gas type FORD SIERRA 1992 2.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

pA Front Caliper We offer high quality re-manufactured
front calipers which are considerably less costly than new.
Calipers are handed left & right and require return core charge.
(drivers- left) M420CL(passenger- right) M420CR
pB
Caliper Repair Kit -w/piston Ford caliper repair kits are
an economical way to service a leaking or "sticky" caliper. Fitting
this kit, after honing the piston bore, will cure most caliper related
problems. (kit does 1 caliper)M420K4A
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Caliper Seal Kit After inspection many calipers only
require new seals to put them right. (kit does 1 caliper) M420K4
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Performance Street Brake Pad Set Premium
Mintex A/F series brake pads will give enhanced brake perform
over a wide temperature range with very little brake dusting.
Mintex pads also incorporate the pad warning sensor wiring.
This is the abusolute best performing street pad we have tested
and for the price they are a steal.
(XR4 & Scorpio)M420M
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Racing Brake Pad Sets Mintex 1144 is a rally/race pad
that is perfectly at home on track or street, offering a high coefficient
of drag (.44) and excellent modulation throughout a very wide
operating range (up to 1200 degrees). Mintex 1144 is supplied pre-
burnished for easy break-in and minimal fade on the first heating
cycle. Both fade resistance and wear characteristics are excellent.
Mintex pads are the only racing brake pads to incorporate the
standard "low pad" sensor wiring. Match a set of these pads with our
drilled or grooved sport rotors and Aeroquip stainless brake lines for
a substantial increase in braking performance.
(XR4 & Scorpio)
Mintex Street/Competition (M1144)M420G
Mintex Full Competition (M1155) M420GA
pE Standard Front Rotors Lesser quality generic "white
box" rotors tend to warp easily, don't even consider fitting them
on your XR4 or Scorpio. BAT supplies only the highest quality
(Brembo -
Italy & United Brake -England) rotors at better than
"bargain" rotor prices. (each)
XR4 M425
Scorpio G425
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Brake System (front)
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See price list for caliper
slide bushings and pins
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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
pF Cross Drilled Front Rotors Cross-drilling brake
rotors is an excellent way to increase brake performance.
Theory being that centrifugal force will draw excess brake
dust and expelled gasses from the pad surface through the
drilled passages into the rotors vented cavity and out. This
process also improves rotor cooling giving improved braking
response and resistance to fade. Our drilled brake rotors
are made from Carballoy (a medium flake graphite fully
pearlitic low phosphorous iron) manufactured to BS 1452
- 1990 grade 180/220 standard. The cross drilling process
is handled by computer CNC milling equipment with holes
arranged in a parabolic pattern giving an even sweeping
effect to the pad surface ensuring maximum cooling with
minimum noise and drag. M425CD
*rotors must by purchased as (handed) pairs- priced as each
Grooved Front Rotors As an option we can supply
slotted (grooved) pattern rotors which are manufactured to
the same high standards as the above listed cross drilled
versions.M425S
*rotors must by purchased as (handed) pairs- priced as each
Drilled & Slotted Front Rotors As an option we can
supply combination drilled & slotted (grooved) pattern
r o t o r s manufactured to the same high standards as the above
listed cross drilled versions.M425CDS
*rotors must by purchased as (handed) pairs- priced as each
pG Master Cylinder high quality Bendix replacement power
brake master cylinder.
(specify year when ordering)M420MC
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Aeroquip Brake Lines One of the more effective brake
modifications you can make is to replace the standard brake
hoses with Aeroquip steel braided lines. These performance
brake hoses incorporate a teflon interior to keep line expansion
"flexing" to a minimum. This greatly reduces the "spongy" pedal
feel common to the XR4 & Scorpio brake system. Our stainless
lines are assembled from genuine Aeroquip AN-3 hose with
premium metric "reusable" (not the lesser quality "swaged" type)
hose ends installed. XR4Ti (state year) M419
Scorpio G419

