way to
counter this from happening is to use a racing specification, mineral (never
synthetic) brake fluid and flush the system after each event for competition or
annually on performance street driven vehicles. Both AP550 and Wilwood 570
brake fluid is DOT approved with a dry boiling point of 550-570 degrees, low
viscosity minimizes aeration and permits easy bleeding.
Brake Fluid AP Competition (16.9oz. 500ml.) MC550
Brake Fluid Wilwood 570 (12oz. 355ml.) MC570
Brake Fluid Wilwood 570 (6 Pack) MC57-6
Brake Fluid Wilwood 570 (24 Case) MC57-C
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Cosworth & Scorpio Rotors For those fortunate few who own
Cosworth Sierras or have converted XR4's to Cosworth type front or rear brakes
and are in need of replacement rotors we have them. Scorpio front or rear rotors
in standard and cross drilled are also available. (see price list page 31)
Cosworth Front 283 x 24mm standard, X-drilled, grooved
Cosworth Rear 273 x 10mm standard, X-drilled, grooved
Scorpio Front 260 x 24mm standard or X-drilled
Scorpio Rear 253 x 10mm standard or X-drilled
Performance Brake Kits Engineered competition brake kits for the
ultimate in stopping power.
pC Front R/S Brake Kit (283 x 24mm)
BAT R/S "big brake" kit allows larger 11.25" (285mm) brake rotors to be fitted
with standard XR calipers. Increasing rotor "swept area" in this way will greatly
improve stopping power (leverage) and help to reduce high brake temperatures
that can cause premature brake fade and poor pedal feel.
Kit includes:
285 x 24mm vented (standard or cross-drilled) rotors, Mintex 1144 brake pad
set, caliper mounting brackets & hardware (fitment with most 15" wheels -
some require slight modification)
kit supplied with standard rotors
M418
kit supplied with cross drilled rotors M418A
pD Front Brake Kit (283 x 24mm) w/4 Piston Calipers
Combine the performance of the R/S large rotor kit with 4 piston calipers for the
ultimate in stopping power.
includes: 283 x 24mm vented rotors,
4-piston alloy Wilwood Superlite 2A calipers with pads. (fitment with most 15"
wheels -some require modification or spacers)
M416W
pD Front Brake Kit (300 x 32mm) w/4 Piston Calipers
For those who are looking for the ultimate brake performance. Quite simply the
largest and most competent competition type brake kit that can be fitted to the XR4.
includes: 300 x 32mm vented rotors with light alloy hats, 4-piston alloy Wilwood
Superlite IIA calipers, caliper mounting brackets & hardware
M417A
(this kit also available for Scorpio ! ) G417A
Rear Kit (XR4 w/16" wheels) 300 x 21mm (See Price List)
includes: 300 x 21mm vented rotors with light alloy hats, 4-piston alloy Wilwood
Superlite 2A calipers, caliper mounting brackets & hardware
pE Wheel Bearings Genuine European Ford wheel bearing kits are
complete with all required service parts to do a first class job. Each kit
include bearings, races, seals and hub nuts to service one wheel.
Front Wheel Bearing Kit (specify left or right) -XR4 M560F
Rear Wheel Bearing Kit (specify left or right) -XR4 M560R
Front Wheel Bearing Kit (specify left or right) -Scorpio G560F
Rear Wheel Bearing Kit (specify left or right) -Scorpio G560R
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Bodywork
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pA Front Fenders European Sierra fenders are a direct replacement for the
XR4Ti and are an attractive alternative considering the high price of the American
version. These fenders also include the holes required for side blinker mounting
(see below).
Note: specify left or right when ordering M806 L/R
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Inner Wheel Well Splash/Liners Replacements for the commonly
cracked, broken or missing inner fender splash on the XR4. Covers full inner
wheel house area as origional USA versions.
specify left or right M808L/R
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Door Skin - (specify left or right)M807 L/R
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Door Handle XR4 & Scorpio - (specify left or right)M362 L/R
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Door Sill (Rocker Panel) - (specify left or right)M803 L/R
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Rear Wheel Arch - (specify left or right)M804 L/R
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Battery TrayM817
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Rear PanelM815
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Cosworth Front Grille Nothing transforms the look of the XR4Ti quite like
adding a Cosworth grille. Designed with a center opening, the Cosworth grille
adds additional air flow to the radiator and A/C condenser for a cooler running
engine and better air conditioning performance. An intercooler could also be fitted
behind the grille opening as is done on the original Cosworth Sierra and R/S 500
models.
