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Automotive Technical

DATA BOOK
    FORD Sierra & Sapphire 1.6 FORD Sierra & Sapphire 1.6i CAT FORD Sierra & Sapphire1.8 FORD Sierra & Sapphire 1.8i CAT FORD Sierra & Sapphire Cosworth FORD Sierra & Sapphire 2000 FORD Sierra & Sapphire 2000i FORD Sierra & Sapphire 2000 FORD Sierra & Sapphire 2.0i/4x4 FORD Sierra & Sapphire 2.0i CAT FORD Sierra 2.8i 4x4 FORD Sierra 2.9i 4x4 FORD Sierra 2.9i 4x4 CAT
    1987 to 1991 1990 to 1993 1988 to 1992 1992 to 1993 1986 to 1990 1987 to 1989 1987 to 1989 1989 to 1991 1989 to 1992 1989 to 1993 1987 to 1989 1989 to 1991 1990 to 1993
Engine and cooling system   FORP4001631                        
Type   LSE (OHC) 55kW 15.04 L6B (CVH) 59kW US83 R2A (CVH) 66kW 15.04 R6A (CVH) 64kW US83 N5A (DOHC 16V Turbo) 15.04 NES (OHC) 77kW 15.04 N4A (OHC) 85kW 15.04 N8A DOHC 8V 80kW 15.04 N9A. DOHC 8V 92kW 15.04 N9C. DOHC 8V 88kW US83 PRT 15.04 B4A (OHV) 110kW 15.04 B4B (OHV) 107kW US83\A12
Capacity (cm 3 ) / number of cylinders   1597 / 4 1596 / 4 1769 / 4 1769 / 4 1993 / 4 1993 / 4 1993 / 4 1998 / 4 1998 / 4 1998 / 4 2792 / 6 2933 / 6 2933 / 6
Compression ratio / pressure bar 9.5 / 11 to 13 9.0 / 12 to 14 9.3 / 11 to 13 9.3 / 11 to 13 8.0 / 8.5 9.2 / 11 to 13 9.2 / 11 to 13 10.3 / 11 to 13 10.3 / 11 to 13 10.3 / 11 to 13 9.2 / >11.5 9.5 / >11.5 9.0 / 11.5 to 12.5
Oil pressure bar 1.0 [2.5] 1.0 [2.8] 1.0 [2.5] 1.0 [2.5] 1.8 [2.4] 1.0 [2.5] 1.0 [2.5] 1.0 [2.5] 1.0 [2.5] 1.6 [3.1] 1.0 [2.5] 1.0 [2.5] 0.98 [2.5]
Oil temperature ºC 80 80 80 80 80 80 80 80 80 80 80 80 80
Valve clearance - inlet mm 0.20±0.03 0: Hyd. 0: Hyd. 0: Hyd. 0: Hyd. 0.20±0.03 0.20±0.03 0: Hyd. 0: Hyd. 0: Hyd. 0.35 0.35 0: Hyd.
Valve clearance - exhaust mm 0.25±0.03 0: Hyd. 0: Hyd. 0: Hyd. 0: Hyd. 0.25±0.03 0.25±0.03 0: Hyd. 0: Hyd. 0: Hyd. 0.40 0.40 0: Hyd.
Firing order   1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-4-2-5-3-6 1-4-2-5-3-6 1-4-2-5-3-6
No 1 cylinder position   TBE TBE TBE TBE TBE TBE TBE TBE TBE TBE FR FR FR
Thermostat opening temperature ºC 85 to 89 85 to 89 88 88 76 to 88 [70 to 82, RS500] 85 to 89 85 to 89 88 85 to 89 85 to 89 79 to 83 79 to 83 79 to 83
Radiator cap pressure bar 1.00 to 1.25 1.00 to 1.25 1.00 to 1.25 1.00 to 1.25 0.85 to 1.10 1.00 to 1.25 1.00 to 1.25 1.00 to 1.25 1.00 to 1.25 1.00 to 1.25 1.2 to 1.5 0.85 to 1.10 0.85 to 1.10
Fuel system                            
Idle speed - manual [auto] rpm 800±50 900±50 850±50 [800±25] 850±50 850±50 875±50 875±50 [800±50] 850±25 875±25 875±25 N/A 900±50 900±50 900±50
Fast idle speed - manual [auto] rpm 1700±100 _ _ _ _ _ _ 1800±50 _ _ _ _ _
CO @ idle speed [3000 rpm] - see page VI % 1.5±0.5 <0.5 1.0±0.25 1.5±0.5 1.25±0.5 0.8±0.2 1.0±0.25 <0.5 <0.5 N/A 1.25±0.25 0.75±0.25 <0.5
HC @ idle speed [3000 rpm] - see page VI ppm <1200 <1200 <1200 <1200 <1200 <1200 <1200 <1200 <1200 <1200 <1200 <1200 <1200
CO2 @ idle speed [3000 rpm] - see page VI % _ _ _ _ _ _ _ _ _ _ _ _ _
O2 @ idle speed [3000 rpm] - see page VI % _ _ _ _ _ _ _ _ _ _ _ _ _
Carburettor / fuel injection   Weber Weber Pierburg Bosh Weber-Marelli Weber Bosh Weber Ford Ford Bosch

