🏷️ Basic Information

Make:

Ford

Model:

Sierra

Product Name:

Ford Sierra Repair Manual

👋 Introduction

Segment:

Compact executive car / family car

Competitors:

Vauxhall Cavalier/Vectra, Volkswagen Passat, Audi 80/A4, BMW 3 Series, Peugeot 405, Renault 25.

Design Philosophy:

Aerodynamic styling, rear-wheel drive (early models), later front-wheel drive and all-wheel drive options, spacious interior, versatile model range (hatchback, saloon, estate, coupe).

Powertrain Options:

Wide range of petrol and diesel engines, including fuel-efficient CVH and Zetec units, as well as more powerful Pinto, Cologne V6, and Cosworth-tuned engines.

Impact:

A significant model for Ford Europe, bridging the gap between the Escort and the Granada, and a popular choice in its segment for both performance and practicality.

📋 Manual Details

Systems Covered:

Engine mechanical, engine performance, fuel system, ignition system, cooling system, exhaust system, lubrication system, manual transmission, automatic transmission, clutch, driveshaft, differentials, axles, suspension (front and rear), steering system, power steering, hydraulic systems, brake system (front and rear, drum and disc), ABS, parking brake, electrical system (wiring diagrams, charging system, starting system, lighting, instruments, accessories), body (chassis, panels, doors, windows, interior trim), heating and air conditioning, emissions control, troubleshooting, diagnostics, maintenance schedules, torque specifications, component replacement procedures.

Pages:

Approx. 1000+

Type:

Factory Service Manual / Workshop Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Complete overhaul procedures, cylinder head removal/installation, valve train, piston/ring replacement, crankshaft/bearing service, connecting rod service, timing belt/chain replacement, engine assembly specifications.

Engine Performance:

Fuel injection system diagnostics, ignition timing adjustment, sensor testing (MAF, MAP, O2, TPS, etc.), idle speed control, emission control system diagnostics.

Transmission:

Manual gearbox overhaul, automatic transmission service (fluid changes, filter replacement), clutch replacement, driveshaft universal joint service, differential overhaul, axle bearing replacement.

Electrical System:

Detailed wiring diagrams for all circuits, charging system testing (alternator, regulator), starting system troubleshooting, component testing (relays, switches, motors), lighting system diagnostics, fuse and circuit breaker identification.

Suspension Steering:

Front and rear suspension component replacement (struts, shocks, control arms, ball joints, bushings), steering rack overhaul, power steering pump and hose service, wheel alignment specifications.

Brake System:

Brake pad and shoe replacement, caliper and wheel cylinder service, brake rotor and drum replacement, brake fluid flush and bleeding procedures, ABS system diagnostics and component testing.

Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, coolant flush and fill, brake fluid replacement, transmission fluid changes, fuel filter replacement, drive belt inspection and replacement, tire rotation and pressure checks, battery maintenance.

Troubleshooting:

Systematic diagnostic flowcharts for common problems (e.g., no start, poor running, braking issues, electrical faults), symptom-based troubleshooting guides, error code interpretation.

Repair:

Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation for all major vehicle systems.

Diagnostics:

Detailed procedures for testing sensors, actuators, control modules, and wiring harnesses using multimeters, oscilloscopes, and specialized diagnostic equipment.

Depth:

Comprehensive, covering everything from basic owner maintenance to advanced engine and transmission rebuilds and complex electrical diagnostics.

📊 Manual Specifications

PDF Quality:

High-resolution, searchable text, clear diagrams and illustrations.

Printable:

Yes, all pages are printable.

Binding:

N/A (Digital)

Paper:

N/A (Digital)

⚙️ Engine Specifications

Common Petrol Engines:

1.3L CVH, 1.4L CVH, 1.6L CVH, 1.6L Zetec, 1.8L CVH, 1.8L Zetec, 2.0L Pinto, 2.0L DOHC, 2.3L Cologne V6, 2.8L Cologne V6, 2.9L Cologne V6, 2.0L Cosworth YB Turbo (Sierra RS Cosworth).

Diesel Options:

1.8L Diesel (indirect injection), 2.3L Diesel (indirect injection).

Typical Horsepower Range:

50 hp (1.3L) to 220 hp (Sierra RS500 Cosworth), with most common variants between 75 hp and 115 hp.

Typical Torque Range:

80 Nm to 300+ Nm (Cosworth models).

Injection Systems:

Carbureted (early models, Weber, Motorcraft), Electronic Fuel Injection (EFI, Bosch, Lucas), Turbocharged with Intercooler (Cosworth models).

Ignition Type:

Electronic Ignition (Distributorless ignition systems on later Zetec models).

