brake light FORD SIERRA 1990 2.G XR4 Workshop Manual

Suspension
pC Camber Shims
pD Front
Strut Tower Brace
pE RearpA
Suspension Packages -XR4
Below is a listing of shock and spring packages available as engineered
suspension packages. Fixed rate or adjustable shocks are supplied as noted.
More information on the shocks that make up these kits is listed elsewhere in
the front and rear suspension sections. Kits are available with either -25mm
or standard ride height sport springs- your choice same price !
Spax Sport Gas Shocks & Sport Springs (-25mm or Standard) M400S
* supplied with fixed rate high performance gas shocks
Bilstein Gas Shocks & Sport Springs (-25mm or Standard) M400B
* supplied with fixed rate high performance gas shocks
Spax Sport Adjust Shocks & Sport Springs (-25mm or Std.) M400A
* supplied with adjustable high performance gas shocks
pB Sport Spring Sets -XR4
Our specially designed progressive rate sport springs will minimize body "roll" while
cornering and reduce "dive" under hard braking. Progressive springs are designed to
become stiffer as they are compressed allowing for a smooth transition between (very
reasonable) straight line comfort and high performance cornering. We recommend
the standard height or -25mm ride height sets for all around performance street and
light competition use, the -40mm springs should be considered for only racing/
competition use. Take into account when lowering your cars ride height that additional
negative camber will be added to the front and rear suspension angles. This is usually
not a problem on the front end, however, cars that are already experiencing noticeable
wear on the inside edges of the rear tires at "standard" ride height will see this increase
when lowering. This condition can be corrected if necessary by using camber shims
(kit available below) at the rear spindle mount to adjust for excessive negative camber.
Notes: Defining "standard" ride height is difficult on the XR4 as the springs on many
cars have already "sagged" 1/2 to 3/4 of an inch since new. In this case if the front
and rear tires are still wearing normally lowering the car another 1/4" or 1/2" (over what
it is currently) should not adversely effect tire wear.
Sport Spring Set -25mm (front & rear) XR M414M
Competition Spring Set -40mm (front & rear) XR M414C
Sport Spring Set*
Standard Height (front & rear) XR M414S
See Price List For Scorpio Spring Applications
pC Rear Camber Shim Kit -XR4
To correct rear camber angles on cars that have excessive negative camber
we offer a handy rear spindle shim kit. This kit is sometimes necessary on cars
with lowered sport springs, but can also be used to correct camber on cars with
"sagging" stock rear springs. The components (instructions and shims)
needed to space the rear bearing spindles between the brake backing plates
are supplied. This camber kit will add roughly 1.5 degrees of positive camber
and adjust rear toe back with in standard range as well.M423R
pD
Front Strut Tower Brace -XR4
The XR4 has a well built chassis structure that does not exhibit much flex
under normal conditions. With the addition of high performance tires and
suspension parts more stress is put on the front strut towers causing some
deflection under hard cornering which will eventually weaken the structure
and lead to unpredictable handling characteristics. Connecting the front strut
towers by adding a upper stressbar (strut tie bar) will improve chassis
stiffness and keep the suspension angles constant under hard use condi-
tions. For this purpose we offer a lightweight aluminum front tower brace
(stressbar) that incorporates a removable tubular cross brace and cast alloy
turret mounts. Highly recommended for cars that are used for track events,
drivers schools, auto-cross and spirited road use.M403F
pE
Rear Shock Mount Brace XR4
Our rear (stressbar) is a nicely finished lightweight tubular aluminum rear
brace which is just the thing for linking left and right hand upper shock mounts.
A slight bit of plastic trimming is required when fitting. Bars are supplied with
an attractive blue finish.M403R

(less expensive steel version of above) M403RS pA
Suspension Packs
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pB Sport Spring Sets

pC
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pA Front Brake Special 260 x 24mm
This kit is just the thing for replacing the standard size, wear related,
front brake components. We supply high quality Euro specification
rotors and premium Mintex brake pads for either XR4 or Scorpio and
at a special price as compared to buying items separately.
Front Brake Special XR4ti M420SP
Front Brake Special Scorpio G420SP
pB
BAT R/S Front Brake Kit (283 x 24mm) XR4ti
BAT R/S Brake Kit allows larger 11.25" (283mm) Cosworth 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. Kits are available in 4 different
component levels from as little as $295.00, which leaves you no
reason not to upgrade to larger brakes.
Kits include: 285 x 24mm
vented (standard or cross-drilled) rotors, Mintex brake pad set
(standard or M1144), caliper mounting brackets & hardware (fitment
with most 15" and larger wheels -some require modification or
spacers)
Front R/S Brake Kit (283 x 24mm) M417
includes standard rotors, standard Mintex pads, brackets & hardware
Front R/S Brake Kit (283 x 24mm) M417A
includes X-drilled rotors, standard Mintex pads, brackets & hardware
Front R/S Brake Kit (283 x 24mm) M418
includes standard rotors, M1144 Mintex pads, brackets & hardware
Front R/S Brake Kit (283 x 24mm) M418A
includes X-drilled rotors, M1144 Mintex pads, brackets & hardware
pC BAT/Wilwood Front Brake Kit (283 x 24mm) XR4ti
This kit combines the performance of the larger 283mm Cosworth rotor
with Wilwood 4 piston Superlite 2A calipers which are extremely ridged
and transfer torque directly without unwanted flex. Construction is
aluminum with stainless pistons for both weight savings and maximum
head dissipation. At just 5 lbs. they are also much lighter than stock
calipers. This goes a long way to reducing "unsprung" weight benefiting
both braking and handling performance.
Kit includes: 285 x 24mm
vented rotors, 4-piston alloy Wilwood Superlite IIA calipers with pads
and aeroquip brake hoses (fitment with most 15" and larger wheels -
some require modification or spacers)
M416W
pD
BAT/Wilwood Front Brake Kit (300 x 24mm) XR4ti
This kit combines even larger 300mm Cosworth rotor with Wilwood
4 piston Billet Dynalite for the ultimate big brake kit. Calipers are
extremely ridged and transfer torque directly without unwanted
flex and are made from aluminum with stainless pistons for both
weight savings and maximum head dissipation. At just 4 lbs. they
are also much lighter than stock calipers. This goes a long way to
reducing "unsprung" weight benefiting both braking and handling
performance.
Kit includes: 300 x 24mm vented rotors , 4-piston
alloy Wilwood Billet Dynalite calipers with pads and aeroquip
brake hoses (fitment with some 15" & most 16" and larger wheels
-some require modification or spacers)
M416W3
Brake Kits & Specials0 8

Brake (related)
pA
pEpA
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
pB
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
pB
pC
pD
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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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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
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BRAKE
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pB
turbo
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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
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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)
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