Market Position:
The Ford Sierra was a significant model for Ford in Europe, positioned as a family car and a performance car depending on the variant. It competed with models like the Opel/Vauxhall Vectra, Volkswagen Passat, and Peugeot 405.
Competitive Analysis:
Known for its advanced aerodynamic design and innovative rear suspension (on some models), the Sierra offered a blend of comfort, handling, and practicality. Its success was varied across different markets and trims.
Key Features:
Aerodynamic styling, rear-wheel drive (later front-wheel drive variants emerged), a wide range of engine options from economical petrol to powerful Cosworth variants, and innovative suspension designs for its era.
Body Styles:
Available in 3-door hatchback, 5-door hatchback, and estate (wagon) body styles. A 4-door saloon (sedan) version was also produced for some markets.
Engine Systems:
Engine mechanicals (including disassembly/assembly), fuel system (carburetor and injection), ignition system, cooling system, lubrication system, exhaust system, engine management systems.
Drivetrain Systems:
Manual transmissions, automatic transmissions, clutch, driveshafts, rear axle assembly, differentials.
Suspension Steering:
Front suspension (including MacPherson struts), rear suspension (including beam axle/independent options), steering system (rack and pinion), wheel alignment specifications.
Braking Systems:
Front and rear brake systems (disc and drum), hydraulic system, parking brake, brake fluid specifications.
Climate Control:
Heating system, ventilation. Air conditioning (if factory-fitted) may be covered, including refrigerant system servicing. Manual will detail operation and repair of these systems.
Fuel Tank And Lines:
Fuel tank removal and installation, fuel lines, fuel filter replacement, fuel pump operation and replacement.
Electrical Systems:
Charging system (alternator, battery), starting system, lighting system, instrumentation, wiring diagrams, fuses and relays, comfort and convenience features.
Body Chassis:
Body construction, exterior panels, interior trim, doors, windows, glass, body repair, chassis components.
Maintenance Procedures:
Scheduled maintenance, fluid checks and changes, filter replacements, spark plug replacement, brake pad replacement, belt replacement.
Diagnostic Procedures:
Troubleshooting guides for common symptoms, diagnostic charts, component testing procedures, electrical diagnosis.
Repair Procedures:
Step-by-step instructions for removal, disassembly, repair, assembly, and installation of all major vehicle components and systems.
Adjustment Procedures:
Carburetor adjustment, ignition timing adjustment, valve clearance adjustment, brake adjustment, clutch adjustment.
Special Tool References:
References to specific Ford special service tools and fixtures required for certain operations, often with illustrations of the tool in use.
Safety Precautions:
Explicit safety notes, cautions, and warnings (DANGER, CAUTION, NOTE) are integrated into procedures to prevent injury and vehicle damage.
Technical Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Includes detailed specifications, torque values, and diagnostic procedures.
Diagrams Illustrations:
Includes detailed pictorial diagrams, exploded views, drawings, and photographs to guide technicians through repair and maintenance procedures.
Factory Specifications:
Provides factory specifications, allowable limits for wear, and critical data such as tightening torques, valve clearances, and alignment angles.
Exhaust System Coverage:
Exhaust manifold, catalytic converter (if applicable), muffler, exhaust pipes, hangers, and mounting hardware. Includes procedures for inspection and replacement.
Wheels Tires Coverage:
Wheel bolt patterns, tire pressure recommendations, wheel balancing, tire rotation, hubcap/wheel cover removal and installation.
Primary Engine Options:
A wide range of Ford's OHC Pinto, CVH, and DOHC Cosworth YB engines were available. Common displacements include 1.3L, 1.6L, 1.8L, 2.0L (including fuel-injected variants like the RS and XR4i), and the high-performance 2.8L Cologne V6 and 2.9L V6, culminating in the iconic 2.0L Cosworth YB turbo (204 PS).
Performance Variations:
Performance varied drastically, from modest fuel economy in the 1.3L and 1.6L models to exhilarating acceleration from the XR4i, XR4x4, and especially the Sierra Cosworth models, which were rally and touring car homologation specials.
Fuel System Types:
Carburetor (e.g., Weber, Solex) for early and base models, and electronic fuel injection (EFI) for later and performance variants. Turbocharged models feature sophisticated fuel injection and engine management.
Ignition System:
Distributor-based ignition systems for early models, progressing to distributorless ignition systems (DIS) and electronic ignition control units (ECUs) for later fuel-injected and turbocharged engines.
Oil Change Interval:
Typically every 10,000 km (6,000 miles) or 12 months, whichever comes first. Specifics may vary by engine and oil type used. The manual will detail exact intervals.
Timing Belt Interval:
ForOHC Pinto and CVH engines, typically every 60,000-80,000 km (37,000-50,000 miles). Cosworth YB engines use a timing chain and belt, requiring checks and replacement as per manual recommendations. Crucial to follow to avoid catastrophic engine damage.
Engine Oil Specification:
Ford specifications vary by engine, but common recommendations include 10W-40 or 15W-40 mineral oil. Synthetic oils like 5W-30 or 5W-40 are often suitable for later models and performance variants. Manual specifies exact viscosity and API/ACEA ratings.
Coolant Specification:
Ethylene glycol based antifreeze. Typically a 50/50 mix with distilled water for optimal protection. Ford specification is usually a green colored coolant (e.g., Ford Super Plus 2000).
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid, depending on the system requirements. Manual will specify the correct type.
Transmission Fluid Manual:
Gear oil for manual transmissions. Specific API GL-4 or GL-5 rating and viscosity grade (e.g., 75W-90, 80W-90) as per manual.
Transmission Fluid Automatic:
Ford ESP-M2C166-H or equivalent Dexron II/III for automatic transmissions. Manual will confirm the exact specification.
Known Issues:
Rust (especially on wheel arches, sills, and around windows), premature wear of suspension components (bushings, ball joints), fuel pump failures, ignition module failures, electrical gremlins in older wiring harnesses, corrosion in coolant passages.
Known Issues Electrical:
Early models can suffer from wiring harness degradation, particularly in the engine bay, leading to intermittent faults. Heater control panel issues are also common.
Known Issues Engine:
CVH engines can suffer from head gasket failures if not properly maintained. OHC engines are generally more robust but require regular timing belt changes.
Known Issues Suspension:
Front strut top mounts and rear trailing arm bushings are common wear items, impacting handling and ride quality.
Known Issues Brakes:
Rear brake drums can seize if the parking brake is left applied for extended periods, especially in damp conditions. Calipers and discs require regular inspection.
Torque Value Importance:
The manual provides critical torque specifications for engine components, cylinder heads, suspension fasteners, and wheel nuts to ensure proper assembly and prevent component failure or safety hazards.
