🏷️ Basic Information

Make:

Ford

Model:

Escort RS Cosworth

Year:

1992-1996

Chassis Code:

N/A (Affectionately known as the 'Cosworth' or 'Cossie')

Engine Code:

Cosworth YB (2.0L DOHC Turbocharged)

👋 Introduction

Market Position:

Performance homologation special, rally-bred road car with iconic status.

Target Audience:

Enthusiasts, rally fans, and drivers seeking a highly capable and iconic performance car.

Competitive Analysis:

Competed against other high-performance rally homologation specials and sports compacts of its era, such as Mitsubishi Lancer Evolution, Subaru Impreza WRX STi, and Toyota Celica GT-Four. Its unique combination of potent Cosworth engine, sophisticated AWD system, and aggressive styling set it apart.

Key Features:

Cosworth 2.0L turbocharged engine, Ferguson viscous coupling all-wheel-drive system, robust chassis, aggressive aerodynamic enhancements (iconic rear wing), rally-derived performance.

Aerodynamics:

Large adjustable rear wing, front splitter, side skirts, and aggressive bumper designs for enhanced downforce and stability at high speeds.

📋 Manual Details

Coverage Areas:

All models and all repairs A-Z for the Ford Escort RS Cosworth 1992-1996

Page Count:

Not specified in product information, but implied to be comprehensive.

Manual Type:

Official Full Service Repair Manual

Language:

English

Format:

PDF

Delivery:

Instant Download

Requirements:

Adobe PDF Reader & WinZip

Compatibility:

All Versions of Windows & Mac

Zoom Capability:

YES

📖 Manual Coverage

Systems Covered:

Engine mechanical, engine management, fuel system, ignition system, cooling system, exhaust system, transmission (manual and automatic, if applicable), drivetrain, suspension, steering, brakes, body electrical, HVAC, interior, exterior body panels, chassis, diagnostics, troubleshooting.

Electrical System Details:

Comprehensive wiring schematics, component location, diagnostic flowcharts for all electrical circuits including engine management, lighting, ignition, accessories, and body controls.

Suspension System:

MacPherson struts front, independent multi-link rear. Manual covers component replacement, alignment angles, and troubleshooting.

Lighting System:

Headlights, taillights, fog lights, interior lighting, wiring diagrams, bulb specifications, and troubleshooting.

Procedures Included:

Routine maintenance, scheduled servicing, diagnostic procedures, repair and replacement of all major and minor components, component testing, electrical system troubleshooting, wiring schematic interpretation, bodywork repair, special tool usage, alignment specifications.

Engine Rebuild:

Detailed procedures for engine disassembly, inspection, component replacement (pistons, rings, bearings, valves, camshafts), cylinder head work, and reassembly with correct torque specifications.

Body Repair:

Includes procedures for panel replacement, rust repair, dent removal, and aerodynamic component fitting/alignment.

Wheel Alignment:

Detailed specifications for camber, caster, toe, and steering axis inclination.

Turbocharger Replacement:

Step-by-step guide for removal, installation, and necessary checks for proper operation and lubrication.

Technical Depth:

Factory-level, comprehensive step-by-step instructions with diagrams and illustrations, suitable for novice to experienced technicians. Covers everything from basic adjustments to complete rebuilds and diagnostics.

Diagnostic Tools:

Information on using factory diagnostic tools (e.g., Ford New Generation Star Tester - NGST, or equivalent era tools) and generic OBD-I/OBD-II scan tools if applicable for specific ECUs.

Torque Specifications:

Extensive list of torque specifications for all critical fasteners, engine components, suspension, and drivetrain parts.

Diagnostic Troubleshooting:

Flowcharts and tables for diagnosing symptoms, identifying causes, and providing solutions for various vehicle problems.

📊 Manual Specifications

File Format:

PDF

Print Quality:

Printable, with zoomable images for clarity.

Binding Type:

Digital (PDF), printable pages.

Paper Type:

N/A (Digital format, printable on demand).

⚙️ Engine Specifications

Primary Engine:

Cosworth 2.0L (1998cc) DOHC 16-valve turbocharged inline-4 (YB engine)

Horsepower:

Approx. 220-230 PS (162-170 kW) depending on market and specific tune (later '94/'96 models slightly higher).

Torque:

Approx. 300 Nm (221 lb-ft) at 3500 rpm.

