Positioning:
Essential resource for owners and enthusiasts of the Ford Sierra RS Cosworth, catering to both routine maintenance and in-depth restoration.
Advantage:
Provides comprehensive, factory-level information often unavailable in generic repair guides. Its detailed nature makes it ideal for preserving and maintaining a performance classic.
Illustrations:
Detailed illustrations, diagrams, photos, and enlarged insets
Instructions:
Step-by-step instructions, numbered instructions, and detailed substeps
Electrical:
Combined troubleshooting, electrical service procedures, and detailed wiring diagrams
Usability:
Numbered table of contents for fast information retrieval
Primary Coverage:
Service, Repair, Maintenance, Troubleshooting, Restoration
Estimated Pages:
Extensive (Specific count not provided, but described as 'highly detailed' and covering 'all major topics')
Type:
Workshop Manual / Service Repair Manual
Engine Mechanical:
Yes (Rebuild, troubleshooting, diagnostics)
Starting Ignition System:
Yes
Engine Controls:
Yes (Including ECU diagnosis)
Transmission Transaxle:
Yes (Manual and potentially automatic variants)
Fuel System:
Yes (Including fuel injection)
Instrumentation Warning Systems:
Yes
Battery Charging System:
Yes
Electrical System:
Yes (Including extensive wiring schematics)
Body Interior Exterior:
Yes
Driveline:
Yes (Including drivetrain components)
Maintenance:
Yes (Step-by-step instructions)
Troubleshooting:
Yes (Combined with electrical service procedures)
Repair:
Yes (All diagnostic and repair procedures in great detail)
Rebuild Refurbish Restore:
Yes (Comprehensive for restoration purposes)
Disassembly Assembly:
Yes
Diagnostics:
Yes (Detailed diagnostic procedures)
Depth:
Comprehensive (From general information to detailed component repair and electrical schematics)
Level Of Detail:
High (Includes substeps, notes, cautions, warnings)
Searchable:
Likely (Standard for modern PDF manuals, facilitating quick information retrieval)
Printable:
Yes (All pages are printable)
Quality:
High (Implied by 'detailed illustrations, diagrams, wiring schematics')
Type:
N/A (Digital format)
Type:
N/A (Digital format)
Engine Type:
Inline 4-cylinder, turbocharged, intercooled, DOHC, 16-valve
Engine Code:
YBG / YBJ (Commonly associated with the Sierra RS Cosworth)
Displacement:
2.0 Liters (1998 cc)
Horsepower Ps:
Approximately 220-225 PS (162-168 kW) for the 1992-1996 models, depending on specific market and tune.
Torque Nm:
Approximately 300-320 Nm (221-236 lb-ft)
Fuel Injection:
Bosch Motronic Electronic Fuel Injection
Fuel Type:
Unleaded Premium (95 RON or higher recommended)
Type:
5-speed Manual (M85 variant, typically from Getrag)
Type:
Limited production automatic transmission variants may exist, though the manual is standard for the RS Cosworth.
Drive Layout:
Rear-Wheel Drive (RWD) with optional Limited Slip Differential (LSD)
Crash Test Results:
N/A for the specific period and models from official contemporary sources, but later facelift Sierras generally saw improvements over early models.
ABS:
Yes (Standard on RS Cosworth models)
Seatbelts:
Yes (Three-point inertia reel seatbelts)
Airbags:
Driver airbag typically optional or standard on later facelift models, not universal.
Audio System:
Factory Ford radio/cassette player, often with amplifier. Basic analog controls.
Cruise Control:
Optional on many models, typically electronically controlled.
Connectivity Features:
Limited to basic automotive electronics; no modern connectivity features like Bluetooth or USB were standard.
Oil Change:
Every 6,000-10,000 miles (10,000-16,000 km) or 12 months, whichever comes first (refer to manual for exact Ford recommendation).
Spark Plugs:
Approximately every 24,000-30,000 miles (40,000-50,000 km), depending on plug type.
Timing Belt:
Crucial: Replace every 30,000-45,000 miles (50,000-70,000 km) or as specified, due to interference engine design. Failure can lead to catastrophic engine damage.
Engine Oil:
Typically 5W-30 or 10W-40 synthetic oil meeting Ford specifications (e.g., WSS-M2C153-E or equivalent).
Coolant:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Ford specification: WSS-M97B44-D or similar green type coolant.
Transmission Fluid:
Manual Transmission: GL-4 or GL-5 gear oil, typically SAE 75W-90 or 80W-90.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Turbocharger:
Bearing wear, oil leaks, and wastegate issues are common if not properly maintained.
Rust:
Prone to rust in common areas: wheel arches, sills, strut tops, rear wings, and around windows. Careful inspection is vital.
Engine Seals:
Oil leaks from rocker cover gasket, front/rear crankshaft seals, and oil cooler seals.
Electrical:
Corroded connectors, wiring harness degradation, especially in older, high-mileage vehicles. ECU issues can occur.
Suspension:
Wear in bushings, ball joints, and shock absorbers can lead to poor handling and alignment issues.
Heritage:
Ford's significant motorsport heritage, particularly in rallying and touring car racing, with the Cosworth name synonymous with performance.
Evolution:
The Sierra RS Cosworth initially debuted in 1986. The 1992-1996 models represent the facelifted Sierra platform, with design refinements and updated mechanics. The 'Sapphire' saloon body style became the dominant form for the RS Cosworth from the late 1980s onwards.
Manufacturing Location:
Genk, Belgium; Saarlouis, Germany; and potentially other Ford European plants.