Trim & Lighting
pA European Emblems & Badges Re-badge your XR4 with Ford ovals
and Sierra emblems or put the finishing touches on that Cosworth clone.
Genuine Ford European logos will distinguish your XR4 or Scorpio from the
rest. Location (on car) for emblems and sticker logos are listed below.
Emblems are chrome and black plastic with self stick backing. Stickers can be
applied to metal or glass surfaces.
Sierra (emblem)
rear hatch leftM321S
Sierra XR4i Red (sticker)
rear hatch leftM352R
Sierra XR4i Anthracite/Gray (sticker)
rear hatch leftM352A
Sierra R/S (emblem)
rear hatch leftM321RS
Cosworth (emblem)
rear hatch left under Sierra R/S emblemM321C
Sierra R/S Cosworth (sticker)
rear hatch leftM352C
R/S (emblem)
side fender XR & ScorpioM352RS
Ghia- crest (emblem)
side fender XR & ScoprioM352G
Oval "Ford" (emblem)
front grille center & rear hatch rightC321
"Ghia"- script (emblem) Scorpio rear hatchG352G
2.9i (emblem)
Scorpio rear hatchG352L
Scorpio (emblem)
Scorpio rear door sail panelG352S
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European Headlamps The standard US spec. XR4 & Scorpio
headlights were pretty poor when new, and get worse with age- especially when
the lenses turn cloudy. European headlamps will provide a significant increase
in light output and they look great too. These lamps utilize all glass lensing with
a halogen H-4 55/60 watt bulb for high/low main beam operation, and a halogen
H-3 55 watt bulb for the built-in driving lamp.
Note: Lamps are supplied in right hand
drive (English) specification which has a subtle different low beam flair pattern,
however, this is not very noticeable. If required left hand (German) type lenses are
available separately (see price list). We recommend installing the lamps first before
opting to swap out the lenses as most customers do not bother.
Sierra XR4 European Headlamp Kit* M318
*kit includes (2) lamps, rear bulk heads panels, bulbs & wiring instructions
Scorpio* European Headlamp Kit G318
*kit includes (2) lamps, left & right lamp lamps/indicators & front grille sections,
bulbs, and wiring instructions
Scorpio Fog Lamp (LH)- complete replacement assembly G349L
Scorpio Fog Lamp (RH)- complete replacement assembly G349R
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Head Lamp Bulbs Replacement and higher wattage bulbs for above
European headlamps and standard XR4 & Scorpio aerolamps. Headlamps- H4
bulbs are fit eurolamps (not stock headlamps), 9004 bulbs are for use with standard
XR4Ti & Scorpio aerolamps. Fog lamps- H3 bulbs are suitable for eurolamps and
Scorpio, 880 bulbs fit
only XR4Ti fogs. Krypton gas 9004 "Bright White" bulbs burn
brighter with more luminous output than standard halogen type bulbs.
"Blue Ion"
bulbs project a, low glare, blue tinted beam- definitely a different look !
H4 55/60 watt (for high/low main beam) Z H4 55/60
H4 55/100 watt (for high/low main beam) Z H4 55/100
H4 80/100 watt (for high/low main beam) Z H4 80/100
H3 55 watt (for fog & driving lamps) Z H3 55
H3 100 watt (for fog & driving lamps) Z H3 100
880 50 watt "Blue Ion" 50 watt (for XR4Ti fog lamps) Z 880/50B
880 50 watt "Amber" 50 watt (for XR4Ti fog lamps) Z 893/50G
9004 "Bright White" 45/65 watt (for high/low main beam) Z 9-45/65W
9004 55/100 watt (for high/low main beam) Z 9-55/100
9004 80/100 watt (for high/low main beam) Z 9-80/100
9004 "Blue Ion" 55/100 watt (for high/low main beam) Z 9-55/100B
Relay (Hella) 12 volt-
(2) required w/ 80/100 bulbsZ Relay12
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Rear Tail Lamp Seals & Lamp Sockets Puddles in the trunk or damp
carpeting might be due to leaking rear tail lamp seals. Non-functioning tail
lamps are usually due to corroded lamp sockets. We have new replacements
for both these USA Ford unavailable parts.
Left or Right Tail Lamp
Seal- XR4 M319S
Left or Right Tail Lamp
Socket- XR4 M319LS
H4 H3 9004 pC
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(h XR) (Scorpio i)
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Scorpio fog lamps
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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
pB
Hose*- heater valve to engine/inlet mfld.G421HB
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Hose*- heater valve (inlet) to heater coreG421HC
pD
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
pL
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
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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
2 2

