🏷️ Basic Information

Make:

Ford

Model:

Escort RS Cosworth & Sierra RS Cosworth

Product Name:

Ford Escort RS Cosworth & Sierra RS Cosworth Service & Repair Manual - PDF

👋 Introduction

Target Audience:

Do-it-yourselfer as well as the experienced mechanic

Value Proposition:

Inexpensive way to keep your vehicle working properly, enabling DIY repairs to save money.

Completeness:

100% Complete and Intact, no missing/corrupt pages/sections.

Market Niche:

These models occupied a significant niche in the performance car market, competing with homologation specials from manufacturers like Lancia, Toyota, and Mitsubishi in rallying, and performance hot hatches/sedans in touring car championships and street performance.

📋 Manual Details

Manual Type:

Complete Service and Repair Manual

Language:

English

Page Count:

Over 1000 pages

Model Coverage:

All models and all engines for both Ford Escort RS Cosworth and Ford Sierra RS Cosworth

File Format:

PDF

Delivery:

Instant Download

Print Quality:

Fully Printable

File Features:

Bookmarked and Searchable

Zoom Capability:

Yes

Compatibility:

All Versions of Windows & Mac, APP ISO, iPhone, iPad, iPod, Android etc.

📖 Manual Coverage

Engine:

Engine Overhaul and Rebuilding, Engine Performance

Brakes:

Brakes, Brake Servicing Procedures

Drivetrain:

Transmission Removal and Installation, Transmission In-Car Servicing, U-Joint and CV-Joint Service Procedures

Suspension Steering:

Front End and Alignment Procedures and Specifications, Suspension

Electrical:

Wiring Diagrams, Computer Diagnostic Trouble Tree Charts, Computer Diagnostic Codes

Body Chassis:

Sunroof

Climate Control:

Air Conditioning Service and Capacities

Maintenance:

Factory Maintenance Schedules and Charts, Timing Belt Replacement, Timing Belt Service Procedures, Serpentine Belt Routings with Diagrams

Diagnostics:

Trouble Codes, Troubleshooting and Diagnostics

Troubleshooting:

Comprehensive troubleshooting guides, diagnostic charts, and common driving concerns.

Repair:

Repair Procedures, Complete Disassembly and Reassembly Guidance

Rebuild:

Engine Rebuilding

Diagnostics:

Diagnostic Procedures, Trouble Shooting Guides

General Maintenance:

Factory maintenance schedules and charts, including fluid capacities, filter replacements, and inspection points.

Detail Level:

Comprehensive, covering every single detail for repair, maintenance, rebuilding, refurbishing, and restoration.

Illustrations:

Detailed illustrations, exploded diagrams, drawings, and hundreds of photos

Specifications:

Detailed specifications on every model covered, complete torque specifications

Wiring:

Complete wiring diagrams, vacuum diagrams

Diagrams:

Detailed diagrams including exploded views, wiring schematics, and vacuum routing diagrams.

Torque Specifications:

Complete and precise torque specifications for all critical fasteners and components.

📊 Manual Specifications

Requirements:

Adobe PDF Reader & WinZip (or equivalent decompression software).

Print Ability:

All pages are printable, allowing users to create physical copies for workshop use.

Digital Binding:

Bookmarked for easy navigation and searching.

Digital Paper:

N/A (Digital PDF format, printable to any paper type).

⚙️ Engine Specifications

Engine Type:

Cosworth YBT (2.0L Turbocharged Inline-4) for Escort RS Cosworth; Cosworth YBD (2.0L Turbocharged Inline-4) for Sierra RS Cosworth. Exact specifications will vary by model year and specific variant but typically feature a Garrett turbocharger, intercooler, and advanced engine management.

Horsepower Range:

Typically between 220-230 PS (217-227 bhp; 162-170 kW) depending on model and market, with significant torque output.

Torque Range:

Around 300-330 Nm (221-243 lb-ft) depending on model and market.

Fuel Delivery:

Multi-point fuel injection with turbocharger and intercooler.

Firing Order:

1-3-4-2 (typical for inline-4 engines, detailed in manual)

Timing Belt:

Critical component requiring specific replacement intervals and procedures; manual provides detailed service procedures.

