ABS FORD SIERRA 1986 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

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)
1 3

Engine Builders Kits
Time for that inevitable engine rebuild? BAT takes the guess work out of acquiring
all the right components by offering these prepackaged performance engine service
kits. Our top end (cylinder head) and bottom end (short block) rebuilding kits are
supplied complete with premium high performance parts. With the help of a competent
machine shop these rebuild kits will restore your engine to better than new condition.
As usual we have gone to great lengths to supply only the absolute best components
for the job and still managed to keep the prices reasonable.
Performance Short Block Rebuild Kit (2.3L Turbo)
(1) Full Gasket Set -Felpro L15AB
(1) Main Bearing Set -ACL Vandervell (specify size; STD, +.010", +.020", +.030") L16A
(1) Rod Bearing Set -ACL Vandervell (specify size; STD, +.010", +.020", +.030") L16H
(4) Forged Pistons -Power Forged (specify size; STD, +.010", +.020", +.030", +.040",
+.060")
L4250F
(1) Gapless Ring Set -Total Seal (specify size; STD, +.010", +.020", +.030", +.040",
+.060")
L4TF
(1) Rod Bolt & Nut Set H.D. -A.R.P. L4FS
(1) Oil Pump- Melling L2P
Short Block Rebuild Kit L501
$649.00
as above listed
Optional Items to Short Block Rebuild Kit
A) Forged Connecting Rod Set - "I" beam type w/ H.D. fasteners (add $350.00)
B) Forged Connecting Rod Set - "H" beam type w/ H.D. fasteners (add $525.00)
C) Main Stud Set H.D. - A.R.P. (add $75.00)
D) Crankshaft (if required) - resized, polished, balanced, indexed (add 349.00)
E) Crankshaft "Power Pulley" (add $90.00)
Performance Cylinder Head Rebuild Kit (2.3L Turbo)
(1) Top End Gasket Set* - Felpro L15BA * see notes below
(1) Cam Bearing Set -ACL Vandervell
L16M
(1) Head Bolt Set L2D
(4) Exhaust Valves -Stainless Hi-flow 1.51" L31A
(4) Inlet Valves -Stainless Hi-flow 1.74" L3HA
(1) Valve Spring Set H.D. L3F
(8) Cam Followers L5B
(1) Hydraulic Adjuster Set (lifters) L5B
(1) Cam Sprocket (index type) L5F
(1) Cam Belt H.D. L5G
(1) Camshaft (.416" / 272 turbo profile) L5H260
Cylinder Head Rebuild Kit L502
$649.00
as listed above
Optional Items to Cylinder Head
(A) Head Stud Kit H.D. - A.R.P. (add 45.00)
(B) Adjustable Cam Sprocket -alloy
"vernier" type (add 50.00)
*Notes: this item (L15BA) is not required when ordering L502 cylinder head kit with
L501 short block kit (it is already included with L501). We will offer a 50.00 discount
when ordering L502 and L501 together.
MOTOR RACING COMPONENTS
SPEED-PRO
RACING PRODUCTS
Engine Components3 0

07/30/02Price List3 6
PAGE 10 driveline components
C.V. Joint- XR & Scorpio M550B 92.50
C.V. Boot Kit- XR & Scorpio M550BK 14.90
C.V. Socket Head Cap Screw (6 per joint) M550CS 1.05ea
C.V. Locking Plate (3 per joint) M550LP 1.35ea
Axle/Halfshaft Complete* (LH)- XR & Scorpio M550L 169.50
Axle/Halfshaft Complete* (RH)- XR & Scorpio M550R 169.50
*axle/halfshaft, joints (2), boots (2), assembled/greased ready for installation
add 75.00 core charge for this item- refundable on return
Driveshaft Coupling- XR & Scorpio M17A 62.50
Drivesahft Center Support Bearing-XR M550SB 109.75
Drivesahft Center Support Bearing- Scorpio G550SB 98.00
Quaife LSD M710 1245.00
Clutch Kit Sachs- XR M519K 179.50
Clutch Kit Sachs- Scorpio G519K 257.50
Clutch Kit Sachs- XR w/ T-5 trans M519T5 179.50
H.D. Clutch Kit Centerforce (30% kit) M519C 309.95
H.D. Clutch Kit Centerforce II (50% kit) M519C2 361.98
Clutch Alignment Tool (1" 23 spline) S11H 6.00
Clutch Cable- XR4Ti M562 29.50
Clutch Cable- Scorpio G562 76.50
BAT is always testing and
developing new products....if
you don't see it listed ask... we
might have what you are looking
for, or can point you in the right
direction.
