Vehicle Classification:
Performance Compact Rally Homologation Special
Target Audience:
Enthusiasts, owners, mechanics, and restoration specialists
Key Competitors Era:
Toyota Celica GT-Four, Mitsubishi Lancer Evolution, Subaru Impreza WRX STI, Peugeot 205 T16
Manual Value Proposition:
Enables self-sufficiency in maintenance and repair, saving significant costs and empowering owners
Manual Quality:
Professional quality, professional technician standard, factory information
Years Covered:
1992, 1993, 1994, 1995, 1996
Models Covered:
All RS Cosworth variants
Engines Covered:
All engine variants (primarily 2.0L YBT Cosworth)
Transmissions Covered:
All transmission types (primarily 5-speed manual)
Trim Levels Covered:
All trim levels
Estimated Page Count:
Hundreds of pages (specific count not provided, but described as 'complete informational book')
Type:
Workshop Repair and Service Manual
Source:
Original Factory Manual / Professional Technician Standard
File Format:
PDF Download
Digital Features:
Printable, Zoom In/OUT, Searchable
Powertrain:
Engine service and repair, transmission service and repair, differential/drive axle service
Chassis:
Brake system, suspension, steering, chassis and body
Electrical:
Electrical system, wiring diagrams, engine control system, restraint system
Comfort And Climate:
Cooling system, fuel injection/fuel system, emission system, heater/air conditioning
Interior:
Interior components and trim
Maintenance:
General maintenance, periodic lubrication, fluid checks and changes
Diagnostics:
Troubleshooting, diagnostic procedures for all systems
Repair:
Detailed step-by-step repair procedures for all covered systems
Disassembly Assembly:
Complete disassembly and reassembly instructions for major components and systems
Electrical Diagnostics:
Wiring diagrams, electrical troubleshooting, component testing
Depth:
Comprehensive (covers everything from basic maintenance to in-depth repairs and diagnostics)
Detail Level:
Detailed substeps, numbered instructions, critical notes, cautions, and warnings
Illustrations:
Detailed illustrations, drawings, and photos; enlarged inset views for specific parts
Engine Type:
Inline-4, turbocharged, intercooled
Engine Displacement:
2.0 Liters (1993 cc)
Engine Code:
YBT (Cosworth YBT)
Engine Block Material:
Cast Iron
Cylinder Head Material:
Aluminum Alloy
Bore X Stroke:
90.8 mm x 96.0 mm
Horsepower Bhp:
224 bhp @ 5500 rpm (standard Europe spec)
Torque Lb Ft:
250 lb-ft @ 2500 rpm (standard Europe spec)
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Turbocharger:
Garrett T25 Turbocharger
Fuel Type:
Unleaded Premium (95 RON or higher)
Type:
5-speed Manual Transaxle (MTX75)
Type:
N/A (Only manual was offered)
Drive System:
Permanent Four-Wheel Drive (4WD) with Ferguson viscous coupling center differential and Torsen rear differential
Gear Ratios:
Specific gear ratios available within the manual
Transmission Fluid Type:
Refer to manual for specific API GL-4 or GL-5 specification and capacity
Length:
Approx. 4155 mm (163.6 in)
Width:
Approx. 1770 mm (69.7 in)
Height:
Approx. 1390 mm (54.7 in)
Wheelbase:
Approx. 2600 mm (102.4 in)
Track Width Front:
Approx. 1460 mm (57.5 in)
Track Width Rear:
Approx. 1474 mm (58.0 in)
Curb Weight:
Approx. 1300 kg (2866 lbs)
Gross Vehicle Weight Rating:
Refer to manual for specific GVWR
Towing Capacity:
Not applicable / not specified for this performance model
Crash Test Results:
Era-specific safety standards; detailed ratings not readily available but equipped with standard safety features
Braking System:
Four-wheel disc brakes with ABS (Anti-lock Braking System)
Traction Control:
Integral part of the 4WD system, limited slip differentials
Airbags:
Driver's airbag standard on later models, passenger airbag optional/variable by market
Seatbelts:
Three-point inertia-reel seatbelts with pre-tensioners
Chassis Structure:
Reinforced safety cell, crumple zones
Audio System:
Factory Ford radio/cassette player, optional CD player; typically basic by modern standards
Gauge Cluster:
Comprehensive analog gauge cluster including boost gauge
ABS:
Standard on RS Cosworth models
Traction Control:
Not typically featured as a separate electronic system, but integrated into AWD
Connectivity Features:
N/A (No factory Bluetooth, USB, or modern connectivity)
Oil Change Interval:
Refer to manual for recommended interval (typically 6,000-10,000 miles or 12 months)
Spark Plug Replacement:
Refer to manual for recommended interval (typically 30,000-50,000 miles)
Timing Belt Replacement:
CRITICAL: Refer to manual for interval (typically 40,000-50,000 miles due to catastrophic engine damage if it fails)
Engine Oil Type:
Refer to manual for specific viscosity and API rating (e.g., 5W-30, 5W-40 synthetic recommended)
Coolant Type:
Ford-spec antifreeze/coolant (ethylene glycol based), typically blue or green
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Power Steering Fluid Type:
Refer to manual; typically Ford specification or ATF Dexron II/III
Common Wear Items:
Turbocharger wear, ignition coil packs, clutch components, suspension bushings
Electrical Gremlins:
Can be susceptible to minor electrical issues due to age and complexity
Rust Prone Areas:
Wheel arches, sills, fuel filler area (dependent on climate and care)
Ford Motorsport Division:
Leverages Ford's extensive rallying and motorsport heritage
Homologation Purpose:
Developed to homologate the Escort for Group A World Rally Championship (WRC) racing
Cosworth Collaboration:
Engine development and performance tuning by Cosworth Engineering
Platform Basis:
Based on the Mk4 Ford Escort, but significantly re-engineered with a wider track, more powerful engine, and AWD system
Unique Styling:
Iconic aggressive styling with large rear spoiler, flared wheel arches, and vented bonnet
Production Period:
1992-1996
Manufacturing Location:
Ford's advanced manufacturing facility in Saarlouis, Germany
Total Production Units:
Approximately 7,300 units (split between original 3-door and later 4-door versions)