Cooling System (Scorpio) supplement
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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)
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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
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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
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pM
pN
pO
pPpQpR
see page 19
for radiators
see page 19
for water pump
Diagram B
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Diagram A
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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.
M470C pC
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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 & Related Items
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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
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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
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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
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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
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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
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L4-218
L2G L4ES
L15D
L15DS
L604A
L15E
L2KS L4FS
2300 Turbo Engine Components
Cylinder Block Bare (H.D. "Turbo" Block) L2G 475.00
Main Cap Stud Set (H.D. ARP) L2KS 94.55
Full Gasket Set (Felpro)
1985 engineL15AA 95.00
Full Gasket Set (Felpro)
1986-89 engineL15AB 124.50
Top End Gasket Set (Felpro)
specify year when orderingL15BA 55.00
Top End Gasket Set (Felpro)
with hi-temp valve cover setL15BB 79.50
Bottom End Gasket Set (Felpro)
1985 engine (cork pan)L15CA 40.10
Bottom End Gasket Set (Felpro)
1986-89 engine (rubber pan)L15CB 73.85
Oil Pan Gasket (1 piece rubber) 1986-89 L15CP 34.25
Head Gasket (Felpro) L15DA 19.50
Competition Head Gasket (Felpro #1035)
steel wire ring typeL15DF 59.50
Competition Head Gasket (extreme duty racing gasket) L15DR 29.50
Valve Cover Gasket- Cork L15E 6.79
Valve Cover Gasket H.D. (1 piece rubber) includes upper manifoldL15EA 24.00
Intake Manifold Gasket Set L15FA 11.40
Exhaust Manifold to Cylinder Head L15GA 7.50
Turbo Charger to Exhaust Manifold (stainless) L521GT 8.75
Water Outlet Gasket L15N CALL
Water Pump GasketL15P CALL
Camshaft Seal L15R 8.25
Auxiliary Shaft Seal L15S 9.25
Crankshaft Front Seal L15T 16.08
Oil Pump (standard)
MellingL2P 42.90
Oil Pump- (high pressure/ high volume) L2HP 73.20
Water Pump (new) L6A 73.10
Water Pump (recon) L6AA 39.00
Fuel Pump- Electric XR4Ti (in line) M10A 165.00
Fuel Pump- Electric XR4Ti (in tank) M10AT 125.00
Engine Components
Utilizing a design similar to the earlier German
2000 OHC "Pinto" engine the 2300 "Lima" en-
gine eventually replaced the 2000 OHC in most
North American Ford 4 cylinder vehicles from
1974 on. Built for lower maintenance with the
addition of hydraulic lash
adjusters the 2300
was designed to
operate in a lower
RPM range using
its larger displace-
ment and in-
creased torque to
its best advan-
tage. Perfor-
mance turbo-
charged versions
of the 2300 began
to appear in 1979 in
the Mustang/Capri and continued through the
80's in a more refined and powerfull EFI turbo
version. A reduced bore 2000 displacement
"Ranger" truck engine (from 1983-87) was also
produced. Some late production "Lima" engines
are equipped with hydraulic roller cam and valve
train, and other versions use dual spark plug
cylinder heads. The 2300 is a fairly rugged
engine in its stock form, however some compo-
nents will require up-rating with performance
components if high RPM duty is required. The
"Lima" series turbo and normally aspirated en-
gines respond quite well with a bit of perfor-
mance tuning and though lacking in refinement
do give quite a bit of bang for the buck.
Main Bearing Set- ACL/Vandervell (std, .010", .020", .030") L16A 32.65
Connecting Rod Set- (4) Forged H-beam 5.20" length L4ES 549.00
Connecting Rod Set- (4) Forged
I-beam 5.20" length L4ESB 398.00
Connecting Rod Set- (4) Forged H-beam 5.70" length L4ESA 549.00
Rod Bearing Set- ACL/Vandervell (std, .010", .020", .030") L16H 16.35
Con Rod Bolt Set- ARP H.D. (for standard 2.3L rod) L4FS 47.70
Head Stud Set- ARP H.D. L2DS 105.00
Cam Bearing Set- ACL/Vandervell L16M 18.50
Cam Bearing Set- ACL/Vandervell (360 degree O.D. groove) L16MA 18.50
Aux. Shaft Bearing L5DC 20.25
Cam Follower- (standard O.E. type)
eachL5B 7.50
Cam Follower- (roller type)
eachL5BR 16.00
Ring Set- Moly type 1/16", 1/16", 3/16" (std, .020", .030", .040", .060")

