My Sierra saloon

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Marc
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My Sierra saloon

Post by Marc » Mon Jul 30, 2018 2:42 am

Maybe some people are interested to see a Europe spec Sierra saloon. I hope you don't mind that I copied old posts off another forum, so all of this is not happening at this moment. :)

By now it's more than 17 years ago (2001) that I bought my Sierra. It was a basic CL version, without even a revcounter although it had a sunroof fitted, and had run about 140.000 km.

At the time it looked like this, although I already fitted the Cosworth spoiler and Cosworth wheels before taking the first pic:

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After that I fitted a Cosworth grill, Cosworth side skirts and RS bumpers.

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And a picture from under the bonnet, with a 2.0i DOHC to which I fitted a Green filter kit.

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Marc
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Re: My Sierra saloon

Post by Marc » Mon Jul 30, 2018 2:47 am

After that I fitted a set of Recaro seats. The trim matched the original upholstry exactly, so it looked like it belonged there.

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And I got some colour coded mirrors fitted.

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Then I found a set of electric windows. As it was a base version it also didn't have those...

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The holes in the door trim I filled with a set of tweeters.

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Later I also got a set or rear electric windows for from the UK.

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Since I didn't have the switches that go with it I fitted a set of Scorpio switches to the standard blanking plate. I think it looks nicer than the standard switches and these are also lit.

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I fitted the rear switches next to the door handles, IMO a much better place than the standard ones. For the rear door trims I used the same tweeters as for the front.

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And the switches in the dark.

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And at the same time I also got an electric sunroof motor.

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Marc
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Re: My Sierra saloon

Post by Marc » Mon Jul 30, 2018 3:01 am

Earlier I already changed the 240 mm front brakes for 260 mm brakes. Now it was time to replace the standard rear drums for discs.

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Removed the exhaust, towbar brackets and the shocks.

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The whole rear beam was being replaced by this:

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The beam from a Scorpio Cosworth 24v, with lsd, 18 mm arb and also disc brakes.

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And with the beam fitted. The shocks have been replaced by Koni shocks for a Sierra Cosworth as the lower fitment is different than on a standard Sierra. It still has the 5 stud Scorpio hubs.

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Removing the Scorpio hubs is a bit of a pain. The Sierra hubs have a hole in the drive flange to undo the bolts to the arms, but the Scorpio doesn't have that.

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I had to modify the towbar brackets a bit because the 7.5" diff didn't fit.

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And changed the Scorpio hubs for the Sierra hubs. I fitted the smaller bearing carriers as I was going to fit the 253 mm solid discs instead of 273 mm.

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And the discs and caliper carriers fitted.

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The rear beam now also had the mounting holes for the ABS sensors. Unfortunately my shell didn't have the holes for the sensors.

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Fitted the calipers to both sides.

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And the exhaust back on.

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I didn't want to cut the ABS cables, so I drilled the holes for the sensor cables in the floor.

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And the car back on its wheels.

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The rear camber was a bit negative now as the Scorpio arms have slightly more camber than the Sierra ones due to the higher ride height.

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To fix the camber problem I fitted a couple of shims in between the bearing carriers and the arms.

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Esteban
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Re: My Sierra saloon

Post by Esteban » Mon Jul 30, 2018 7:27 am

Very nice progress. Where did you find such PERFECT seats?

Marc
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Re: My Sierra saloon

Post by Marc » Mon Jul 30, 2018 8:01 am

At the time the seats were advertised on a second hand parts site (a bit like eBay). They were probably from a Escort or Fiesta RS Turbo, as they had the handle to fold them forwards like a 3 door car needs. I was very lucky to find them as I have never come across anything like those ever since. :D

Marc
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Re: My Sierra saloon

Post by Marc » Tue Jul 31, 2018 2:25 am

As I now already had the ABS sensors for the rear wheels it seemed nice to also have ABS. So I also fitted some front hubs with sensors and got all the rest of the ABS stuff.

First I put in all the wiring and the computer, as I needed to keep the car driveable as I needed it everyday to get to work. But once that was done it was time to change the MC.

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And the ABS MC, ready to be installed.

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The old one out.

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Later I had the brake warning light coming on in a traffic jam. It turned out it was getting too hot without the heat shield. So I found one off a Scorpio and fitted that. After that no more issues with the system.

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Marc
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Re: My Sierra saloon

Post by Marc » Tue Jul 31, 2018 2:28 am

As the wiring and the fuse box was a bit of a mess (I added the revcounter, electric windows, delayed interior lighting, variable wiper intermittant) I wanted to improve that.

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Luckily I found a '90 Ghia Sierra in the scrapyard, which is quite rare in Holland. I took the loom and all the other electric goodies from that car so I could upgrade my own CL to Ghia spec.

The complete Ghia loom.

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Taking the old CL loom out.

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Some parts lying in the garage.

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Putting the Ghia loom in.

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Marc
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Re: My Sierra saloon

Post by Marc » Tue Jul 31, 2018 2:31 am

Found a set of new front Koni shocks on eBay Germany for a nice price.

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Old shocks removed.

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One of the old shocks turned out to be leaking, never noticed though...

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And found a fuel computer on eBay UK. I had never seen one in Holland before. Luckily it plugged right into the Ghia loom behind the clocks.

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Fitted the fuel computer next to the AWS system.

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Marc
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Re: My Sierra saloon

Post by Marc » Wed Aug 01, 2018 2:31 am

As I was driving 200 km each day the twincam was running on LPG. I always wanted a faster Sierra, but a Cosworth wasn't suitable for the long distance or LPG. Therefore I got the idea to fit a 2.9 V6 and run that on LPG. So I bought a 2.9 12v Scorpio with a manual box.