Note: Grilles are O.E. quality (injection moulded plastic) not shoddy fiberglass
replicas. Suppled (primed) un-painted- includes "Ford" emblem
M320
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Grille Surround Gasket This gasket will almost always need to be
replaced when fitting a new grille.M320S
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European Side Blinker Lamp Kit Add an extra degree of safety when
signaling to turn. Side blinkers fit above European fenders without modification
and can also be fitted to standard Merkur XR4Ti fenders by drilling a mounting
hole. Kit includes (2) lamps, wiring and templates.M317
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Cosworth Hood Original equipment Ford Sierra Cosworth hoods are
designed to receive hood vents/louvers for additional under hood cooling. These
hoods look quite distinctive as the raised center section is lower and wider than
on the standard XR4 hood giving the car a more aggressive appearance.M813
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Cosworth Hood Vents Hood louvers/vents are both visually striking and
functional as they help to ventilate the engine compartment. These O.E. Ford vents
(pair) bolt into the Cosworth hood (above) or can be fitted to standard hoods by cutting
a hole and bonding them in place.
(see pg 11 for fiberglass versions)M814
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Cosworth Front Spoiler/Bumper We supply everything required to
install the stunningly attractive Cosworth Sierra front spoiler/bumper to your
XR4Ti. All components are original Ford including; bumper, bumper bar
brackets, lower side fender mounting panels, fog lamps, turn signal lamps, and
assorted hardware (clips & fasteners).
Note: bumpers are supplied in white-
can be painted to match other colors.
M353
(R/S 500 Version) M353RS
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pA Replica Cosworth Body Components
Fiberglass body panels are an alternative to the more expensive, and
becoming unavailable, factory Ford versions. We have searched far and wide
to import only the highest quality fiberglass replica bodywork. Even so,
fiberglass is more prone to incidental damage (cracking) than the more
flexible ABS plastic or urethane original Ford components. Also keep in mind
that fitting is totally DIY and most items will require paint prep work, fabricated
brackets and other hardware.
Important Note: We often hear horror stories
from customers who have ordered similar fiberglass items from European
mail-order suppliers only to receive broken or substandard components, and
now you own it! Worse yet, the shipping costs involved importing large, bulky,
items like these can far exceed the cost of the part, and what started out as
a bargain now has become a expensive learning experience. Our pricing on
all items, including sheet metal & body panels,
includes inbound freight from
Europe. Once here, some items that are too large for UPS (or other carriers)
will be shipped truck freight collect, we will also extend our 25% C.F. Motor
Freight discount.
Front Spoiler Bumper (R/S Cosworth type) M353F
Front Spoiler Bumper (R/S 500 Type) with lower "splitters*" M353FA
*lower chin spoiler moulded in on lower edge
Rear Bumper (R/S Cosworth type)
Rear Wing Airfoil (R/S Cosworth type)
see information belowM306F
Rear Wing Airfoil (R/S 500 type) M306FA
Lower Rear Wing (R/S 500 type) M306L
Cosworth Wheel Arches (4) & Side Skirts (2)
see information belowM302F
Cosworth Hood (complete with vent louvers)
Hood Vent Louvers (2)
fiberglass (functional)M814F
Hood Vent Louvers (2)
stick-on ABS plastic (non functional)M814FS
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Cosworth Sierra Arches & Skirt
Sadly the factory Ford wheel arches have recently become unavaiable. Some
side skirts still remain but for the most part the R/S arches and skirts have gone
the way of all the factory R/S 500 stuff "not availabe- not replaced". In place
of the origionals we can offer a reasonable cost & quality fiberglass alternative
wheel arch and side skirt kit. For anyone searching out new factory arches and
skirts we might still have a couple odd arches & skirts available (no full sets)
call for more information & pricing.
Cosworth Wheel Arches (4) & Side Skirts (2)-
fiberglassM302F
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Cosworth Rear Airfoil
One of the trademarks of the Cosworth Sierra is its large rear wing/airfoil.
Perhaps a bit gaudy for some tastes, none the less it does a great job at
keeping the rear end planted. At speeds over 100mph as much as 45 lbs. of
downforce is created for added high speed stability. Anyone interested in this
item had one of two choices. The factory Ford Cosworth rear wing/airfoil (still
available from Ford Europe) but at over $1800.00 who can afford it. Or the
usual aftermarket fiberglass versions, although much cheaper in cost the
quality suffers greatly. When we sampled most of these we were genuinely
concerned that some of the replica wings might come apart, or even fly off at
speed ! This dilemma prompted us to undertake manufacturing a super high
quality fiberglass replica that solves all the above problems. It is extremely
well built, can be securely attached to the car and is attractively priced.
Note:
rear wings are designed to fit smaller hatch 1985-87 cars- the mounting foot
will overhang on the hatch glass molding on later cars and will have to be trimmed.
Rear Wing Airfoil (R/S Cosworth type) M306F
see above section for larger RS500 version
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Bodywork
(See Price List) (See Price List)
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Accessories
pA Scorpio R/S Rear Wing This hot looking rear wing goes a long way
in transforming Scorpio's look. For installation R/S wings will require
painting to match your cars color, and some mounting holes from the
standard spoiler will need to be filled and spot painted. Also note that a rear
brake light will need to be located elsewhere in the rear window.G306
Scorpio R/S Side Skirts Matching Rally Sport rocker panel side skirt
set looks great with above rear wing or without. Other than just good
looks, side skirts help to keep the door sides and rockers cleaner and with
less stone chips. Easy to fit, paint and install.G302S
pB Scorpio Cowl Cover What is it, and why doesn't my car have one?