*for above "performance pistons" - specify sizeL4R 85.90
Ring Set*- Gapless Moly type 1/16", 1/16", 3/16" (std, .020", .030", .040", .060")

*for above "performance pistons" - specify sizeL4TF 98.00
Ring Set*- Gapless Moly type 1/16", 1/16", 3/16" (std, .025", .035", .045", .065")

*for above "performance pistons" - file fit top ringL4T1 127.50
Ring Set*- Gapless Moly type 2mm, 2mm, 4.75mm (std, .020", .030", .040", .060")
*for standard OE type pistons - specify sizeL4TFA 98.00
Performance Piston- Power Forged #250F (std, +.020", +.030", +.040", +.060 sizes)
exact replacement for standard 2.3 turbo piston, light weight "power forged"
design, 1.589" comperssion height for 8.0:1 compression, 2mm 2mm 4.75mm
ring land, supplied with wrist pins and locks.
L4-250F 62.20
Performance Piston- Forged (custom)
BAT can supply custom forged pistons to your specifications. Information regarding
bore size, ring land sizes & locations, compression height, and wrist pin bore size
is required for ordering. Pricing is on request
2 8

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

pA
pB
pC
pD
pEpF
pHpI
pJ
pG
Transmission & Related Components
pHShifter- A serious short throw competition gear lever
featuring a robust large diameter shaft placed within a
spherical bearing. The all metal construction will cause
additional transmitted noise but this is a small penalty to
pay against the strength, speed and quality of the gear
change achieved. M717
pIGear Oil- Torco synthetic gear oil is designed to
withstand tremendous heat and provide extreme anti-
score protection under high torque "shock loading"
conditions. That is why most Indy car and drag race teams
rely on Torco protection. Torco SAE 75w90 gear oil is GL-
6 rated and includes limited slip additives. Great for both
transmission and differential applications. Torco synthetic
gear oil greatly improves the shift "feel" of T9 transmission,
shifting becomes light and precise, almost like a tune-up in
a bottle. Notes: transmission will require 2 quarts (2.25 to
3.34 pint capacity depending on year) and rear axle 1 quart
(1.6 pint capacity) Gear oil not for T5 transmissions (use
ATF type fluid). C2S
pJQuadrant & Pawl Kit- When the clutch pedal "ratchet
adjuster" wears out it contributes to poor pedal feel and an
annoying clicking noise. Renewing the quadrant and pawl with
this handy kit will alleviate the problem. M368
pK Rebuilt T9 Transmissions- Highest quality factory
certified remanufactured T9 transmissions with European
gear ratios (3.65:1, 1.97:1, 1.37:1, 1.00:1, 0.82:1). M700
pAOil Seal- input Shaft (front) T9 TransmissionM703
pB
Gasket- input bearing retainer to main case (front)
T9 TransmissionM702G
pC
Gasket- top Cover T9 TransmissionM716
pDOil Seal- extension housing (tail shaft) T9
TransmissionM719
pE
Gasket- adaptor plate (bearing carrier) to main case T9
TransmissionM709
pFGasket- adaptor plate (bearing carrier) to extension
housing (tail shaft) T9 TransmissionM708
pG Short Shift Kit- If anything can be added to enhance
the "link" between driver and transmission while rowing through
the gears on the XR4 or Scorpio 5-speed this is it. We have a
dynamite quick shift kit that fits standard T9 Hummer transmis-
sions. If you like the shifter "feel" on Hurst equipped Mustang
GT, this kit offers similar results. Customers often remark that
this shift kit is one of the best modifications that they have made
to their cars, especially considering the price and ease of
installation. Just think about how many gear changes you make
in a day, let alone a week, or year. Shouldn't every shift be quick,
light and precise? M715
pK
3 2