weight FORD SIERRA 1992 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
0 3
pB Sport Spring Sets

pC
pDpBpA
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

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
pB
pD
pC
pA
pE
pG pF
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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
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