PAGE 8 brake kits & specials
Front Brake Spacial- XRM420SP 105.00
Front Brake Spacial- ScorpioG420SP 115.00
Front R/S Brake Kit 283x24mm (standard) M417 295.00
Front R/S Brake Kit 283x24mm (w/x-drill) M417A 329.00
Front R/S Brake Kit 283x24mm (standard/M1144 ) M418 339.00
Front R/S Brake Kit 283x24mm M1144/x-drill) M418A 395.00
BAT/Wilwood Brake Kit 283mm M416W 645.00
BAT/Wilwood Brake Kit 300mm M416W3 725.00
PAGE 9
rear brake components
Rear Wheel Cylinder- XRM420WC 35.95
Rear Brake Shoe Set (Motorcraft/Mintex)- XRM420R 49.95
Rear Brake Drum
- XRM420RD 74.00
Rear Brake Drum (grooved)
- XRM420RDG 129.50Aeroquip Rear Brake Lines (pair)- XRM419R 47.50
Rear Brake Line O.E. Rubber (each)- XR4 (1985-89)M419SR 27.45
Aeroquip Rear Brake Lines (4 line set)- ScorpioG419R 85.00Rear Brake Hardware Kit- XR M420K5 25.60
Rear Brake Special- XR M420RSPL 125.00
Rear Disk Brake Kit- XR M420RK 689.00
Hand Brake Cable- XR M564 44.00
Handbrake Cable- Scorpio G564 44.00
Hand Brake Cable- Cosworth Z16567 44.00
Rear Caliper* (specify left or right) for M420RK kit127.50
*this item requires an additional 75.00 core charge refundable upon core return
Rear Rotor (each) for M420RK kit52.50
Rear Brake Pad (set) for M420RK kit25.00
Rear Rotor (standard)- Scorpio (each)G425R 39.75
Rear Rotor (x-drilled)- Scorpio (each)G425RCD 92.00Rear Caliper (left)- Scorpio (each)G420RL 124.50
Rear Caliper (right)- Scorpio (each)G420RR 124.50
*this item requires an additional 75.00 core charge refundable upon core returnRear Brake Pad Set- Scorpio (Semi-Metalic)G420R 39.00
ABS Brake Sensor Scorpio/XR4- Rear G420SR 177.25
PAGE 7 front brake components
Front Caliper* (left)- XR & Scorpio M420CL 64.75
Front Caliper* (right)- XR & Scorpio M420CR 64.75
M420CL/CR calipers are not supplied with slide pins or bushings (available below)
Front Caliper Complete* (LH) includes mount & pads M420CL-L 90.00
Front Caliper Complete* (RH) includes mount & pads M420CL-R 90.00
*this item requires an additional 75.00 charge refundable upon core return
Caliper Repair Kit- XR & ScorpioM420K4A 55.00
Caliper Seal Kit-
XR & ScorpioM420K4 17.75
Caliper Slide Bushings (2) does 1 caliper M420CB 14.00
Caliper Slide Pins (2) does 1 caliper M420CP 16.35
Caliper Spring (anti-rattle) each M420CS 6.39
Front Brake Pad Set*- Mintex A/F (Semi-Metalic) M420MM 39.00
Front Brake Pad Set*- Mintex 1144 (street/competition) M420G 75.00
Front Brake Pad Set*- Mintex 1155 (full competition) M420G 112.30
*brake pads will fit both XR4 and Scorpio
