air condition FORD SIERRA 1989 2.G XR4 Workshop Manual

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 Windshield Wiper Headlamp Switch Stalk We supply a new
Ford Europe replacement for this commonly required electrical item.
Note: please check associated fuses before ordering- this item is not
returnable.
Windshield Wiper Headlamp Switch/Stalk (XR4)M304
pB Turn Signal Flash/Hazard Switch Stalk We can supply a new
Ford Europe replacement for this commonly required electrical item.
Note: please check associated fuses before ordering- this item is not
returnable.
Turn Signal Flash/Hazard Switch Stalk (XR4)M305
pC Fuse Box Cover Missing, cracked, or not staying closed are all
reasons to replace the fuse box (lid) cover on the XR4. Getting water in
the fuse block can completely ruin a car or make for some very time
consuming and expensive electrical repairs. Don't delay fixing this
condition any longer, we have new Ford European replacements in stock.
Fuse Box CoverM474
pD Door Post Black-Out Trim (stick-on) Is it time to replace the
cracked or peeling door post black-out trim located between the door and
rear quarter window ? We have high quality reproductions of this
discontinued Ford item.
Left Side Door Post (black-out) Trim- 2 pieces M340TL
Right Side Door Post (black-out) Trim- 2 pieces M340TR
pE Pedal Pads The next time you give your cars interior a good detailing
don't forget the finishing touches. New pedal pads not only improve the
look of any interior, but are much safer too. Also it's not a bad idea to
replace pedal pads right before entering a car show or selling a vehicle
as smart buyers and judges will commonly check the pad wear as an
indicator of how (hard) the car is driven.
Accelerator Pedal Pad- XR4 & Scorpio M365A
Clutch Pedal Pad- XR4 & Scorpio M365C
Brake Pedal Pad (manual)- XR4 & Scorpio M365B
Brake Pedal Pad (auto)- XR4 & Scorpio M365BA
pF Rear Hatch Lift Struts Have you resorted to using a wooden
broomstick as a prop rod to hold up the rear hatch on your car ? If you
answered yes you are a definite candidate for new hatch lift struts. XR4's
and Scorpios have heavy rear lift gates (hatches) and when one or both lift
struts are worn forget about having the thing stay up, let alone raise up slowly
and unassisted as when they were new. BAT has new German manufac-
tured lift strut replacements guaranteed to keep things on the up and up.
Rear Hatch Lift Strut- XR4 (each) M308
Rear Hatch Lift Strut- Scorpio (each) G308
pG Rear View Mirror Has your rear view mirror fallen off more times
than you can count ? Don't mess around with nasty glues that only last
a week before redepositing the mirror back on the floor. BAT has the
correct Ford replacement day/night mirror with a (self stick peel-off)
adhesive backing that should keep it attached for another 10 years.
Rear View Day/Night Mirror- XR4 & ScorpioC339
Replacement "Stick-on Pad"
(for stock mirror)M339S
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Accessories
fuse box cover
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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
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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
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Mechanical Fan Clutch- Quality Ford O.E.G422
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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
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Heater A/C Blower Motor- New Ford heater blower motor
for Scorpio with 8 wire harness/plug.
G470H
see (diagram A) on page 20
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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.
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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
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Expansion Valve- Meters the volume of refrigerant to the
evaporator. Expansion valve assembly should be replaced with
evaporator or if found faulty. M470EV
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Blower Motor- HVAC system blower motor includes motor
and fan wheel. (Scorpio) G470A (XR4) M470A
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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.
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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
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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
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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

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
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