Positioning:
The Ford Sierra was a significant model for Ford of Europe, intended to replace the popular Ford Taunus/Cortina. It competed in the highly competitive mid-size family car segment.
Competitors:
Key competitors included the Opel Rekord/Vauxhall Carlton, Volkswagen Passat, Peugeot 505, Renault 25, and Austin Montego.
Design Innovation:
Aerodynamic 'jelly mould' styling, pioneering 'Procon Ten' safety system (a mechanical seatbelt tensioning system before airbags were common), independent rear suspension on some variants.
Performance Variants:
RS Cosworth models were highly acclaimed performance versions.
Engines:
OHC (Pinto), Cologne V6, Duratec (later models), Zetec (later models), DI/TDI Diesel (later models)
Transmissions:
4-speed Manual, 5-speed Manual, 3-speed Automatic, 4-speed Automatic
Estimated Pages:
1000-1500 (typical for comprehensive factory service manuals of this era)
Type:
Factory Service Manual (FSM) / Workshop Manual
Format:
Digital (PDF) / Software (likely a CD-ROM or downloadable application for older software)
Powertrain:
Engine mechanical (including timing, valve train, lubrication, cooling, fuel injection/carburetion), Exhaust system, Transmission (manual and automatic), Drivetrain (rear-wheel drive, optional AWD)
Chassis:
Suspension (front struts, rear beam axle/independent suspension depending on model), Steering (rack and pinion, power steering), Brakes (front discs, rear drums/discs, ABS on later models), Wheels and Tires
Electrical:
Ignition system, Charging system (alternator, battery), Starting system, Lighting, Instrumentation, Power accessories (windows, locks, mirrors), Climate control electronics, Engine control unit (ECU) diagnostics, Wiring diagrams
Body And Interior:
Body panels, Doors, Glass, Upholstery, Seats, HVAC (heating, ventilation, air conditioning) systems, Body trim, Safety systems (seatbelts)
Maintenance:
Oil changes, Filter replacements, Spark plug replacement, Coolant flushes, Brake fluid changes, Belt inspections and replacement, Lubrication points
Troubleshooting:
Diagnostic procedures for engine performance, electrical faults, transmission issues, braking problems, HVAC malfunctions; use of diagnostic codes (where applicable)
Repair:
Engine overhaul (rebuilds), Transmission overhaul, Clutch replacement, Brake caliper/rotor/drum replacement, Suspension component replacement, Steering rack replacement, Electrical component repair/replacement, Bodywork repair procedures
Diagnostics:
On-board diagnostics (OBD-I for later models), symptom-based diagnostic flowcharts, wiring diagram interpretation
Depth:
Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring schematics.
Digital Format:
PDF with searchable text and high-resolution diagrams (assuming digital version is software-based or a modern PDF conversion)
Print Quality:
High quality, black and white with clear diagrams and illustrations (typical for factory manuals). If a printed version, expect durable paper.
Binding:
Digital: N/A. Printed: Spiral-bound or Perfect-bound for durability in workshop environments.
Paper Quality:
Durable, coated paper suitable for workshop use (if printed).
Engine Family 1:
Ford Valencia/Pinto OHC (Inline-4)
Displacement 1:
1.6L (1593cc), 1.8L (1773cc), 2.0L (1993cc)
Power 1 Range:
Approx. 70-115 hp
Torque 1 Range:
Approx. 115-175 Nm
Engine Family 2:
Ford Cologne V6 (V6)
Displacement 2:
2.3L (2293cc), 2.8L (2792cc), 2.9L (2935cc)
Power 2 Range:
Approx. 100-150 hp (non-turbo), up to 204 hp (2.8i V6, RS500)
Torque 2 Range:
Approx. 175-260 Nm (non-turbo), up to 290 Nm (2.8i V6, RS500)
Fuel Delivery:
Carburetted (Weber, Solex) for early models, Electronic Fuel Injection (EFI) for later and higher-performance models.
Rs Cosworth Engines:
2.0L YB DOHC Turbocharged I4 (204 PS standard, 220 PS RS500)
Transmission Type Standard:
4-speed Manual (early/base models), 5-speed Manual (common)
Transmission Type Optional:
3-speed Automatic (C3), 4-speed Automatic (AXOD)
Drivetrain:
Rear-Wheel Drive (RWD). Optional All-Wheel Drive (AWD) available on some performance models (e.g., Sierra XR4x4).
Euro Ncap Era:
Pre-Euro NCAP structure, but safety was a focus for its time.
Brakes Type:
Front ventilated discs, Rear drums standard. Optional rear discs on higher trims. ABS available on later models.
Procon Ten:
Standard on many models, a mechanical pre-tensioning system for seatbelts.
Airbags:
Not standard, became available as an option on very late models.
Audio System:
Period-appropriate AM/FM radio, cassette player. Options for upgraded stereo systems with more speakers.
ABS:
Available as an option on later models, primarily on higher-specification vehicles.
Interior Features:
Central locking, electric windows, electric mirrors were available on higher trim levels as options.
HVAC System:
Basic ventilation, heater, and optional air conditioning systems.
Oil Change Interval:
Every 12,000 km or 12 months, whichever comes first (typical for the era; consult manual for specific engine).
Timing Belt Replacement:
For OHC engines, typically every 60,000-80,000 km or 4-5 years. Crucial to follow due to potential for catastrophic engine damage if it breaks.
Engine Oil Type:
API SF/SG or ACEA A1/B1, viscosity typically 10W-40 or 10W-30, depending on climate. Consult manual for precise specifications.
Coolant Type:
Ethylene glycol-based antifreeze. Ford specification (e.g., Ford Spec ESB-M97B44-A) or equivalent. Typically a 50/50 mix with distilled water.
Transmission Fluid Manual:
GL-4 Hypoid gear oil, e.g., SAE 75W-90 or 80W-90.
Transmission Fluid Automatic:
Type 'H' Automatic Transmission Fluid (ATF) or Ford ESW-M2C33-F/G equivalent.
Rust Corrosion:
Common issue, particularly around wheel arches, sills, and door bottoms, due to materials and underbody protection of the era.
Ignition System:
Distributorless ignition systems (DIS) on later OHC engines can be prone to coil pack failure.
Suspension Wear:
Worn ball joints, tie rod ends, and strut mounts are common maintenance items due to age and mileage.
Fuel System Leaks:
Fuel lines and pump seals can degrade over time, leading to potential leaks.
Ford Europe Focus:
Ford Sierra was a key model in Ford of Europe's strategy to modernize its lineup and compete effectively in the European market.
Facelifts:
Received significant facelifts in 1987 and 1990, improving styling and interior comfort, addressing some early criticism of the original design.
Production Period:
1982-1994 (European production)
Manufacturing Locations:
Primary plants in Germany (Cologne), Belgium (Genk), UK (Dagenham), and Spain (Valencia).
Legacy:
Succeeded by the Ford Mondeo.
European Car Of The Year:
Not a winner, but a strong contender and influential design.
Motorsport Success:
Highly successful in motorsport, particularly the Sierra RS Cosworth and Sierra RS500 in touring car championships (BTCC, DTM).
