🏷️ Basic Information

Make:

Ford

Model:

Escort RS Cosworth

Model Generation:

Mk4 / Sierra Cosworth platform (often referred to as 'Mk5' Escort by enthusiasts due to its distinct design and performance)

Production Years Covered:

1992, 1993, 1994, 1995, 1996

Chassis Code:

GBA (Escort)

👋 Introduction

Market Niche:

High-performance homologation special, rally icon, enthusiast-focused performance vehicle.

Comparative Vehicles:

Competed with cars like the Lancia Delta Integrale, Toyota Celica GT-Four, Mitsubishi Lancer Evolution, and Subaru Impreza WRX/STI of the era, though it was based on a front-wheel-drive platform with a converted all-wheel-drive system.

Performance Focus:

Designed for motorsport homologation, featuring aggressive styling, advanced aerodynamics, and a powerful turbocharged engine.

Manual Advantage:

Provides comprehensive, factory-accurate information for maintenance and repair, enabling cost savings and empowering owners to maintain their specialized vehicle.

📋 Manual Details

Primary Coverage:

Comprehensive service, repair, and maintenance for the Ford Escort RS Cosworth (1992-1996).

Estimated Page Count:

Hundreds of pages (exact count not specified, but implied to be extensive).

Type:

Official Full Factory Service Repair Workshop Manual

Language:

English

Format:

PDF (Digital Download)

📖 Manual Coverage

Engine:

Engine service/repair, engine control system, fuel injection, fuel system, emission system.

Transmission:

Transmission service/repair, differential/drive, axle.

Brakes:

Brake system.

Electrical:

Wiring diagram, electrical system.

Suspension Steering:

Suspension, steering.

Cooling Heating Ac:

Cooling system, heater/air conditioning.

Body Interior:

Chassis/body, interior, restraint system.

Maintenance:

General maintenance, periodic lubrication, preventative maintenance.

Troubleshooting:

Troubleshooting diagnostics and solutions.

Repair Rebuild:

Step-by-step instructions based on complete disassembly and reassembly of components.

Depth:

Comprehensive, covering basic maintenance to advanced repair procedures, suitable for DIYers and experienced mechanics.

📊 Manual Specifications

Compatibility:

All versions of Windows and macOS.

Access Method:

Downloadable PDF, accessible via web browser on PC, smartphone, and tablet.

Software Requirements:

Adobe PDF Reader and Winzip (both free).

Printability:

Printable (entire manual or specific pages).

Binding Type:

N/A (Digital PDF Format)

Paper Type:

N/A (Digital PDF Format)

⚙️ Engine Specifications

Engine Code:

YBT

Configuration:

Inline 4-cylinder, 16-valve, DOHC, turbocharged

Displacement:

2.0 Liters (1998 cc)

Horsepower Ps:

225 PS @ 6250 rpm (early models), 220 PS (later models).

Torque Nm:

300 Nm (approx. 221 lb-ft) @ 2500 rpm.

Fuel Delivery:

Multi-point Fuel Injection (MPI) with Cosworth-designed turbocharger (Garrett T3/T04B).

ECM Type:

Ford EEC-IV with specific Cosworth calibration.

🔧 Transmission

Type:

5-speed manual transaxle

Type:

N/A (Manual transmission only)

Drivetrain:

Permanent All-Wheel Drive (AWD) with a Ferguson viscous coupling and a 50:50 torque split (variable under load).

Gearbox Oil Type:

API GL-4, SAE 75W-90 (specific Ford specification WSD-M2C200-B).

📐 Dimensions

Length Mm:

4340 mm

Width Mm:

1770 mm

Height Mm:

1370 mm

Wheelbase Mm:

2600 mm

Kerb Weight Kg:

Approx. 1320 kg

Gross Vehicle Weight Kg:

Approx. 1750 kg

🛡️ Safety Features

NHTSA Rating:

Not officially rated by NHTSA in the US market as it was not sold there.

Braking System:

AP Racing 4-piston front calipers with 330mm ventilated discs, 280mm ventilated rear discs.

ABS:

Anti-lock Braking System (ABS) - standard.

Airbags:

Driver airbag standard; passenger airbag optional or standard depending on market and year.

Seat Belts:

Three-point inertia-reel seatbelts front and rear.

💡 Technology Features

Audio System:

Factory fitted radio/cassette player, optional CD player in later models. Basic sound systems for the era.

Features:

ABS, limited-slip differential (in some configurations or aftermarket). No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist.

Features:

N/A (No built-in connectivity features like Bluetooth or USB as per modern standards).

🔧 Maintenance

Oil Change:

Every 10,000 km or 12 months, whichever comes first.

Spark Plugs:

Replace every 20,000-30,000 km depending on type (e.g., copper vs. platinum). Check manual for specific interval.

Timing Belt:

Replace every 80,000 km or 5 years (crucial due to interference engine design).

Engine Oil Type:

Ford WSS-M2C153-E or ACEA A3/B3 compliant synthetic oil, SAE 5W-30 or 5W-40 recommended.

Coolant Type:

Ford specification ESE-M97B44-A (or equivalent green ethylene glycol-based antifreeze).

Brake Fluid Type:

DOT 4 (Ford specification WSS-M6C57-A).

Common Problems:

Turbocharger wear/failure, oil leaks (rocker cover, oil cooler), coolant leaks, clutch wear, differential whine, electrical gremlins, turbo lag (inherent to some tuning stages).

Performance Considerations:

Requires regular maintenance due to high-performance nature; sensitive to fuel quality and proper warm-up/cool-down procedures.

📚 Vehicle History

Motorsport Legacy:

Ford's rich motorsport history, particularly in rallying, directly influenced the development of the RS Cosworth models.

Development Basis:

Developed by Ford Europe in collaboration with Tickford and Cosworth Engineering. Based on the Ford Escort Mk5 platform but extensively re-engineered with a Sierra Cosworth drivetrain and chassis components.

Manufacturing Location:

Ford's Saarlouis plant in Germany.

Production Volume:

Approximately 7,100 units produced globally between 1992 and 1996.

🏆 Awards & Recognition

Motorsport Achievements:

While not directly an award, its design and engineering were heavily influenced by rally homologation requirements, leading to success in international rallying (e.g., WRC).