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Ford SIERRA RS COSWORTH 1992-1996 Service Repair Manual

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🏷️ Basic Information Identification Make: Ford Model: Sierra RS Cosworth Model Years Covered: 1992-1996 Chassis Code: Sierra (Mk3/Facelift) Engine Variant Covered: 2.0L I4 DOHC Turbocharged (YBD/YBP) 👋 Introduction Market Position...
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Type: Car
Vendor:
Sku: 506309
Ford SIERRA RS COSWORTH 1992-1996 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Ford
Model:
Sierra RS Cosworth
Model Years Covered:
1992-1996
Chassis Code:
Sierra (Mk3/Facelift)
Engine Variant Covered:
2.0L I4 DOHC Turbocharged (YBD/YBP)
👋 Introduction
Market Position
Market Position:
Performance homologation special, revered as a modern classic and sought-after enthusiast vehicle
Competitive Analysis
Competitive Analysis:
Competed against a range of high-performance saloons and hatchbacks of the era, including Lancia Delta Integrale, BMW M3 (E30/E36), and Opel Kadett GSi, excelling with its powerful turbocharged engine and advanced chassis dynamics
Key Features
Key Features:
Cosworth YB 2.0L turbocharged engine, advanced Cosworth-engineered chassis, potent performance figures, distinctive body kit, rally-bred heritage
Manual Value Proposition
Manual Value Proposition:
Essential resource for owners and mechanics to maintain, repair, and restore the Sierra RS Cosworth, ensuring reliability and preserving its performance pedigree
📋 Manual Details
Coverage Areas
Coverage Areas:
Full service, repair, maintenance, diagnostics, troubleshooting, electrical systems, bodywork, specifications
Page Count
Page Count:
Estimated 1500+ pages (typical for comprehensive service manuals of this era)
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine mechanical, fuel injection, ignition, cooling, lubrication, exhaust, transmission (MT75), driveline, suspension (front & rear independent), steering, braking system (ABS optional), electrical system (including wiring diagrams), climate control, body & chassis, interior trim, diagnostics
Procedures Included
Procedures Included:
Routine maintenance, scheduled servicing, troubleshooting guides, diagnostic procedures, component removal & installation, overhaul procedures, component testing, torque specifications, wiring harness repair, body panel repair, glass replacement
Technical Depth
Technical Depth:
Comprehensive, covering from basic maintenance to advanced engine rebuilds and electrical system diagnostics
Troubleshooting
Troubleshooting Coverage:
Extensive troubleshooting guides for common drivability issues, electrical faults, and mechanical problems, often with flowcharts
Wiring Diagrams
Wiring Diagrams:
Comprehensive electrical schematics covering all vehicle systems, including engine management, lighting, instruments, and accessories
Body And Trim
Body And Trim Coverage:
Procedures for interior component removal/installation, exterior trim fitting, bumper removal, door panel access, etc.
Torque Specifications
Torque Specifications:
Detailed torque values for all critical fasteners (engine components, suspension, brakes, wheels, etc.)
Specifications Tables
Specifications Tables:
Comprehensive tables for all fluid capacities, electrical component resistance, engine timing, and dimensional data
Paint And Trim Codes
Paint And Trim Codes:
Likely includes references to paint codes and interior trim designations
Diagnostic Codes
Diagnostic Codes:
Procedures for reading and interpreting engine fault codes (DTCs) via diagnostic connectors
Bodywork Repair
Bodywork Repair Coverage:
Guidance on repairing dents, corrosion, and damage to body panels; procedures for replacing trim pieces and glass.
