Segment:
Family car, executive car (depending on trim and engine).
Target Audience:
Owners seeking to maintain and repair their Ford Sierra, DIY mechanics, professional garages.
Key Competitors:
Vauxhall Cavalier, Volkswagen Passat, Austin Montego, Peugeot 405, Renault 21.
Vehicle Attributes:
Aerodynamic styling, advanced (for its time) suspension, rear-wheel drive and later all-wheel drive options, wide range of engine choices.
Engine Mechanical:
Detailed disassembly, assembly, inspection, and repair of all engine variants including 5-bearing Pinto OHC, Cologne V6, and CVH engines.
Engine Management And Ignition:
Carburettor and fuel injection system diagnostics and repair (e.g., Weber, Ford EFI), ignition system troubleshooting, electronic engine control (EEC-IV) for later models.
Transmission:
Manual transmission overhaul (e.g., Type 9, MT75), automatic transmission operation and servicing (e.g., C3, C5).
Drivetrain:
Clutch system, driveshafts, rear axle and differential servicing, front wheel drive components for XR4i/XR4x4 models.
Suspension:
Front and rear suspension component diagnosis, replacement (e.g., MacPherson struts, trailing arms), wheel alignment procedures.
Steering:
Power steering system diagnosis and repair, manual steering rack servicing.
Brakes:
Front disc and rear drum brake system maintenance and repair, hydraulic system troubleshooting, parking brake adjustments.
Electrical System:
Complete wiring diagrams for all models, fuse box layouts, lighting system repair, starter motor and alternator servicing, battery maintenance.
Body And Interior:
Door panel removal, seat adjustment mechanisms, interior trim replacement, body panel alignment, rust repair basics.
Heating And Ventilation:
Heater matrix replacement, blower motor servicing, air conditioning system refrigerant handling (if equipped).
Scheduled Maintenance:
Detailed service schedules for oil changes, filter replacements, spark plugs, timing belt inspection/replacement, brake fluid changes.
Troubleshooting:
Systematic diagnostic procedures for common running issues, electrical faults, and mechanical problems.
Repair And Rebuild:
Step-by-step instructions for component removal, repair, and reinstallation, including engine rebuilds and transmission overhauls.
Diagnostics:
Fault code retrieval (OBD-I for later models), sensor testing, and component-level diagnostics.
Depth Of Coverage:
Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds, including detailed torque specifications and tolerances.
Engine Options:
1.3L (4-speed), 1.6L OHC, 1.8L OHC, 2.0L OHC (Pinto), 2.0L DOHC (Zeta/I4), 2.3L Diesel, 2.8L Cologne V6, 2.9L Cologne V6 (XR4x4).
2.0L Ohc (Pinto) Horsepower:
~90-105 PS (depending on fuel system)
2.8L Cologne V6 Horsepower:
~135-150 PS (depending on tune)
Early Fuel System:
Weber 2V or 3V Carburetors (e.g., 273, 32/36 DFEV)
Later Fuel System:
Ford Electronic Fuel Injection (EFI), Bosch K-Jetronic/Motronic on some variants.
Timing Belt Replacement Interval:
Every 30,000-40,000 miles or 4 years for OHC engines, refer to specific engine section for exact interval and procedure. DOHC engines may have chain or belt.
Common Manual Transmission:
Ford Type 9 (5-speed), earlier 4-speed units.
Optional Automatic Transmission:
Ford C3, C5 (3-speed automatic).
Mt75 Transmission:
Introduced on later models and XR4x4, offering improved shift quality.
Type 9 Gearbox Oil:
Ford ESA-M2C184-A (GL-4) or equivalent, 1.5 litres.
Automatic Transmission Fluid:
Ford ESP-M2C33-F or ESP-M2C33-G (ATF Type F/G), capacity varies by model.
Euro Ncap Rating:
Not tested under modern Euro NCAP protocols. Safety features were basic by today's standards.
Braking System:
Front ventilated discs, rear drums (later models and performance variants offered rear discs).
Optional ABS:
Available on later high-spec models (e.g., XR4x4i).
Seatbelts:
Standard three-point front seatbelts, lap belts in rear (later models may have three-point rear belts).
Rollover Protection:
Reinforced roof structure, though less advanced than modern standards.
Oil And Filter Change:
Every 6,000-10,000 miles or 6-12 months (depending on engine and oil used). Check manual for specific recommendation.
Air Filter Replacement:
Every 12,000-18,000 miles or annually.
Spark Plug Replacement:
Every 15,000-30,000 miles for standard plugs, up to 60,000 miles for platinum/iridium types. Refer to engine specifications.
Brake Fluid Change:
Every 2 years.
Engine Oil Specification:
API SG or ACEA A3/B3. Viscosity: 10W-40 or 15W-50 typically, 5W-30/5W-40 for colder climates. Consult manual for specific engine and ambient temperature recommendations.
Coolant Specification:
Ethylene glycol-based antifreeze with corrosion inhibitors. Typically a 50/50 mix with distilled water. Ford specification: WSS-M97B44-D or equivalent.
Rust And Corrosion:
Common areas include wheel arches, sills, floor pans, suspension mounting points, and strut tops, especially on early models. Early Mk2 models improved but still susceptible.
Electrical Gremlins:
Degradation of wiring insulation, corroded connectors, particularly in the engine bay and under the dashboard. Fuse box issues are also common.
Suspension Wear:
Worn ball joints, tie rod ends, bushings, and rear trailing arm bushes can lead to poor handling and alignment issues.
Gearbox Synchromesh Issues:
Worn synchromesh rings in Type 9 gearboxes can cause difficulty engaging gears, particularly 2nd and 3rd.
Engine Oil Leaks:
Common from rocker cover gaskets, sump gaskets, and crankshaft seals, especially on higher mileage engines.
Ford Europe Heritage:
Ford of Europe's successor to the Ford Taunus/Cortina, designed to compete in the new executive compact segment.
First Generation:
Launched in 1982 with aerodynamic styling, rear-wheel drive, and a focus on handling. Known for its distinctive 'jelly mould' design.
Facelifts:
Significant facelift in 1986 (Mk2 Sierra) introduced revised interior, exterior styling cues, and improved corrosion resistance. Introduction of all-wheel-drive (XR4x4).
Performance Variants:
Sierra XR4, XR4i, XR4x4, and the highly successful Sierra RS Cosworth (RWD) and Sierra Sapphire RS Cosworth 4x4.
Manufacturing Locations:
Primary production in Genk, Belgium, with assembly in other European plants.
Total Production Numbers:
Over 2.7 million units produced worldwide.
