🏷️ Basic Information

Make:

Ford

Model:

Sierra

Year:

1991

Chassis Code:

GBC, GBD, GBG, GB4 (Global Sierra Platform)

👋 Introduction

Target Audience:

Professional technicians and Do-It-Yourself (DIY) mechanics with basic electrical and mechanical knowledge

Comparison To Factory Manuals:

Designed to mirror content typically found in factory service manuals and owner's manuals.

Learning Method:

Step-by-step guidance, teaching factory-level knowledge

Availability:

Instant Download

Illustrations:

Includes illustrations, diagrams, and pictures to aid in repair procedures.

Skill Level Caveat:

Advises users without basic knowledge to avoid complex repairs due to potential safety implications.

📋 Manual Details

Coverage:

Comprehensive service, repair, and maintenance

Estimated Page Count:

Likely 800-1200+ pages (typical for comprehensive factory-level manuals)

Type:

Repair Service Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Engine construction, assembly, disassembly, lubrication, cooling, fuel, exhaust, ignition, emissions control, engine tuning, performance testing

Engine Electrical:

Starting and charging systems, ignition system diagnosis and repair, sensor testing, ECU (Engine Control Unit) diagnostics, wiring diagrams

Transmission:

Manual and automatic transmission overhaul, clutch systems, driveshafts, differentials, service procedures

Brakes:

Hydraulic system, ABS (Anti-lock Braking System) if equipped, disc and drum brake service, parking brake

Suspension And Steering:

Front and rear suspension components, steering gear, power steering systems, alignment specifications

Electrical Body:

Lighting systems, power windows, door locks, wipers, horn, instrument cluster, comfort controls, exterior and interior lighting

Body:

Body panel removal and installation, doors, hood, trunk, bumpers, glass, rust prevention, collision repair basics

Fuel System Components:

Fuel pumps, injectors, fuel pressure regulators, fuel filters, and tank service.

Exhaust System:

Catalytic converters, mufflers, exhaust pipes, oxygen sensors (if fitted), and mounting hardware.

Climate Control:

Heating system, ventilation, and air conditioning (HVAC) system diagnosis and repair (if equipped).

Chassis:

Includes wheel bearing replacement, hub servicing, and chassis lubrication points.

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, lubrication, tune-up procedures

Troubleshooting:

Diagnostic charts, common problems and their solutions, fault finding for engine, transmission, electrical, and chassis systems

Repair Rebuild:

Detailed step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly

Diagnostics:

Component testing, circuit diagnosis, use of diagnostic tools

Electrical Diagrams:

Comprehensive wiring diagrams for all vehicle systems, crucial for diagnosing electrical faults.

Torque Specifications:

Precise torque values for all critical fasteners, essential for correct assembly and preventing damage.

Body Repair:

Procedures for door panel removal, window regulator repair, lock mechanisms, and minor body panel adjustments.

Depth:

Comprehensive, covering everything from routine maintenance to major component overhauls and diagnostics, suitable for professional technicians and advanced DIYers

Diagnostic Codes:

Procedures for reading and interpreting diagnostic trouble codes (DTCs) if applicable to the era's early onboard diagnostics systems.

Troubleshooting Methodology:

Emphasizes systematic diagnostic approaches and problem-solving techniques.

Completeness:

Full Service Manual (covers repair, maintenance, diagnostics, specifications)

📊 Manual Specifications

File Format:

PDF

Print Quality:

Full Printable

Binding Type:

Digital (N/A for paper binding)

Paper Type:

Digital (N/A for paper type)

Zoom:

Zoom IN/OUT supported

Software Requirements:

Adobe PDF Reader, WinZip

Operating Systems:

All Versions of Windows & Mac

⚙️ Engine Specifications

Engine Options:

Likely includes 1.6L (CVH), 1.8L (CVH/ZVH), 2.0L (DOHC I4), 2.3L (OHC I4), 2.8L/2.9L (V6 Cologne), and potentially diesel variants (e.g., 2.3L/2.5L) depending on market. Specific engine codes will be detailed in the manual.

Power And Torque:

Varies significantly by engine. For example, a 2.0L DOHC engine typically produced around 125-130 PS. Specific figures for each engine variant will be available in the manual.

Fuel Delivery:

Carbureted (early models or base engines) and Fuel Injection (MPI - Multi-Point Injection) for later or higher-spec models.