Bosch
      Type / ref   2V (DFTH) CFI with EEC-IV control 2V (2E3) EFHD CFI EEC IV Electronic injection /ignition 2V (DFTH) L-Jetronic 2V (TLD) EEC IV EEC IV K-Jetronic

L-Jetronic (Ford EEC IV)
      Main jet / needle   97, 110 [95, 115 economy] _ 100, 105
[AT: 97.5,105]		 _ _ 112, 135 [AT: 110, 135] _ 115, 157 _ _ _ _ _
      Injection pressure bar _ 1.0 _ 1.0±0.1 3.5 _ 2.5 2.5±0.2 2.5±0.2 3.7 to 4.5 3.0 3.0
Pump pressure bar 0.24 to 0.38 3.0 0.24 to 0.38 >3.0 >5.0 0.24 to 0.38 >5.0 0.24 to 0.38 >3.0 >3.0 5.2 to 6.0 >5.0 >5.0
Octane rating RON 97[R]  (1) 95[U] 97[E 95RON] 95[U] 97[RA] 97[R] 97[R] 97[E 95 RON] 97[E 95 RON] 95[U] 97[R] 97[E 95 RON] 95[U]
Ignition system                            
Type - Electronic DIS ESC II DIS Computerized ESC II Computerized ESC II ESC IV ESC IV Electronic Electronic ECC IV
Ignition coil - Bosch, Femsa, Polmot High output twin coils Bosch, Femsa, Polmot 37kV High output Motorcraft Bosch, Femsa, Polmot Bosch, Femsa, Polmot Bosch, Femsa, Polmot High output High output Bosch, Femsa, Polmot Bosch, Femsa, Polmot 25kV
    Primary resistance ohms 0.72 to 0.88 0.50±0.05 0.72 to 0.88 0.50±0.05 0.72 to 0.88 0.7 to 0.9 0.72 to 0.88 0.72 to 0.88 0.72 to 0.88 0.72 to 0.88 0.72 to 0.88 0.72 to 0.88 0.72 to 0.88
    Ballast resistor ohms _ _ _ _ _ _ _ _ _ _ _ _ _
    Voltage - Tmnl 15(+) to earth V _ _ _ _ _ _ _ _ _ _ _ _ _
Distributor   _ Motorcraft Marelli Bosch Bosch Motorcraft Bosch/Motorcraft Bosch/Motorcraft Bosch Motorcraft Motorcraft
    Points gap (air gap) mm _ _ _ _ [0.20 to 0.30] _ _ _ _ _ _ _
    Dwell angle º  (%) _ _ _ _ _ _ _ _ _ _ _ _
    Condenser capacity µF _ _ _ _ _ _ _ _ _ _ _ _
    Rotation   Clockwise Clockwise Clockwise Clockwise Clockwise Clockwise Clockwise Clockwise
Ignition timing - basic [static º Crankshaft @ rpm 10 BTDC @ idle 10±2 BTDC @ idle N/A 20 BTDC @ idle _ 16 BTDC @ idle [RS500: 13°] 10 BTDC @ idle  12 BTDC @ <900 12 BTDC  [15 BTDC] N/A 12 BTDC @ idle 12 BTDC @ <900 [15 BTDC]
    V = Vacuum NV = No Vacuum   NV V V _ NV NV NV _ _ _ _ _ _
Total ignition advance º Crankshaft @ rpm 13 to 29 @ 2000 _ _ _ _ _ _ _ _ _ _ _ _
  º Crankshaft @ rpm _ _ _ _ _ _ _ _ _ _ _ _ _
  º Crankshaft @ rpm _ _ _ _ _ _ _ _ _ _ _ _ _
    Centrifugal check. º Crankshaft @ rpm 1 to 8 @ 2000 Computer control EEC IV control Computer control EEC IV control EEC IV control _ Computer control Computer control
  º Crankshaft @ rpm 5.5 to 12 @ 3000 _ _ _ _ _ _ _ _ _ _ _ _
  º Crankshaft @ rpm 9 to 16 @ 4000 _ _ _ _ _ _ _ _ _ _ _ _
     Vacuum range check mbar 0 to 280 Computer control EEC IV control Computer control EEC IV control EEC IV control _ Computer control Computer control
       Maximum vacuum advance º Crankshaft 13 to 29 _ _ _ _ _ _ _ _ _ _ _ _
Spark plugs   Motorcraft/Champion Motorcraft