Front "Low Pad" Sensor Wiring Harness- XR/Scorpio M420WS 32.49
Front Rotor (standard)- XR (each)M425 42.50
Front Rotor (standard)- Scorpio (each) G425 49.75
Front Rotor (x-drilled)- XR (each)M425CD 79.50
Front Rotor (x-drilled)- Scorpio (each) G425CD 99.00
Front Rotor (x-drilled & slotted combo)- XR (each)M425CDS 89.50
Front Rotor (x-drilled & slotted combo)- Scorpio (each)G425CDS 109.00
Master Cylinder* XR4 1985-86 (Bendix)- XRM420MC 109.50
*this item requires an additional 20.00 charge refundable upon core return
Master Cylinder* XR4 1987-89 (Bendix)- XRM420MCL 122.50
*this item requires an additional 50.00 charge refundable upon core return
Aeroquip Front Brake Lines (pair)- XR4 (1985-88)M419 42.50
Front Brake Line O.E. Rubber (each)- XR4 (1985-86)M419SF 25.75
Aeroquip Front Brake Lines (pair)- XR4 (1987-89)G419 52.40
Aeroquip Front Brake Lines (pair)- ScorpioG419 52.40
ABS Brake Sensor Scorpio/XR4- Front G420SF 179.75
PAGE 11 brake components
Brake Fluid AP550 (500 ml) MC550 10.70
Brake Fluid Wilwood 570 (355 ml) MC570 5.95
Brake Fluid Wilwood 570 (6-pack) MC57-6 33.00
Brake Fluid Wilwood 570 (24 case) MC57-C 119.00
Front Rotor Cosworth 283 x 24mm (standard) M426 75.00
Front Rotor Cosworth 283 x 24mm (X-drilled) M426CD 108.00
Front Rotor Cosworth 283 x 24mm (Grooved) M426G 130.00
Rear Rotor Cosworth 273 x 10mm (standard) 45.00
Rear Rotor Cosworth 273 x 10mm (X-drilled) 65.00
Rear Rotor Cosworth 273 x 10mm (Grooved) 86.50
Front Rotor Scorpio 260 x 24mm (standard)G425 49.75
Front Rotor Scorpio 260 x 24mm (X-drilled)G425CD 99.00
Rear Rotor Scorpio 253 x 10mm (standard)G425R 39.75
Rear Rotor Scorpio 253 x 10mm (X-drilled)G425RCD 92.10
Front Brake Kit- BAT R/S 285 x 24mm (standard) M418 339.00
Front Brake Kit- BAT R/S 285 x 24mm (x-drilled) M418A 395.00
Front Brake Kit- Wilwood 283 x 24mm M417 645.00
Front Brake Kit- Wilwood 300 x 32mm M416A 1295.00
Front Brake Kit- Wilwood 300 x 32mm (Scorpio) G416A 1395.00
Rear Brake Kit- Wilwood 300 x 21mm 1200.00
Front Wheel Bearing Kit (RH)-XR M560FR 42.00
Front Wheel Bearing Kit (LH)-XR M560FL 42.00
Front Wheel Bearing Kit (RH) Scorpio G560FR 59.00
Front Wheel Bearing Kit (LH) Scorpio G560FL 59.00
Rear Wheel Bearing Kit (RH)-XR M560RR 42.00
Rear Wheel Bearing Kit (LH)-XR M560RL 42.00
Rear Wheel Bearing Kit (RH) Scorpio G560RR 98.75
Rear Wheel Bearing Kit (LH) Scorpio G560RL 98.75
Nut- Front Hub (LH) blue M550N-LF 6.65
Nut- Front Hub (RH) yellow M550N-RF 6.65
Nut- Rear Hub (LH) white M550N-LR 7.42
Nut- Rear Hub (RH) white M550N-RR 7.42