Ignition Type:

Distributor-based ignition systems, potentially with electronic ignition control.

Cooling Method:

Pressurized liquid cooling system with fan (mechanical or electric).

Diesel Engines:

Available with diesel engines, often 2.3L or 2.5L naturally aspirated or turbocharged variants. Manual will cover these diesel specific procedures.

🔧 Transmission

Standard Transmission:

5-speed manual transmission (e.g., Type 9).

Optional Transmission:

4-speed automatic transmission (e.g., C3 or A4LD depending on engine/drivetrain).

Drivetrain:

Rear-Wheel Drive (RWD) standard. All-Wheel Drive (AWD) was an option on certain models (e.g., Sierra XR4x4).

📐 Dimensions

Body Styles:

3-door hatchback, 5-door hatchback, 5-door estate (wagon), 4-door saloon (sedan). Also available as a convertible in some markets.

Curb Weight:

Varies by engine and body style, typically ranging from 1050 kg to 1400 kg.

Wheelbase Range:

Approximately 2600 mm for most models.

🛡️ Safety Features

Crash Test Data:

Limited comparable data from modern standards due to the era of manufacture. The manual will detail safety features available at the time.

Active Safety:

Potentially ABS (Anti-lock Braking System) on higher trims, disc brakes front and rear.

Passive Safety:

Seat belts (front and rear), reinforced body structure, impact-absorbing steering column.

💡 Technology Features

Audio System:

Factory fitted radio/cassette players. The manual will cover basic electrical connections for aftermarket replacements.

ABS:

Anti-lock Braking System (ABS) was an optional feature on higher trim levels and specific engine variants, particularly in later production years.

Remote Keyless Entry:

Not a standard feature for 1991 models, though aftermarket systems could be installed.

🔧 Maintenance

Oil Change Interval:

Typically every 10,000 km or 6 months, but this manual will provide specific Ford recommendations.

Timing Belt Replacement:

Crucial for interference engines (e.g., DOHC), usually at 60,000-80,000 km or 4-5 years. Manual will specify intervals and belt part numbers.

Engine Oil Specification:

Likely API SG/SH or ACEA A2/A3, with viscosity grades such as 10W-40 or 5W-30 depending on climate and engine type. Manual will list specific Ford specifications (e.g., Ford WSS-M2Cxxx-A).

Coolant Specification:

Ethylene glycol based antifreeze. Manual will specify Ford coolant type and mix ratio.

Brake Fluid Specification:

DOT 3 or DOT 4 brake fluid. Manual will provide the exact specification.

Transmission Fluid Type:

Manual: Gear oil GL-4 (e.g., SAE 75W-90). Automatic: Type 'Mercon' or equivalent ATF. Manual will confirm exact specifications and capacities.

Power Steering Fluid:

Specific hydraulic fluid type for power steering systems. Manual will specify Ford specification.

Common Faults:

Rust (wheel arches, sills, strut tops), electrical gremlins (particularly associated with wiring harnesses and earth points), worn suspension bushes, potential gearbox synchro issues (manual), radiator leaks, and alternator failures are commonly reported for the Sierra. The manual will provide diagnostic steps for these.

Oil Filter Example:

Part numbers are specific to engine variants. For example, a common oil filter for a 2.0 DOHC might be a Motorcraft EF-12 or equivalent from brands like Mann-Filter, Bosch, or Fram.

Spark Plugs:

Specific spark plug types and gap settings for each engine variant will be detailed in the manual.

📚 Vehicle History

Ford Europe Legacy:

The Sierra was a highly significant model for Ford of Europe, replacing the popular Ford Cortina and aiming for a more modern, aerodynamic design. It was part of Ford's 'world car' concept.

Generation Updates:

The 1991 model year falls into the later part of the Sierra's production life, likely featuring the 'facelift II' updates which introduced revised styling, interior improvements, and potentially updated engine options. Key models included the Ghia, XR4i, and XR4x4.

Production Period:

1982-1994 (Europe)

Manufacturing Plants:

Primarily built in Germany (Cologne), Belgium (Genk), and the UK (Halewood).

🏆 Awards & Recognition

Design And Engineering:

The Sierra's aerodynamic design was considered innovative for its time, contributing to its reputation for good fuel economy and stability at higher speeds. It garnered various European motoring accolades during its lifespan.