Motorcraft/Champion

 Motorcraft/Champion

Motorcraft/Champion

Motorcraft/Champion
    Type   BRF32C / F7YC AGPR32CD1/RC7YCC AGPR32C1/RC7YC AGPR32CD1 AGPR902P / C59C BRF32C / F7YC BRF22C / F7YC AGPR32CD / RC7YC AGPR22CD / RC7YCC AGPR22CD / RC7YCC AGR22C / RN7YC AGPR32C / RC7YC AGRF42C1 / RS9YCC
    Electrode gap mm 0.75 1.00 1.00 1.00 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 1.00
Electrical system                            
Battery V / CC / RC 12 / 200 / 70 or 250 / 80 12 / _ 12 / 200 / 70 or 250 / 80 12 / 200 / 70 or   250 / 80 12 / 500 / 70 or 590 / 90 12 / 200 / 70 or 250 / 80 12 / 200 / 70 or 250 / 80 12 / 200 / 70 or 250 / 80 12 / 200 / 70 or 250 / 80 12 / 200 / 70 or 250 / 80 12 / 200 / 70 or 250 / 80 12 / 250 / 80 12 / _
Alternator voltage / full load current / engine rpm 13.5 / _ / 3000 13.5 / _ / 3000 13.5 / _ / 3000 13.5 / _ / 3000 13.7 to 14.6 / _ / 4000 13.5 / _ / 3000 13.5 / _ / 3000 13.5 / _ / 3000 13.5 / _ / 3000 13.5 / _ / 3000 13.5 / _ / 3000 13.7 to 14.6 / _ / 3000 13.7 to 14.6 / _ / 3000
Starter motor current / voltage - cranking A / V _ _ _ _ _ _ _ _ _ _ _ _ _
Starter motor current / voltage - locked A / V _ _ _ _ _ _ _ _ _ _ _ _ _
Running gear                            
Brakes -                              
    Front (min. friction material thickness) mm 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5
    Rear (min. friction material thickness) mm 1.0 1.0 1.0 1.0 1.5 1.0 1.0 1.0 1.0 1.0 1.5 1.5 1.5
Tyres                            
    Saloon Size 165x13: 195/65x14: 185/65x14 165x13: 185/65x14 165x13:195/65x14:  185/65x14 195/65x14: 185/65x14 205/50x15 165x13: 195/65x14 165x13: 195/65x14 185/70x13:185/65x14: 195/65x14 185/70x13:185/65x14: 195/65x14 (1) 185/70x13:185/65x14: 195/65x14 (1) 195/60x14 195/60x14 195/60x14
    Estate / Van Size 185/70x13: 185/65x14:195/65x14 185/70x13:185/65x14: 195/65x14 185/70x13:195/65x14: 185/65x14 195/65x14: 185/65x14 _ 175x13: 195/65x14 175x13: 195/65x14 185/70x13:195/65x14: 185/65x14 185/70x13:195/65x14: 185/65x14 (1) 185/70x13:195/65x14: 185/65x14 (1) 195/60x14 195/60x14 -
    Pressure - front / rear - Saloon bar 1.8 / 1.8 1.8 / 1.8 1.8 / 1.8 1.8 / 1.8 2.1 / 2.3 1.8 / 1.8 1.8 / 1.8 1.8 / 1.8 1.8 / 1.8 (2) 1.8 / 1.8 (2) 2.0 / 2.0 2.0 / 2.0 2.0 / 2.0
    ressure - front / rear - Estate / Van bar 1.8 / 1.8 1.8 / 1.8 1.8 / 1.8 1.8 / 1.8 _ 1.8 / 1.8 1.8 / 1.8 1.8 / 1.8 1.8 / 1.8 (2) 1.8 / 1.8 (2) 2.0 / 2.0 2.0 / 2.0 -
Front suspension / wheel alignment                             
    Toe-in (+) / Toe-out (–) mm [º] +2.0±1.0 +2.0±1.0 +2.0±1.0 +2.0±1.0 +2.0 +2.0±1.0 +2.0±1.0 +2.0±1.0 +2.0±1.0 (3) +2.0±1.0 (3) 0±1.0 +1.0±1.0 0±1.0
    Camber   -21’±1°.               Estate: -19’±1° -21’±1°.               Estate: -19’±1° -21’±1°.       Est: -19’±1° -21’±1°.                Est: -19’±1° -1°28’ -21’±1°. Est: -19’±1° -21’±1°. Est: -19’±1° -21’±1°. Est: -19’±1° -21’±1°. Est: -19’±1° (4) -21’±1°. Est: -19’±1° (4) -1°17’±1°. Est: -1°12’±1° -1°20’±1° -1°17’±1°
    Castor   +1°52’+1°30’-1° +1°52’. Est: +1°50’+1°30’-1°  (2) +1°52’.Est:+1°50’ (+1°30’-1°) +1°52’.Est: +1°50’ (+1°30’-1°) +3°5’ +1°52’. Est: +1°50’+1°30’-1° +1°52’. Est: +1°50’+1°30’-1° +1°52’. Est: +1°50’+1°30’-1° +1°52’. Est: +1°50’+1°30’-1° (5) +1°52’. Est: +1°50’+1°30’-1° (5) +2°58’. Est: +2°38’+1°30’-1° +3°53’±1° +2°58’+1°30’-1°
    King pin inclination   2 _ _
_
_
_
_
_
_
_
_
_
_
Rear suspension / wheel alignment         

