sport mode FORD SIERRA 1989 2.G XR4 Workshop Manual

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Page 2 of 45

FORD SIERRA 1989 2.G XR4 Workshop Manual Introduction0 1
BAT BATBAT BAT
BAT is pleased to be able to offer this line of components
for the U.S. specification "Merkur" XR4ti, Scorpio and the
other European models of Sierra lineage. European

Introduction0 1
BAT BATBAT BAT
BAT is pleased to be able to offer this line of components
for the U.S. specification "Merkur" XR4ti, Scorpio and the
other European models of Sierra lineage. European Sierra
models have been manufactured since 1982 and include
two versions or body styles. We will concern ourselves with
the Mark 1 as it is more similar to our U.S. version. The high
water marks of the MK1 series are the XR4i and the Sierra
Cosworth and R/S 500 models. From the exterior, XR4i is
very similar to the U.S. Merkur XR4Ti in overall looks.
However, under the hood it is powered by a 2.8L V-6 engine
where we have the 2.3L 4 cylinder turbo. The other notable
MK1 car the Cosworth Sierra is simply one of the more
outrageous vehicles Ford has ever offered. The Cosworth
starts life as a base Sierra three door body shell and adds a
high performance engine, suspension, transmission, and
aerodynamics, making it one of the fastest 4 passenger road
cars in the world. Power comes from a 2.0L Cosworth Turbo
YB series engine rated at 205 h.p. in its base form, and
upwards of 550 h.p. in modified rally form. The R/S500
homologation outgrowth of the R/S Cosworth version is
basically a de-tuned race car in street trim. Sierra MK2
versions received a sheet metal make over but share most of the mechanicals of the MK1. Interesting MK2
Sierra's include the Sierra Sapphire Cosworth, and Sierra XR 4x4 - an advanced 4 wheel drive 4 door sedan.
What all this Sierra history means to us is an abundance of specialized
performance parts, many of which bolt-on to our U.S. spec. Merkur. With
this in mind Merkur owners can make an good vehicle even better. It is
very amusing how much attention a Merkur that has been outfitted with
Ford badges and Sierra logos and Cosworth grille commands, let alone
a car equipped with the complete Cosworth body work!
BAT BATBAT BAT
BAT is a recognized Ford Motorsport USA and Ford Motorsport/
Rallysport European dealer with over 30 years of experience of tuning
European Ford automobiles. From Cortinas, Lotus Cars and Anglias
during the 60's through the 70's with Pinto and Capri and into the 80's
and 90's with Fiesta, Escort and Merkur. Our expertise with building and
racing 4 cylinder Ford powered cars includes Formula Ford, Formula
Continental & Atlantic, SCCA Production, Showroom Stock, Auto-X,
Improved Touring and Circle Track racing classes. We have a highly
capable staff and you can confidently allow them to handle even your
most difficult technical needs. Better still, our ability to buy in quantity,
import products directly, and manufacturer speciality components
assures you are getting the right parts at the right price
.
P.S. We have recently added a considerable number of parts for the Merkur Scorpio. Most of the XR4 items
will have a Scorpio alternate available. See the price list for more information. You can also view and
download updates to this catalog from our web site at www.batinc.net
Peter Thompson Eric Odenweller
and the staff at
BAT BATBAT BAT
BAT Inc.

Page 19 of 45

FORD SIERRA 1989 2.G XR4 Workshop Manual Accessories
pApA
Cosworth Sierra Steering Wheel This sporty 3 spoke design
leather wrapped steering wheel is standard factory issue on the Sierra
Cosworth and RS500 models. The smaller wheel diamet

Accessories
pApA
Cosworth Sierra Steering Wheel This sporty 3 spoke design
leather wrapped steering wheel is standard factory issue on the Sierra
Cosworth and RS500 models. The smaller wheel diameter (13.9 inch) helps
make the steering ratio more effective and the fatter rim grip offers both comfort
and control. Wheel is available in black and included center horn button with
Ford logo and horn symbol.M322
pB Cosworth Sapphire Steering Wheel This 3 spoke leather wrapped
wheel from the Sierra Sapphire 4x4 steering wheel is a departure on the
original Coswoth version. It's wider center spokes are positioned lower for
comfortable hand position and a better view of the instrumentation. The smaller
wheel diameter (13.9 inch) helps make the steering ratio more effective and the
fatter rim grip offers both comfort and control. Wheel is available in black and
included center horn button with Ford logo and horn symbol.M322A
Standard Horn Button for the standard XR4 steering wheel we have the
European "Ford" oval logo horn button. Just the thing for finishing the interior
off while fitting Ford logos to the exterior.
Z61551
pC Contoured Dash Overlay just the ticket for covering up a cracked
vinyl dash pads which are so common on the XR4 & Scorpio. This moulded
plastic dash overlay is simple to install and covers up a world of sin, quickly
returning the interior to its original splendor.
note: supplied in black can be easily
painted to match interior color
(for XR4) M323

NEW (for Scorpio) G323
pD White Gauge Face Set Colored gauges are quite the rage. They add
a very unique look to the interior, and are easy to read in daylight or when
illuminated at night. We have a gauge face kit that will replace the standard
(black) speedo, tach/boost, fuel and water temp, gauges and indicator lamps
with a thick self adhesive mylar faces that are white in color. These gauge
faces are manufactured specially for BAT by a original equipment instrument
supplier to Ford, GM, Vauxhall so quality is outstanding. They illuminate from
the rear "back light", just as the standard gauges, and will not opaque with age
like typical cheap reproductions will. An added benefit of our gauge face kit
is the speedo is calibrated beyond 85mph all the way to 150mph. Updating
earlier cars with 85mph speedos is a snap.
(available spring 99) M341W
pE
170 mph Speedometer For the owners of land based cruise
missiles we offer the original equipment Sierra Cosworth speedometer
calibrated in mph (170 in white) and kmph (270 in yellow) with re-setable
trip-meter. A slight bit of tweaking is required to fit.
M341A
150 mph Speedometer Sierra XR4's and later Merkurs came with a more
realistic 150 mph speedometer which easily replaces the American (only
calibrated to 85 mph) version.M341
Dash Instrument Panel Bulb lamp with (white) socketM330L
Dash Warning Lamp Bulb lamp with (gray) socketM330WL
pF Torch Key & Battery complete Ford key blank and lamp/battery.
Torch key blanks and lamp batterys are also listed separately below.
C309KL
Torch Key Blank replacement key blank for XR4 (less lamp)Z61179
pG Lamp & Battery lamp and battery for XR4 & Scorpio keysC309KLB
pH Standard Keys as an extra key or an alternative to the more bulky torch
key, this European key blank has a molded plastic grip with wide ring slot with
Ford logo.
(for Scorpio) G309K (for XR4) C309K
Hatch Lock Assembly lock assem. w/housing & 2 keysM815L
Hatch Striker commonly required replacement itemM815S
Hatch Lock Retaining Clip commonly required replacement itemM815C
Complete Car Lock Set doors, hatch, ignition w/ 2 keysM309LS
pD
pE
BRAKE
pF
pHpG pC
pB
turbo
1 8

Page 21 of 45

FORD SIERRA 1989 2.G XR4 Workshop 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

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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FORD SIERRA 1989 2.G XR4 Workshop Manual Engine & Related Items
pA
pB
pC
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 lea

Engine & Related Items
pA
pB
pC
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

Page 35 of 45

FORD SIERRA 1989 2.G XR4 Workshop Manual Complete Rear Differential Assembly- New assembled
Ford rear differentials with limited slip (3.92:1 ratio). Remove
old center section as a whole and replace. Not inexpensive,
but a value when you