Coolant Type:

Ethylene Glycol based antifreeze (typically Ford specification).

🔧 Transmission

Manual Gearboxes:

4-speed Manual, 5-speed Manual (e.g., MT75, T9).

Automatic Gearboxes:

3-speed Automatic (e.g., C3), 4-speed Automatic (e.g., EATON, ZF).

Drive Layout:

Rear-Wheel Drive (RWD) standard, Optional Four-Wheel Drive (4WD) on some performance and estate models.

Manual Gearbox Oil:

API GL-4 or GL-5, SAE 75W-90 or 80W-90 (refer to specific gearbox manual section).

Automatic Transmission Fluid:

Mercon V or equivalent (for later models), Dexron II/III or equivalent (for earlier models).

📐 Dimensions

Length Estate:

Approx. 4680 mm

Width Excluding Mirrors:

Approx. 1700-1750 mm

Height Hatchback:

Approx. 1390 mm

Kerb Weight Range:

Approx. 1100 kg to 1400 kg depending on body style and engine.

🛡️ Safety Features

Euro Ncap:

N/A (Euro NCAP not established during most of the Sierra's production run).

Braking Assistance:

Anti-lock Braking System (ABS) - optional on many models, standard on later high-specification and performance variants.

Seatbelts:

Three-point inertia reel seatbelts in front, lap belts in rear (later models introduced three-point rear belts).

Driver Airbag:

Optional on some models, standard on late-model Sierras.

Passenger Airbag:

Rarely offered, typically on very late models or specialist imports.

💡 Technology Features

Audio Systems:

Factory fitted analogue radios, cassette players, and later CD players. Aftermarket head unit upgrades are common.

Dashboard Features:

Basic analogue gauges (speedometer, tachometer, fuel, temperature), warning lights, and often a central analogue clock.

Cruise Control:

Optional on higher specification models and larger engine variants.

External Ports:

N/A (No integrated connectivity features as per modern standards).

🔧 Maintenance

Oil Change Petrol:

Typically 5,000 - 7,500 miles or 12 months, whichever comes first (depending on oil type and driving conditions).

Oil Change Diesel:

Typically 5,000 miles or 12 months.

Timing Belt Replacement:

For CVH and Zetec engines, typically 40,000 - 60,000 miles or 4-5 years (critical to follow manual for specific engine variant).

Engine Oil Viscosity:

Commonly 10W-40 or 5W-30 (for modern synthetic oils). Specific recommendations vary by engine and climate. Check manual for API service classification (e.g., API SF, SG, SH).

Coolant Capacity:

Approx. 5-7 litres, depending on engine and radiator size.

Brake Fluid:

DOT 3 or DOT 4.

Body Corrosion:

Susceptible to rust, particularly around wheel arches, sills, chassis points, and door bottoms. Early models with less galvanizing are more prone.

Electrical Gremlins:

Wiring loom degradation, faulty earth points, minor electrical faults can occur due to age. Common areas include lighting, indicators, and window regulators.

Suspension Wear:

Bushing wear (control arms, anti-roll bars), worn ball joints and tie rod ends are common due to age and mileage, impacting handling and ride quality.

Cooling System:

Radiator leaks, hose deterioration, and thermostat failure can lead to overheating issues.

Gearbox Mounts:

Worn gearbox or engine mounts can lead to clunking noises on acceleration or deceleration.

Fuel Pumps:

Early models with in-tank fuel pumps can experience failures.

📚 Vehicle History

Ford Europe Legacy:

Successor to the Ford Taunus/Cortina, a cornerstone of Ford's European passenger car strategy for decades.

Generations:

Introduced in 1982 as the 'Cargest' project, replacing the Ford Cortina/Taunus. First generation (1982-1993). Facelifted in 1987 with revised styling, interior, and updated engines.

Production Years:

1982 - 1993

Manufacturing Locations:

Various Ford plants across Europe, including Germany, UK, Belgium, Spain.

Cosworth Heritage:

Iconic Sierra RS Cosworth (1986) and Sierra RS500 Cosworth (1987) were homologation specials for rallying and touring car racing, featuring potent turbocharged Cosworth YB engines and advanced aerodynamics. These models significantly boosted the Sierra's performance image.

🏆 Awards & Recognition

Design Awards:

The Sierra's aerodynamic design was praised at its launch and received several design commendations for its futuristic styling at the time.

Motoring Journalism Reviews:

Generally positive initial reviews for its handling, comfort, and practicality, although some early critics noted the rear-wheel drive handling characteristics could be challenging in slippery conditions.

Homologation Specials:

The Sierra RS Cosworth and RS500 were specifically homologated for motorsport, earning significant recognition and success in various racing series.