   

 

  

 

 

 

 

 

 

 
    Toe-in (+) / Toe-out (–) mm [º] _ _ _
_
_
_
_
_
_
_
_
_
_
    Camber   _ _ _
_
_
_
_
_
_
_
_
_
_
Torque wrench settings                            
Cylinder head - stage 1 Nm 35 to 40 20 to 40 40 to 60 40 to 60 45 to 50 N 35 to 40 35 to 40 25 25 25 39 to 54 35 to 40 35 to 40
Cylinder head - stage 2 Nm 70 to 75 40 to 60 - 180° - 180° + 180±10° 70 to 75 70 to 75 55 55 55 54 to 69 70 to 75 70 to 75
Cylinder head - stage 3 Nm Wait 5 min. + 90° + 90° 40 to 60 + 90° 40 to 60 + 90° 110 Wait 5 min. Wait 5 min. + 90° + 90° + 90° 95 to 115 (1) Wait 5 min. Wait 5 min.
Cylinder head - stage 4 Nm _ + 90° + 90° + 90° _ + 90° + 90° + 90° (1) + 90° (6) + 90° (6) 95 to 115 (2) + 90° + 90°
Big-end bearings Nm 40 to 47 30 to 36 35 to 41 35 to 41 55 to 60 40 to 47 40 to 47 6 to 8, THEN (2) 6 to 8, THEN (7) 6 to 8, THEN (7) 26 to 33 26 to 33 26 to 33
Main bearings Nm 88 to 102 90 to 100 90 to 108 90 to 108 88 to 102 88 to 102 88 to 102 90 to 104 90 to 104 90 to 104 90 to 104 90 to 104 90 to 104
Clutch cover Nm 17 to 21 20 to 25 20 to 25 20 to 25 19 to 22 17 to 21 17 to 21 17 to 21 17 to 21 17 to 21 20 to 25 17 to 21 17 to 21
Flywheel [driveplate] Nm 68 to 74 82 to 92 73 to 91 73 to 91 64 to 70 64 to 70 64 to 70 64 to 70 64 to 70 64 to 70 64 to 70 68 to 74 68 to 74
Front hubs Nm 310 to 350 310 to 350 310 to 350 310 to 350 315 to 350 310 to 350 310 to 350 310 to 350 310 to 350 (8) 310 to 350 (8) 205 to 235 205 to 235 205 to 235
Rear hubs Nm 250 to 290 250 to 290 250 to 290 250 to 290 250 to 290 250 to 290 250 to 290 250 to 290 250 to 290 250 to 290 250 to 290 250 to 290 250 to 290
Wheel nuts / bolts Nm 70 to 100 70 to 100 70 to 100 70 to 100 100 70 to 100 70 to 100 70 to 100 70 to 100 70 to 100 70 to 100 70 to 100 70 to 100
