Target Audience:
Ford Sierra RS Cosworth owners, enthusiasts, mechanics, restorers
Authenticity:
Genuine Factory Manual (Not 3rd Party)
Content Value:
Enables self-servicing, saving significant labor costs compared to professional shops
Usability:
Easy to use interface, searchable text, printable pages for on-the-go referencing
Benefit:
Empowers owners to perform maintenance and repairs with factory-level knowledge
Powertrain:
Engine Service/Repair, Transmission Service/Repair, Differential/Drive, Axle
Chassis:
Brake System, Suspension, Steering, Chassis/Body
Electrical And Electronics:
Wiring Diagram, Electrical System, Engine Control System
Comfort And Climate:
Heater/Air Conditioning
Emission And Fuel:
Fuel Injection/Fuel System, Emission System
Interior And Safety:
Restraint System, Interior
Maintenance:
General Maintenance, Periodic Lubrication
Diagnostics And Repair:
Troubleshooting, Complete Diagnostic and Repair Procedures
Rebuilding And Restoration:
Rebuild, Refurbish, Restore Vehicle Components
Engine Mechanical:
Engine assembly/disassembly, cylinder head removal/installation, piston and connecting rod service, crankshaft service, timing belt replacement.
Fuel System Repair:
Fuel pump testing/replacement, injector servicing, fuel pressure regulator diagnosis, fuel tank removal/installation.
Brake System Service:
Brake pad/shoe replacement, caliper overhaul, disc rotor replacement, brake line inspection/replacement, ABS system diagnostics.
Electrical Diagnostics:
Troubleshooting starter motor, alternator, ignition system, lighting, dashboard instruments, ECU diagnostics.
Suspension And Steering Repair:
Ball joint replacement, shock absorber/strut replacement, wheel bearing service, steering rack overhaul, power steering pump diagnosis.
Cooling System Service:
Radiator inspection/replacement, water pump removal/installation, thermostat replacement, fan operation diagnosis.
Chassis And Body Repair:
Body panel alignment, door mechanisms, hood and trunk latches, bumper repair, frame inspection.
HVAC Service:
Blower motor testing, heater core access, air conditioning system diagnostics (refrigerant handling not detailed due to safety/legal reasons typically).
Transmission And Drivetrain Service:
Clutch inspection/replacement, gearbox fluid change, driveshaft U-joint inspection, differential inspection.
Depth:
Comprehensive (Factory Trained Technician Level)
Detail Level:
Step-by-step instructions, detailed illustrations, diagrams, photos, inset views for parts examination
Torque Specifications:
Detailed torque values for critical fasteners across all systems.
Alignment Procedures:
Wheel alignment specifications and adjustment procedures.
Diagnostic Charts:
Comprehensive troubleshooting charts for identifying and resolving common issues.
Engine Type:
Cosworth YB 2.0L DOHC Turbocharged Inline-4
Horsepower Range:
Approx. 204-230 bhp (depending on specific year/variant)
Torque Range:
Approx. 275-300 Nm
Induction:
Bosch L-Jetronic Fuel Injection (later models may have updated systems)
Turbocharger:
Garrett AiResearch T3 (with intercooler)
Oil Type Specification:
Ford recommends specific viscosity grades (e.g., 5W-30 or 5W-40 synthetic) for turbocharged engines. Consult manual for exact specification and API/ACEA ratings.
Coolant Type:
Ethylene Glycol based coolant with corrosion inhibitors (Ford specification).
Historical Safety Standards:
Reflects safety standards of the late 1980s and early 1990s, likely not subjected to modern NCAP or IIHS testing.
Braking System:
Ventilated front disc brakes, solid rear disc brakes (often with ABS on later models)
Seatbelts:
Standard 3-point seatbelts
Restraint System:
Covered in manual includes seatbelts, potentially driver airbag on some later variants.
Oil Change Interval:
Typically every 6,000-10,000 miles or 12 months (refer to manual for precise recommendation based on usage).
Spark Plug Replacement:
Intervals vary, often around 20,000-30,000 miles for performance plugs. Manual will specify.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (refer to manual for exact Ford specification).
Power Steering Fluid:
Specific power steering fluid (refer to manual).
Common Problems:
Turbocharger wear, head gasket issues (if overheated), electrical gremlins, corrosion (especially in older examples).
Maintenance Focus:
Importance of proper cooling system maintenance and regular oil changes for longevity of the YB engine.
Motorsport Connection:
Developed for homologation for Group A touring car racing, iconic rally heritage.
First Generation Introduction:
1986 (Sierra RS Cosworth)
Key Updates:
Introduction of the 5-door Sierra Sapphire RS Cosworth in 1990, minor powertrain and styling updates throughout production.
Manufacturing Location:
Ford-Werke GmbH, Cologne, Germany and Ford Motor Company Limited, Great Britain.
Production End Year:
1992
