🏷️ Basic Information

Make:

Ford

Model:

Sierra RS Cosworth, Escort RS Cosworth

Sierra Rs Cosworth Engine Code:

YBT (2.0L Turbocharged I4)

Escort Rs Cosworth Engine Code:

T35 (2.0L Turbocharged I4)

Sierra Rs Cosworth Generation:

First Generation (1986-1993)

Escort Rs Cosworth Generation:

Fifth Generation (1992-1996)

👋 Introduction

Target Audience:

Owners and technicians specializing in or interested in the Ford Sierra RS Cosworth and Ford Escort RS Cosworth. Aimed at those seeking to maintain, repair, or restore these iconic performance vehicles.

Value Proposition:

Offers a cost-effective solution for maintaining these specialized performance cars, providing access to the same technical information used by professional workshops. Crucial for owners who value originality and correct repair procedures.

Manual Features:

Comprehensive step-by-step instructions, hundreds of detailed illustrations/photos, enlarged insets for critical parts, numbered instructions, bold figure numbers for easy reference, cautions and warnings, and a well-organized table of contents for quick information retrieval.

Purpose Statement:

Prepared as an aid to improve repair quality by providing serviceman with accurate product understanding and correct repair methodologies. Encourages full utilization for optimal vehicle maintenance and performance.

📋 Manual Details

Systems Covered:

Engine (including 4x4 variants), Fuel System, Ignition System, Cooling System (including 4x4 variants), Exhaust System (including 4x4 variants), Starting System, Engine Management and Emission Systems (for both Sierra and Escort), Braking System (specific for Sierra and Escort), Power Assisted Steering (specific for Sierra and Escort), Front Axle and Suspension (for Sierra, Sierra 4x4 with MT75, and Escort), Rear Axle, Suspension and Driveshafts, Manual Transmission and Clutch (Borg Warner and MT75 variants), Wheels and Tyres, Exterior Lights, Direction Indicators, Horn, Windscreen Wipers (specific for Sierra and Escort), Interior Lights, Instruments, Instrument Panel Controls (Escort), Heating and Ventilation (Sierra), Air Conditioning (Escort), Interior and Exterior Trim, Wiring Diagrams.

Estimated Page Count:

Extensive (comprehensive coverage across two volumes implies significant page count, likely exceeding 1000 pages total).

Manual Type:

Workshop Service and Repair Manual

Language:

English

Format:

Adobe Acrobat Document (.pdf) / WinRAR archive (.rar)

📖 Manual Coverage

Powertrain:

Comprehensive coverage of the 2.0L Cosworth YBT/T35 turbocharged engines, including detailed sections on engine assembly, disassembly, tuning, troubleshooting, and emissions control systems specific to these high-performance variants. Covers both Sierra and Escort applications.

Chassis And Suspension:

Detailed information on front and rear suspension systems, including specific components, alignment procedures, and repair techniques for both the Sierra (including 4x4 variants) and Escort models. Covers power steering systems specific to each model.

Brakes And Wheels:

In-depth coverage of the braking systems for both Sierra and Escort, likely detailing ABS (if equipped), hydraulic components, and brake pad/rotor replacement. Includes information on wheels and tyres.

Electrical And Lighting:

Extensive wiring diagrams are included, crucial for diagnosing electrical faults. Covers exterior lighting, direction indicators, horn, windscreen wipers/washers for both models, and interior lighting/instrumentation for the Escort.

Maintenance And Tune Up:

Covers pre-delivery inspections, routine maintenance schedules, fluid changes, filter replacements, spark plug servicing, and general tune-up procedures. Specific recommendations for high-performance engines are expected.

Repair And Rebuild:

Step-by-step repair instructions for major components, including engine overhaul, transmission rebuilds (Borg Warner and MT75), suspension component replacement, brake caliper overhauls, and body panel repairs. Detailed illustrations and exploded views are a key feature.

Diagnostics And Troubleshooting:

Includes sections on diagnosing common faults, identifying symptoms, and applying corrective procedures. Specific focus on engine management and emission control system troubleshooting is highlighted.

Depth Of Information:

High. Designed for both experienced mechanics and DIY enthusiasts, offering detailed technical data, specifications, and precise repair instructions. Covers everything from basic maintenance to complete component overhauls.

📊 Manual Specifications

File Format Details:

Provided in Adobe Acrobat (.pdf) and WinRAR (.rar) archive formats, ensuring broad compatibility across operating systems (Windows and Mac). PDF format allows for easy printing and searching.

Print Quality Description:

Designed for high-quality printing of individual pages or the entire manual. Content includes detailed illustrations, drawings, and photos with enlarged inset views for clarity.

Binding Type Description:

Digital format (PDF/RAR), offering flexibility to print and bind as desired by the user. No physical binding is provided with the digital download.

Paper Type Description:

N/A (Digital product). User can choose print paper type upon printing.

⚙️ Engine Specifications

Engine Type:

2.0L (1993cc) DOHC 16-valve turbocharged inline-4 (Cosworth YBT/T35)

Sierra Rs Cosworth Power:

Approx. 204 PS (150 kW; 201 hp) for early models, later models (e.g., Sierra Sapphire RS Cosworth 4x4) around 220 PS (162 kW; 217 hp).

Escort Rs Cosworth Power:

Approx. 227 PS (167 kW; 224 hp) for early 'Blue Top' models, up to 235 PS (173 kW; 232 hp) for later 'Red Top' models.

Cosworth Engine Torque:

Typically in the range of 300-350 Nm (221-258 lb-ft) depending on the specific variant and tune.