This is a commonly asked question regarding this item. Ford equipped
very few Scorpios bound for the US market with these European cowl
covers. This moulded plastic cover keeps dirt, debris and small animals
from winding up in the ventilation fan and associated duct work. Clean
out this area once and for all, then install a new cowl cover- your Scorpio
will thank you.G369C
pC Mini-Lite Wheels (15" x 7") for XR4 Cars of English heritage,
XR4's included, look great on classic Mini-Lite type wheels. These
wheels are both lightweight and attractive with a bright silver clear coat
finish. Specifications: 4 x 108mm pattern, 15" x 7" size, 38mm offset,
18lbs each, center caps included.M411M
pD Thrust Wheels (15" x 7") for XR4 We are often asked to supply
inexpensive road wheels, and here they are. The Thrust is a 10 spoke
light alloy wheel with locking center cover, available in either silver, or
charcoal w/silver lip. You will not find a better quality, proper wheel
fitment for the price. Specifications: 4 x 108mm pattern, 15" x 7" size,
35mm offset, 18lbs each, locking center covers included.M411T
pE Floor Mats Foul weather mats, commonly referred to as "ice cube
trays" or "waffle mats", are made of heavy duty rubber with small
compartments to catch melting ice, water, mud etc. from your shoes or
boots. These Euro. Ford mats are the best protection for your interior for the
winter months or when going afield. Can be placed over standard plush
mats or directly on carpeting. When dirty or filled with water- remove, drain,
hose off, and reinstall. Front mats will fit both XR4 and Scorpio, rear mats
are for XR4 only.
Front Mat set M1010 Rear Mat SetM1011
First Aid Kits We are often asked to supply the First Aid kits that Ford
equips new cars with in Europe. Includes more than just a selection of
"Band-Aids". Think of it as good insurance.M102
Fuse Box Covers A common breakage item on XR4's. We have new
European Ford replacements.M474
pF Sunroof Wind Deflector The buffeting effect, and wind noise, that
takes place with the sunroof open at speed can be eliminated with a
Sunroof Wind Deflector. Tinted smoke (grey) acrylic, fits both XR4 and
Scorpio- hardware included.M307
pG Side Window Wind Deflector for XR4 A similar product to the
Sunroof Deflector the Side Window Deflector keeps the wind noise levels
to a minimum while allowing maximum ventilation. Effective even in light
rain! Tinted smoke (grey) acrylic, easy installation- no holes to drill. For
XR4 only- sold in pairs.M340WD
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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.
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Hose- heater valve to pipe (leads to oil cooler) M421HC
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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
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Heater Valve- heater control valve XR & Scorpio M421V
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Hose- water pipe (lower) to oil coolerM421HE
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Hose- oil cooler to water pipe (from heat valve)M421HB

(note: pF interchanges with pC )
pG Hose- oil cooler to intake manifoldM421HD
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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
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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
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Water Pump- quality replacement pump L6A
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Thermostat Housing- H.D. cast Iron version L2F
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Hose- radiator (lower) 1985-88 (MT & AT)M421BH
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Hose- radiator (lower) 1989 (auto & manual)M421BH9
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Hose- radiator (upper) 1985-88 (MT & AT)M421TH
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Hose- radiator (upper) 1989 (MT & AT) M421TH9
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Cooling System (XR)
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Plumbing Schematic
1985-88 XR4Ti w/5 speed
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pN Hose- expansion tank (top fitting) to valve cover pipe
(note: shape of hose not accurate in drawing)M421TT
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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
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Hose- expansion tank (lower fitting) to radiator drain line
M421TL
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Hose- expansion tank (middle fitting) to radiator (upper)
M421TM
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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
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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
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Blower Motor & Fan A/C & Heater -for heater and A/C,
check fuse & relay first before ordering. M470A
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Heater Core- New O.E. Ford heater cores. M471
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Turbo Water Hose -high temperature CPE silicone hose for
turbo (water) inlet/outlet pipes. (1 foot makes 3 hoses)
M421WT
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Hose- Lower drain pipe @ radiator lower M421HF
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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
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Hose*- heater valve to engine/inlet mfld.G421HB
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Hose*- heater valve (inlet) to heater coreG421HC
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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
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Hose- coolant tank to thermostat housingG421HF
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Hose- top radiator hose (88-89)G421TH
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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
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Water Pump- new Ford water pumpG421
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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
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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
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Radiator Cap- cap for Scorpio and XR4's with thread-on
coolant tankG421C
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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
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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

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