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The goal was to put this engine and gearbox in the Sierra. The original twincam had done 252.000 km and still going strong, but a V6 is nicer. :D

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Marc
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Re: My Sierra saloon

Post by Marc » Wed Aug 01, 2018 2:53 am

Then it was time to take the Scorpio apart. Maybe a bit of a waste as it was quite a nice and low mileage (140.000 km) car. :|

Anyway, the car on axle stands and the head lights, grill and bumper removed.

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Front suspension removed.

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Rear beam removed.

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After that I put a few jacks underneath the subframe and gearbox to take the engine out.

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The engine and gearbox out.

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Engine and gearbox seperated.

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After I took all useable things off the empty shell was picked up by a scrapper.

Marc
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Re: My Sierra saloon

Post by Marc » Wed Aug 01, 2018 3:29 am

Since the engine and box where ready to go in it was time to remove the twincam. So up on a two post lift and removed the exhaust and front suspension.

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Prop removed.

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Disconnecting everything from the engine.

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After that the bolts from the subframe and gearbox mount were loosened. The car was going to go up with the lift leaving the engine and box on the trolley.

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And of course we forgot a wire. :D

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Out with the twincam.

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Empty engine bay...

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Rolled the 2.9 12v underneath using the same trolley.

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Then lowered the car back over the engine and bolted it back and refitted the prop.

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Still some time left to fit the radiator.

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But after that it was time to call it a day.

Marc
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Re: My Sierra saloon

Post by Marc » Wed Aug 01, 2018 3:32 am

After that it was time to put the remaining things back on. The 2.9 normally uses a viscous fan, but I don't really like that, so I put the electrical fans from the twincam on. I also put the front suspension and the exhaust back on. I also put the calipers back on and bled them, as I took them off to remove the front subframe.

As the loom, and fuel lines weren't done yet I towed the car home. At home I fitted the throttle and clutch cable and removed the DOHC loom.

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The next day I started modifying the Granada loom to be fitted to the Sierra. The Scorpio uses 2 plugs and a relay behind the dash to connect the engine loom to the main loom.

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In a Sierra (1990 model) there are no relays in the engine loom as they are all in the fuse box. That's why the Sierra has 3 instead of 3 plugs to connect the engine loom to the main loom. To mod the Scorpio loom I got a Sierra DOHC loom from the scrapyard.

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Removed the tape and checked where all the wires need to go.

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After that I cut the wires to the correct length and fitted them to the 3 Sierrra plugs.

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When everything was connected I taped it back in to make a Sierra 2.9 loom (2.9 Sierras are very rare in Holland, otherwise I would have saved all the work and simply got an XR4x4 loom).

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After that I made a small loom for the electric fans.

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Taped in.

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Marc
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Re: My Sierra saloon

Post by Marc » Wed Aug 01, 2018 8:35 am

To switch the twincam electric fans I put an adapter in the hose from the thermostat to the rad.

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After that I put the loom and ECU in. Then it was time to connect the fuel lines.

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Filled up the PAS and the coolant system before firing it up for the first time. Luckily it ran straight away, so no errors made whiling modifying the loom.

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Time for the first test drive. Everything was fine, although I noticed the speedo wasn't working. It turned out the Scorpio gearbox didn't have a mechanical speedo drive as the Scorpio only uses the electrical signal from the gearbox.

Fortunately I still had the box from the twincam, so I took the speedo drive from that one. Jacked the Sierra up again, took the exhaust, heat shield and gearbox mount off.

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The speed sensor from the twincam box.

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But after checking it a bit better I found out the worm wheel inside the gearbox was also different, so I also had to swap those.

Picked up some tools from the local Ford garage, who are always very helpful.

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A new 12-sided 30 mm nut, a new oil seal and a speedo cog with 23 teeth. Originally the twincam had a speedo cog with 22 teeth, but that is not the correct one. :roll:
And a 30 mm, 12-sided deep socket to get the nut from the output shaft of the gearbox and pully puller to pull the drive flange from the output shaft.

Removed the flange from the twincam box so I could take out the worm wheel.

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The worm wheel that was the reason for everything.

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Now I had to do everything again but now underneath the car to remove the old worm wheel and fit the new one. The Sierra and Scorpio one next to each other, the difference is quite clear...

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Fitted the speedo cog and the cable to the box and put the gearbox mount, heat shield and exhaust back on. Finally ready! :D

Marc
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Re: My Sierra saloon

Post by Marc » Sun Aug 05, 2018 8:18 am

Some time later I bought a Kent fastroad cam kit for my 2.9 12v.

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To put the cam in the heads need to be taken off, so we started with removing the top of the inlet manifold.

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After that the distributor and fuel rail were taken off.

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And the inlet manifold off.

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Removed the rocker shafts.

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And both cilinder heads removed.

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And lastly, the timing cover.

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After one day the car was standing like this.

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The next day the heads were cleaned, the valves were lapped in and the new valve springs were fitted. We also fitted the new cam but I forgot to take pictures. :(

The heads and the inlet fitted again.

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Fuel rail, rocker shafts and distributor back on.

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And after that fully back together again of course, but I again forgot to take more pictures...

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Re: My Sierra saloon

Post by DAReese » Mon Aug 06, 2018 2:08 pm

Cool posts, although I hated seeing the Scorpio crushed. If you still have the rear panel between the tail lights, I'm interested.
David Reese

88 XR4Ti - mono white T5, someday to be bi wing
89 Scorpio - waiting on some parts before it hits the road again
88 XR4Ti - mono red C3, parts car
used to own 86 dark blue traded in on a min van, what was I thinking?

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