Suspension Geometry
Suspension Geometry Specifications:
Wheel alignment specifications (camber, caster, toe) for front and rear suspension
Brake System Details
Brake System Details:
Detailed information on front ventilated discs and rear solid discs, including pad replacement, caliper servicing, and ABS system troubleshooting.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
Full Printable, high resolution for clarity
Binding Type
Binding Type:
Digital Download (PDF)
Paper Type
Paper Type:
N/A (Digital)
Additional Features
Additional Features:
Zoom IN/OUT capability, Searchable text (if OCR processed), Instant Download
Software Requirements
Software Requirements:
Adobe PDF Reader, WinZip (or similar unzipping utility)
Compatibility
Compatibility:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Primary Engine:
Ford Cosworth YB 2.0L (1998cc) DOHC 16-valve Inline-4 Turbocharged
Performance
Horsepower:
225 PS (222 bhp / 165 kW) @ 6000 rpm (standard European spec)
Torque:
280 Nm (207 lb-ft) @ 4500 rpm (standard European spec)
Fuel System
Fuel System:
Ford EEC-IV Electronic Engine Control with Bosch L-Jetronic fuel injection and Garrett T3 turbocharger with intercooler
Ignition System
Ignition System:
Electronic ignition with distributor
Bore X Stroke
Bore X Stroke:
90.8 mm x 77.0 mm
Compression Ratio
Compression Ratio:
8.0:1
Engine Code
Engine Code:
YBD (early), YBP (later/calibrated)
Turbocharger Details
Turbocharger Details:
Garrett T3, Wastegate-controlled boost pressure
Engine Management System
Engine Management System:
Ford EEC-IV (Electronic Engine Control)
🔧 Transmission
Standard
Standard Transmission:
Ford MT75 5-speed manual transmission
Optional
Optional Transmission:
N/A (Exclusively manual)
Features
Features:
Rear-wheel drive (RWD), performance-oriented gearing, limited-slip differential (LSD) typically standard
Clutch Type
Clutch Type:
Hydraulically operated single dry plate clutch
📐 Dimensions
Exterior
Length:
4425 mm (174.2 in)
Width:
1702 mm (67.0 in)
Height:
1390 mm (54.7 in)
Wheelbase:
2604 mm (102.5 in)
Weights
Curb Weight:
Approx. 1250 kg (2756 lbs)
Gross Vehicle Weight Rating:
Typically around 1750 kg
Cargo
Cargo Volume:
Approx. 340 liters (boot)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Euro NCAP not established in its primary production years; industry standard for the era)
Active Features
Active Features:
Optional ABS (Anti-lock Braking System), performance-oriented braking system (ventilated discs front/rear), limited-slip differential
Passive Features
Passive Features:
Seat belts (front and rear), reinforced safety cell, driver's side airbag (optional/later models), energy-absorbing steering column
💡 Technology Features
Infotainment
Infotainment:
Basic Ford radio/cassette player, often upgraded by owners
Driver Assistance
Driver Assistance:
Optional ABS (Anti-lock Braking System)
Connectivity
Connectivity:
N/A (pre-dates modern connectivity standards)
🔧 Maintenance
Service Intervals
Service Intervals:
10,000 miles or 12 months for routine service; 20,000 miles or 24 months for major service (typical, consult manual for specifics)
Fluid Specifications
Engine Oil Specification:
API SG/SH or ACEA A2/A3, SAE 10W-40 or 10W-50 (high performance synthetic recommended), Capacity: 4.25 litres (with filter)
Coolant Specification:
Ford Super Plus Premium Coolant (or equivalent ethylene glycol-based, 50/50 mix with distilled water)
Transmission Fluid Specification:
Ford WSD-M2C200-C (or equivalent API GL-4, SAE 75W-90 synthetic manual transmission fluid), Capacity: 1.8 litres
Differential Fluid Specification:
API GL-5, SAE 80W-90 (or synthetic equivalent)
Brake Fluid Specification:
DOT 4
Known Issues
Known Issues:
Turbocharger wear/failure, head gasket failure (especially if poorly maintained or modified), differential leaks, wiring loom degradation (age-related), clutch wear, suspension bush wear, rust (especially wheel arches, sills, rear valence)
Spark Plugs
Spark Plugs:
Typically NGK BCP7EVX or equivalent (heat range dependent on tuning)
Timing Belt Replacement
Timing Belt Replacement Interval:
Every 30,000 miles or 3 years (critical due to interference engine design)
Filter Part Numbers
Oil Filter Part Number:
Ford equivalent: 1687872; Mann: W712/33; Mahle: OC32; Fram: PH3563
Air Filter Part Number:
Ford equivalent: 1687798; Mann: C2534; Mahle: LX890/1
Fuel Filter Part Number:
Ford equivalent: 1663920; Mann: WK58/1
📚 Vehicle History
Brand Heritage
Brand Heritage:
Ford's history in motorsport, particularly rallying and touring car racing, with strong ties to Cosworth Engineering
Model Evolution
Model Evolution:
The Sierra RS Cosworth was born out of Ford's need for a homologation special to compete in Group A touring car racing. Evolved from the standard Sierra range, it received significant mechanical and aerodynamic enhancements.
Production
Production Period:
1986-1992 (original Sierra RS Cosworth), with the final facelifted Sierra RS Cosworth 4x4 being produced until 1992. This manual covers models potentially built up to 1996 under special import or niche markets, though primary production ended in 1992 for the UK market. The '1992-1996' may reflect late registrations or specific regional availability of the facelifted models (Mk3 Sierra) which retained the RS Cosworth mechanics.
Manufacturing Locations
Manufacturing Locations:
Genk, Belgium (for most production)
🏆 Awards & Recognition
Recognitions
Recognitions:
Highly acclaimed by automotive press for its performance and handling; winner of numerous touring car championships globally
Ratings
Ratings:
Consistently rated as one of the greatest performance cars of its era
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