1992 FORD SIERRA XR4 Workshop Manual

Wheels
4 Spoke "Turbo" Wheel
Stylish 4 spoke "Turbo" wheel available
in 16" diameter with either a 6" or 6.5"
width. Finish is bright silver. We highly
recommend these factory Ford wheels
for guaranteed quality fit and finish.
Center cap included.
4 Spoke "Turbo" Wheel
16 x 6" $195.00
16 x 6.5" $195.00
2 x 4 Spoke Wheel
Stylish 2 x 4 spoke wheel available
in 16 & 17" diameters from 6.5" to
7.5" widths. Finish is bright silver.
We highly recommend these factory
Ford wheels for guaranteed quality
fit and finish.
Center cap included.
2 x 4 Spoke Wheel
15 x 7" $209.00
16 x 6.5" $209.00
17 x 7.5" $209.00
TW "Thrust" Wheel
10 spoke "Thrust" light alloy
wheel with a locking center
cover. Available in charcoal
grey with polished silver lip in
15 x 7" size. A great looking
wheel at a budget price.
TW "Thrust" Wheel
15 x 7" $109.00
Wheels FYI
We offer only direct fit wheels for the Contour in the 4 x 108mm pattern and 35-40mm offset range. Most
are factory Ford or Ford Motorsport authorized wheels which guarantees quality fit and finish. BAT imports
these wheels directly from Europe and our prices include all inbound freight charges. Outbound freight
from our location to you by UPS ground will cost between 30.00 to 50.00 per set of 4 wheels- depending
on your location. Please note: We often hear horror stories from customers who have ordered wheels
from European mail-order suppliers only to receive damaged or substandard components, and now you
own it! Sending it back or trying to get the freight carrier to pay for the damage is next to impossible they
will just claim it was "improperly packed" or "it wasn't that way when it left here". Worse yet, the shipping
costs involved importing large, heavy, items like wheels can far exceed the cost of the part (expect 50.00
to 100.00 per wheel) What started out as a bargain now has become a expensive learning experience.
Avoid the hassles, let us supply your wheels to your door at a fair
price. When you do the math you will find we are saving you money.
ST200 Wheel
Stylish 14 spoke wheel available in 17" diameter with a 7" width. Factory
equipment on the Mondeo ST200. Finish is bright silver. We highly
recommend these factory Ford wheels for guaranteed quality fit and finish.
Center cap included. (wheel might requite a spacer for XR fitment)
ST200 Wheel 17 x 7" $209.00 each
1 6

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
1 7

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

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
pA
pB
pC
pD
pG
pF
pE
Accessories
fuse box cover
1 9

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

pJ
pI
pM
pK
pV
pU
continuation
pV
pG
pH
pE
pC pB
pA
pL
pP
pF
pN
pQ
pD
pO
The cooling system on the XR4Ti is fairly unique. If there is
another car with more individual hoses in the cooling system,
we have yet to see it. Compound this with the changes
throughout the model run and it gets even more complex. We
have a good inventory of the hoses and other cooling related
components that fit 1985-87 XR4Ti and some (where similar
or noted) for 88-1989 cars.
pA
Hose- heater valve to pipe (leads to oil cooler) M421HC
pB
Hose- heater valve to heater coreM421H

(note: pB interchanges with pJ)
pC Hose- heater valve to pipe along valve cover (upper)
at rear
(note: pC interchanges with pF )M421HB
pD
Heater Valve- heater control valve XR & Scorpio M421V
pE
Hose- water pipe (lower) to oil coolerM421HE
pF
Hose- oil cooler to water pipe (from heat valve)M421HB

(note: pF interchanges with pC )
pG Hose- oil cooler to intake manifoldM421HD
pH
Oil Cooler- replacement water to oil heat exchangerAWC1
pI Hose- pipe along valve cover (lower) @ front to water
pump. This one is a common problem.M421HA
pJ
Hose- pipe along valve cover (upper) @ front to thermostat
housing (heater supply). Don't hit the road without an extra one
of these!
(note: pJ interchanges with pB )M421H
pK
Water Pump- quality replacement pump L6A
pK1
Thermostat Housing- H.D. cast Iron version L2F
pL
Hose- radiator (lower) 1985-88 (MT & AT)M421BH
pL
Hose- radiator (lower) 1989 (auto & manual)M421BH9
pM
Hose- radiator (upper) 1985-88 (MT & AT)M421TH
pM
Hose- radiator (upper) 1989 (MT & AT) M421TH9
pS
pK1
Cooling System (XR)
pW
Plumbing Schematic
1985-88 XR4Ti w/5 speed
pTpR
pN Hose- expansion tank (top fitting) to valve cover pipe
(note: shape of hose not accurate in drawing)M421TT
pO
Expansion Tank- Thread-on cap (similar to Scorpio) Ford
tanks, some with, or without, the fluid level sensor port. Tank
caps, fluid level sensors, and sensor mounting parts are also
available. (see price list for complete listing)
Tank 1985-88 M421E Tank 1989 w/o sensor M421E9
pP
Hose- expansion tank (lower fitting) to radiator drain line
M421TL
pQ
Hose- expansion tank (middle fitting) to radiator (upper)
M421TM
pR
Radiator- O.E. type replacement radiators for 1985-89 manual
or 1985-88 auto transmission XR4Ti's.
(1985-88 manual) M421R (1985-88 auto) M421RA
(1989 manual) M421R9 (1989 auto) M421R9A
Mount/Bushing- @ radiator top mounting locationM421RM
pS
Electric Fan- An altermative to the sometimes troublesome
dual cooling fans on the XR4Ti, this highly efficent (1100 cfm) 16"
electric "puller" fan does the work of both. Wire directly or use our
(optional) adjustable 165-215 degree thermostat/relay pack.
(16" puller fan) A16F-PL (thermo/relay) AFTR1
pT
Blower Motor & Fan A/C & Heater -for heater and A/C,
check fuse & relay first before ordering. M470A
pU
Heater Core- New O.E. Ford heater cores. M471
pV
Turbo Water Hose -high temperature CPE silicone hose for
turbo (water) inlet/outlet pipes. (1 foot makes 3 hoses)
M421WT
pW
Hose- Lower drain pipe @ radiator lower M421HF
2 1

pA
pB
pC
pD
pE
pF
pG
pH pJ
pK
pL
pP
pIpN
pOpM
pS
pR pQ
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
pC
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
pF
Hose- coolant tank to thermostat housingG421HF
pG
Hose- top radiator hose (88-89)G421TH
pG
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
pI
Water Pump- new Ford water pumpG421
pI
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
pJ
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
pN
Radiator Cap- cap for Scorpio and XR4's with thread-on
coolant tankG421C
pO
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
pQ
Heater Core- Quality Ford O.E. heater cores.G471
pR
Mechanical Fan Clutch- Quality Ford O.E.G422
pR
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
pS
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
pA
pF
pHpJ
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)
pK
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
pN
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
pK
pM
pN
pO
pPpQpR
see page 19
for radiators
see page 19
for water pump
Diagram B
pC
pDpB pE
pG
pS pLpS
Diagram A
pI
2 3