Cosworth Codes:

Cosworth YBT (Escort), Cosworth YBD (Sierra). Manual covers the nuances between these closely related but distinct engines.

🔧 Transmission

Transmission Type:

5-speed manual transmission (e.g., MT75 or equivalent performance gearbox).

Optional Transmission:

Not typically offered with automatic transmissions on these performance models.

Drivetrain:

All-wheel drive (AWD) with Ferguson viscous coupling center differential and limited-slip differentials front and rear (specific configuration varies slightly between Escort and Sierra). Manual details transfer case and differential servicing.

Gear Ratio Details:

Manual provides detailed gear ratios for the 5-speed transmissions, crucial for performance tuning and diagnostics.

📐 Dimensions

Body Styles:

Escort RS Cosworth: 3-door hatchback; Sierra RS Cosworth: 3-door hatchback, 5-door hatchback, and 4-door sedan (depending on generation and variant).

Curb Weight:

Curb weight varies by model and specification, but typically around 1200-1350 kg for the Escort RS Cosworth and slightly more for the Sierra RS Cosworth variants. Manual may contain specific weight data.

🛡️ Safety Features

Safety Equipment:

Seat belts, crumple zones, reinforced chassis structures. Specific features like airbags varied by market and model year.

Braking System:

Anti-lock Braking System (ABS) typically standard, performance-oriented brake calipers and discs (e.g., AP Racing or Ford motorsport components).

💡 Technology Features

Audio System:

Basic to mid-range Ford audio systems of the era, often with cassette or CD players. Manual covers basic electrical system diagnostics for these components.

Driver Aids:

ABS was the primary electronic driver assistance system. Focus is on mechanical performance and handling rather than electronic aids.

ECU:

Advanced engine control units (ECUs) for their time, managing fuel injection, ignition timing, and turbo boost. Manual includes diagnostic procedures and trouble codes.

🔧 Maintenance

Oil Change Interval:

Typically every 6,000-10,000 miles or 6-12 months, depending on driving conditions. Manual will specify exact intervals and oil types.

Engine Oil:

High-performance synthetic oil, typically 5W-30 or 5W-40, meeting Ford specifications (e.g., WSS-M2C153-E or equivalent performance standard). Manual will detail exact specifications and capacities.

Coolant:

Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Ford specification coolant (e.g., Motorcraft Premium Engine Coolant) is recommended. Manual will specify capacity and type.

Brake Fluid:

DOT 4 or higher specification brake fluid. Manual will detail correct type and bleeding procedures.

Transmission Fluid:

Manual transmission fluid (MTF) meeting specific Ford specifications. Capacities and types for gearbox and differentials are detailed in the manual.

Power Steering Fluid:

Manual will specify the correct type of power steering fluid (likely ATF or specific hydraulic fluid).

Clutch Fluid:

Typically brake fluid (DOT 3 or 4), manual will confirm type and capacity.

Common Wear Items:

Turbocharger wear, clutch wear, suspension bushings, ignition components, potential for head gasket issues on high-mileage or poorly maintained engines. Manual provides diagnostic guidance.

Timing Belt Replacement Interval:

Critical service, typically recommended every 40,000-60,000 miles or 4-5 years due to the interference engine design. Manual provides exact intervals.

📚 Vehicle History

Ford Motorsport:

Both models are direct descendants of Ford's highly successful motorsport programs, particularly in rallying and touring car racing. Developed by Ford Special Vehicle Engineering (SVE).

Sierra Rs Cosworth:

Introduced in 1986, evolving through multiple iterations (e.g., 2WD, 4x4, Sapphire). Known for its aggressive styling and potent performance.

Escort Rs Cosworth:

Launched in 1992, it was a homologation special for rallying. Featured a distinctive large rear wing and a unique chassis based on the Escort Mk5 but with Cosworth mechanicals, including a modified Sierra RS Cosworth engine and drivetrain.

Production Period:

Sierra RS Cosworth: 1986-1992 (all variants). Escort RS Cosworth: 1992-1996. Limited production runs for both models.

🏆 Awards & Recognition

Motorsport Heritage:

Both vehicles achieved significant success in motorsport, particularly in rallying (WRC). The Escort RS Cosworth, in particular, was a dominant force. Manual provides information relevant to maintaining these high-performance engines and drivetrains, essential for enthusiasts.