Fuel Delivery:

Multi-point fuel injection (MPI) with advanced engine management systems.

Cooling System Type:

Pressurized liquid cooling system with fan assistance. Specific details for 4x4 variants are provided.

Ignition Type:

Electronic ignition system with distributorless ignition (DIS) or distributor-based systems depending on the specific model year and region.

🔧 Transmission

Transmission Type Sierra:

5-speed manual (e.g., Borg Warner T-5 for RWD models, MT75 for 4x4 models).

Transmission Type Escort:

5-speed manual (Getrag or Borg Warner variants).

Optional Transmission:

Primarily manual transmissions for these performance models. Automatic transmissions were generally not offered or were rare in these specific RS Cosworth variants.

Transmission Fluid Spec:

Specific manual transmission fluid (MTF) specifications will be detailed, likely API GL-4 or GL-5 rated synthetic oils for optimal performance and longevity.

📐 Dimensions

Sierra Rs Cosworth Dimensions:

Approximate dimensions: Length: ~4400-4500 mm, Width: ~1700-1750 mm, Height: ~1350-1400 mm (Varies slightly by specific Sierra variant).

Escort Rs Cosworth Dimensions:

Approximate dimensions: Length: ~4230 mm, Width: ~1774 mm, Height: ~1424 mm.

Sierra Rs Cosworth Weight:

Kerb weight typically around 1250-1350 kg, depending on equipment and drivetrain (RWD vs. 4x4).

Escort Rs Cosworth Weight:

Kerb weight typically around 1270-1320 kg.

Wheel Size:

Commonly 15-inch or 16-inch alloy wheels for Sierra RS Cosworth, and 15-inch or 16-inch (later 17-inch) alloy wheels for Escort RS Cosworth.

Tyre Specifications:

Specific tyre sizes will be detailed, e.g., 205/50VR15, 225/50VR16 for Sierra, and 205/50VR15, 225/50VR16, 215/40ZR17 for Escort. Torque wrench settings for wheel nuts are essential.

🛡️ Safety Features

Safety Rating Context:

Safety ratings from the era may not directly translate to modern NCAP standards. The manual will detail safety systems present on the vehicles.

Active Safety Systems:

Likely includes ABS (Anti-lock Braking System) on many variants, powerful disc brakes on all wheels, and advanced suspension geometry for stability.

Passive Safety Features:

Reinforced body structure, seatbelts, and potentially front airbags on later models. The manual covers the operation and maintenance of these systems.

💡 Technology Features

Infotainment Systems:

Basic infotainment systems for the era, likely including analog radios, cassette players, and basic speaker systems. Advanced features were not common.

Driver Assistance Features:

Limited driver assistance features typical of the late 80s/early 90s. Focus was on mechanical performance and handling rather than electronic aids.

Connectivity Features:

No modern connectivity features like Bluetooth or USB. Vehicle systems rely on mechanical and basic electrical connections.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-10,000 miles or 6-12 months, depending on driving conditions. High-performance engines often benefit from more frequent oil changes. Refer to the manual for exact intervals and severe driving conditions.

Spark Plug Replacement:

Intervals vary based on plug type (e.g., copper, platinum, iridium), but often around 20,000-40,000 miles for performance applications. Manual will specify correct types and gaps.

Engine Oil Specification:

Likely 5W-30 or 10W-40 synthetic or semi-synthetic oil, meeting specific Ford specifications. Crucial to use appropriate oil for turbocharging. Manual will detail exact API/ACEA ratings.

Coolant Specification:

Ethylene glycol based antifreeze mixed with distilled water. Manual will specify the correct mixture ratio and Ford specification number.

Cosworth Engine Maintenance:

Turbocharger health, oil lubrication, intercooler integrity, and timely replacement of timing belt/water pump are critical. Early Cosworth engines were known for potential head gasket issues if not maintained properly.

Bodywork Corrosion:

As with many cars of this era, rust can be a concern. The manual may cover rust prevention and repair procedures.

Filter Part Numbers:

The manual would typically reference part numbers for common service items like oil filters, air filters, fuel filters, and brake pads/discs. (Specific numbers not provided in product info but covered in manual).

📚 Vehicle History

Ford Motorsport Division:

The RS (Rennsport) designation signifies Ford's commitment to performance and motorsport. The Cosworth name is legendary in automotive engineering, particularly for its engines.

Sierra Cosworth Evolution:

The Sierra RS Cosworth was a homologation special born from Group A touring car racing. It evolved from the original 2-door to the 4-door Sapphire and the 4x4 variants, each offering enhanced performance and handling.

Escort Cosworth Evolution:

The Escort RS Cosworth was a unique, low-volume homologation special built on a shortened Sierra platform and featuring the iconic Cosworth YBT engine and a distinctive large rear wing. It was designed for WRC rally success.

Sierra Production Years:

Ford Sierra RS Cosworth: 1986–1992. Ford Sierra Sapphire RS Cosworth: 1988–1992. Ford Sierra RS Cosworth 4x4: 1990-1992.

Escort Production Years:

Ford Escort RS Cosworth: 1992–1996.

🏆 Awards & Recognition

Motorsport Legacy:

Both the Sierra RS Cosworth and Escort RS Cosworth have significant motorsport heritage, achieving success in touring car racing and rallying, respectively. This manual supports the continued enjoyment and preservation of these performance icons.

Performance Reputation:

Renowned for their performance, handling, and distinctive styling, considered 'modern classics' and highly sought after by enthusiasts.