Engine:
Complete service, repair, and overhaul procedures for the Cosworth YB 2.0L Turbocharged engine, including cylinder head, block, pistons, crankshaft, camshafts, valvetrain, oil system, and cooling system.
Fuel System:
Detailed coverage of the Bosch L-Jetronic fuel injection system, fuel pump, injectors, fuel pressure regulator, fuel lines, and evaporative emission control system.
Ignition System:
Diagnosis and repair of the electronic ignition system, including coil packs, ignition control module, and spark plugs.
Transmission:
Service and repair of the T5 manual transmission, including clutch operation, gear shifting mechanisms, and fluid specifications.
Drivetrain:
Detailed information on the rear-wheel-drive system, including driveshaft, differential, and axle shafts.
Suspension:
Front and rear suspension component diagnosis and replacement, including shock absorbers, springs, control arms, bushings, and anti-roll bars.
Steering:
Service and repair of the power steering system, including steering rack, pump, and hydraulic lines.
Brakes:
Complete brake system overhaul, including front and rear disc brakes, calipers, master cylinder, brake lines, and ABS system (if equipped).
Electrical System:
Comprehensive wiring diagrams, fuse box layouts, component testing, and troubleshooting for all electrical systems, including lighting, instruments, and power windows.
Body And Chassis:
Body panel repair, structural integrity checks, door mechanisms, glass replacement, and underbody protection.
Heating Ventilation And Air Conditioning:
Service and repair of the HVAC system, including heater core, blower motor, and A/C components (if applicable).
Emission Control:
Diagnosis and repair of emission control systems, including catalytic converter, oxygen sensors, and EGR (if applicable).
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections, and lubrication points.
Troubleshooting:
Diagnostic procedures, fault code interpretation, and step-by-step troubleshooting guides for common and complex issues across all vehicle systems.
Repair:
Detailed instructions for the removal, installation, and adjustment of all mechanical and electrical components.
Overhaul:
Complete engine and transmission overhaul procedures with torque specifications and assembly sequences.
Electrical Diagnosis:
Testing of sensors, actuators, control modules, and wiring harnesses using multimeters and diagnostic equipment.
Wheel Alignment:
Specifications and procedures for checking and adjusting wheel alignment parameters.
Recalibration:
Procedures for recalibrating systems after component replacement (e.g., engine sensors).
Depth:
Comprehensive factory-level detail, suitable for professional mechanics and advanced DIY enthusiasts. Includes disassembly, assembly, torque specifications, diagnostic charts, and technical service bulletins (TSBs) if available within the original documentation.
Oil Change Interval:
Every 7,500 miles or 12 months, whichever comes first (synthetic oil recommended).
Spark Plug Replacement:
Every 30,000 miles.
Timing Belt Replacement:
Refer to manual for specific interval, typically around 40,000-60,000 miles due to critical nature of the YB engine.
Engine Oil Type:
SAE 5W-40 or 10W-40 (API SG or higher specification, synthetic recommended).
Engine Oil Capacity:
4.5 Liters (4.8 US Quarts) with filter change.
Coolant Type:
Ethylene Glycol based coolant (50/50 mix with distilled water).
Transmission Fluid Type:
Ford ESW-M2C83-C (or equivalent manual transmission fluid).
Brake Fluid Type:
DOT 3 or DOT 4.
Differential Fluid Type:
API GL-5 80W-90 hypoid gear oil.
Head Gasket:
Potential for head gasket failure due to high boost pressure and heat; proper torque and coolant levels are critical.
Turbocharger Wear:
Wear on the turbocharger seals and bearings can lead to oil consumption and reduced performance; regular oil changes are vital.
Suspension Bushings:
Wear in rubber suspension bushings can lead to imprecise handling and noise.
Rust:
Common rust points include wheel arches, sills, and around windows due to age and environmental exposure.