Spark plugs Nm 20 to 28 17 to 33 17 to 33 17 to 33 28 to 33 20 to 28 20 to 28 17 to 33 17 to 33 17 to 33 30 to 40 30 to 40 30 to 40
Capacities                            
Engine oil & filter litres 3.75 3.5 4.0 4.0 3.4 3.75 3.75 4.5 4.5 4.5 4.7 4.65 4.65
Gearbox - 4-speed [5-speed] litres B: 1.5 C/N: 1.25 1.25 1.25 1.25 2.6 1.25 1.25 1.2 1.2 (9) 1.2 (9) 1.25 (3) 1.2 (1) 1.2 (1)
Automatic transmission - refill litres _ _ 8.5 8.5 _ 8.5 8.5 8.5 8.5 8.5 _ _ _
Final drive litres 6.5 -  0.8. 7.0 - 0.9 0.9 0.9 0.9 1.0 0.9 0.9 7.0 - 0.9. 7.5 - 1.3 7.0 - 0.9 (100) 7.0 - 0.9 (100) Front: 1.0. Rear: (4) Centre: 1.0. Rear (2) Centre: 1.0. Rear (2)
Cooling system litres 8.0 9.5 8.7 8.7 7.5 8.0 8.0 7.0 7.3 7.3 8.5 8.5 8.5
Fuel tank litres 60 60 60 60 60 60 60 60 60 60 60 60 60
Notes and Illustrations                            
    1) 91 ©: [E 95 RON]
2) Est: +1°50’+1°30’-1°		       [E 95 RON]: 12° BTDC @ idle 85HF-9510-CB/DBcarburettors: 110, 130 [E 95 RON]: 8° BTDC @ 900 (1) M8: 36 to 39 N
(2) 15 to 20 + 85 to 95°		 (1) 185/70x13: 195/60x14
(2) 4x4: 2.0 / 2.0
 (3) 4x4: 0±1.0(
(4) 4x4: -1°17’±1°. Estate 4x4: -1°12’±1°		 (1) Wait 10 to 20 minutes
(2) Warm engine and retorque to stage 4
(3) Transfer box: 0.5
(4) 0.9		 (1) Transfer box: 0.5
(2) 0.9
      

     
1769 not DIS		    

    (5) 4x4: +2°58’+1°30’-1°. Estate 4x4: +2°38’+1°30’-1°
(6) M8 bolts: 36 to 39 N
(7) 15 to 20 + 85 to 95°
(8) 4x4: 205 to 235
(9) 4x4 transfer box: 0.5
(100) 7.5: 1.3. 4x4: Front: 1.0. Rear: 0.9

    Weber 2V

1 idle speed 
2 CO / Mixture		   Pierburg 2E3

1 idle speed 
2 CO /Mixture		     Weber DTFH

1 idle speed 
2 CO /Mixture
2 CO /Mixture		 Weber TLD

1 idle speed 
2 CO /Mixture		 EEC IV not cat

2 CO /Mixture		   K-Jetronic

1 idle speed 
2 CO /Mixture

L-Jetronic 2933 cm

2: CO / Mixture
                         
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