Segment:
Family Car, Executive Car, Estate/Station Wagon
Era:
Late 20th Century, European market focus
Key Competitors:
Opel Rekord/Vectra, Volkswagen Passat, Peugeot 505, Renault 21, Audi 80/100, BMW 3 Series (E30)
Design Philosophy:
Aerodynamic styling, spacious interior, rear-wheel drive (later optional four-wheel drive), front-wheel drive variants
Innovations:
Recessed door handles, integrated bumpers, aerodynamic efficiency
Primary Coverage:
Mechanical, Electrical, Bodywork, Maintenance, Diagnostics, Repair Procedures
Engine Coverage:
All petrol and diesel variants within the specified years
Transmission Coverage:
Manual and Automatic transmissions
Body And Chassis Coverage:
Exterior panels, interior trim, suspension, steering, brakes
Electrical System Coverage:
Wiring diagrams, component testing, diagnosis of electrical faults
Estimated Page Count:
800-1200 (typical for comprehensive service manuals of this era)
Type:
Official Service and Repair Manual
Powertrain:
Engine overhaul, fuel injection, ignition system, exhaust system, cooling system, lubrication system
Drivetrain:
Clutch, gearbox, differentials, driveshafts, axles
Chassis:
Front and rear suspension, steering system, braking system (including ABS where applicable)
Electrical:
Battery, charging system, starting system, lighting, instrumentation, audio systems, power windows, central locking
Body:
Body panel repair, interior trim removal and installation, glass replacement, seals and weatherstripping
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, spark plug replacement, belt adjustments
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs) interpretation (for OBD-I systems), circuit testing
Repair:
Engine component replacement (pistons, valves, bearings), gearbox overhaul, brake caliper rebuilding, suspension arm replacement
Rebuilds:
Detailed procedures for engine, transmission, and differential rebuilds
Wiring Diagrams:
Complete, detailed wiring schematics for all electrical systems
Depth:
Comprehensive, covering from basic maintenance to full engine and transmission rebuilds, including factory specifications and tolerances.
Engine Family:
Ford Pinto/Valencia, Ford CVH, Ford Cologne V6, Ford Duratec (later models)
Petrol Engines:
1.3L (1297cc), 1.6L (1593cc), 1.8L (1798cc), 2.0L (1993cc), 2.8L V6 (2792cc), 2.9L V6 (2935cc)
Diesel Engines:
2.3L (2304cc) naturally aspirated and turbocharged diesel
Hp Range:
Approx. 60 hp (1.3L Diesel) to 150 hp (2.9i V6)
Torque Range:
Approx. 95 Nm to 230 Nm
Early Models:
Carbureted (e.g., Weber, Motorcraft 2150/2700)
Later Models:
Electronic Fuel Injection (EFI), Motronic, EEC-IV
Type:
Distributor-based, breakerless ignition (e.g., TFI, EEC-IV controlled)
Gearbox Options:
4-speed manual, 5-speed manual (e.g., Ford MT75, T9)
Automatic Transmission:
3-speed automatic (e.g., Ford C3, C5), 4-speed automatic (e.g., Ford A4LD)
Drive Layout:
Rear-Wheel Drive (RWD), Optional All-Wheel Drive (4x4)
Manual Gearbox Oil:
API GL4/GL5, SAE 75W-90 or 80W-90 (refer to specific manual chapter for precise type)
Automatic Transmission Fluid:
ESSO LT 71141, Ford Mercon (for later models)
Body Styles:
3-door Hatchback, 5-door Hatchback, 5-door Estate ( Turnier), 2-door Coupe (Sierra XR4i/XR4x4), 2-door Convertible (later XR4i)
Length:
Approx. 4430-4570 mm (depending on body style)
Width:
Approx. 1690-1700 mm
Height:
Approx. 1380-1440 mm (depending on body style)
Curb Weight:
Approx. 1050 kg to 1350 kg (depending on engine and specification)
Era Specific Ratings:
Limited standardized crash testing in early years; later models saw improvements, but no direct Euro NCAP equivalent for the entire period.
Braking:
Front disc brakes, rear drum brakes (all-round discs on higher trims and performance models), optional Anti-lock Braking System (ABS) on later models.
Steering:
Rack and pinion, optional power steering
Seatbelts:
Three-point front seatbelts, lap belts rear (often three-point on higher trims)
Body Structure:
Reinforced safety cage, impact-absorbing zones
Audio Systems:
Factory fitted cassette players, AM/FM radios, often with 2 or 4 speakers. Higher trims featured upgraded systems and amplifier options.
Dashboard:
Basic analogue instrumentation with tachometer on higher performance models. Warning lights for various systems.
ABS:
Optional Anti-lock Braking System (ABS) available on higher specification models, particularly from the mid-1980s onwards.
Early Era Connectivity:
Limited to radio antenna and basic wiring for optional accessories.
Oil Change:
Typically every 5,000-10,000 miles or 6-12 months (depending on engine and oil type used).
Air Filter:
Replace every 12,000-24,000 miles or 12-24 months.
Spark Plugs:
Replace every 20,000-40,000 miles depending on type (copper, platinum).
Timing Belt:
Replace every 36,000-60,000 miles or 4-5 years for OHC engines (e.g., CVH, DOHC); OHC engines with chains generally require no scheduled replacement.
Engine Oil:
API SG/SH, SAE 10W-40 or 15W-40 common. Consult manual for specific viscosity based on temperature range and engine type.
Coolant:
Ethylene glycol based antifreeze, typically a 50/50 mix with distilled water. Ford specification 'Super Plus' or equivalent.
Brake Fluid:
DOT 3 or DOT 4.
Rust:
Corrosion is a significant concern, particularly around wheel arches, sills, floor pans, and suspension mounting points. Check strut tops and inner wings.
Electrical:
Faulty grounds, corroded connectors, failing relays, and intermittent issues are common due to age. Heater control panel issues.
Suspension:
Worn ball joints, tie rod ends, and bushings leading to imprecise steering and knocking noises. Rear axle mountings can fatigue.
Engine:
CVH engines can suffer from head gasket failures; camshaft wear; oil leaks. V6 engines can have oil cooler leaks and timing chain wear.
Transmission:
Clutch wear; synchromesh issues in manual gearboxes; leaks from automatic transmission seals.
Manufacturer:
Ford Motor Company
Generation I:
Introduced in 1982 as a replacement for the Ford Taunus. Featured advanced aerodynamics for its time. Included the sporty XR4i and XR4x4 variants.
Facelift 1986:
Significant facelift in 1986 (often referred to as 'Sierra Mk2'). Smoother front end, revised interior, and updated powertrains. Introduction of front-wheel drive and more powerful engines.
Later Years:
Continued with minor updates until production ceased in 1993 in Europe (1994 for some markets).
Manufacturing Locations:
Mainly Genk (Belgium), Dagenham (UK), Saarlouis (Germany)
Production Volume:
Over 2.7 million units produced worldwide.