0 To 60 Mph:

Approx. 5.7 - 6.2 seconds.

Fuel System:

Bosch L-Jetronic fuel injection with Garrett T3 turbocharger, intercooler, and often a Bosch ignition system.

Injection Type:

Multi-point fuel injection (MPFI)

Turbocharger Model:

Garrett T3, often with an uprated compressor or turbine housing on later models.

ECU Type:

Ford EEC-IV or EEC-V electronic engine control unit (depending on model year updates).

Ignition System:

Distributorless ignition system (DIS) or distributor-based system depending on specific ECU and market.

🔧 Transmission

Standard:

5-speed manual transmission (MT75).

Optional:

No automatic transmission was officially offered for the RS Cosworth.

Features:

Full-time all-wheel-drive system with Ferguson viscous coupling center differential and a limited-slip rear differential.

Transfer Case:

Integrated transfer case with viscous coupling.

📐 Dimensions

Length:

Approx. 4230 mm (166.5 in)

Width:

Approx. 1750 mm (68.9 in)

Height:

Approx. 1390 mm (54.7 in)

Track Width Front:

Approx. 1470 mm (57.9 in)

Track Width Rear:

Approx. 1470 mm (57.9 in)

Curb Weight:

Approx. 1280-1350 kg (2822-2976 lbs)

Wheelbase:

Approx. 2550 mm (100.4 in)

Gross Vehicle Weight Rating:

N/A (Not typically specified for performance homologation specials).

Towing Capacity:

N/A

🛡️ Safety Features

Ratings:

Not subject to modern crash testing standards due to its era. Focus on active safety through AWD and braking.

Active Features:

Anti-lock Braking System (ABS), advanced all-wheel-drive system.

Braking System Front:

Ventilated disc brakes, typically 280mm or larger.

Braking System Rear:

Disc brakes, typically 270mm or larger.

Passive Features:

Reinforced chassis structure, seat belts, potentially driver airbag (market dependent).

💡 Technology Features

Infotainment:

Basic factory Ford radio/cassette player, often with aftermarket upgrades common due to age.

Speaker System:

Basic factory speaker setup, often 4 or 6 speakers.

Driver Assistance:

Limited by modern standards. Primarily relied on mechanical grip and driver skill, with ABS as the primary electronic aid.

Connectivity:

None by modern standards; analog systems.

🔧 Maintenance

Oil Change Interval:

Typically every 6,000-10,000 miles (10,000-16,000 km) or 6-12 months, depending on driving conditions.

Timing Belt Interval:

Crucial to replace every 30,000-40,000 miles (50,000-60,000 km) or 4 years due to potential catastrophic engine damage if it fails.

Spark Plug Replacement:

Refer to manual; typically around 30,000 miles, depending on spark plug type.

Air Filter Replacement:

Refer to manual; typically every 15,000-30,000 miles or as needed based on inspection.

Engine Oil:

API SG/SH or higher, SAE 5W-30 or 5W-40 recommended (check manual for exact specs).

Coolant:

Ford Super Plus coolant or equivalent ethylene glycol-based antifreeze with corrosion inhibitors.

Transmission Fluid:

Refer to manual for specific MT75 gearbox fluid specification (typically a high-quality gear oil).

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

Refer to manual; typically a specific power steering fluid or ATF Dexron II.

Clutch Fluid:

Refer to manual, typically brake fluid (DOT 3 or DOT 4).

Known Issues:

Turbocharger wear/failure, ignition coil issues, oil leaks (gaskets, seals), turbo lag susceptibility, suspension bush wear, intercooler hose degradation, ECU capacitor failure (on early ECUs).

Turbo Cooling System:

Potential for oil coking in the turbocharger due to insufficient cool-down periods; manual will detail proper shutdown procedures.

All Wheel Drive System:

Regular fluid changes for viscous coupling and differentials are crucial for longevity.

Heater Matrix:

Potential for leaks or blockages, requiring dashboard removal for replacement.

Wiring Harness Degradation:

In older vehicles, wiring insulation can become brittle; manual will show layouts for inspection and repair.

📚 Vehicle History

Brand Heritage:

Ford's motorsport legacy, particularly in rallying, with the Escort nameplate being a long-standing champion.

Model Evolution:

Developed as a homologation special for Group A rallying. Based on the Escort Mk5/Mk6 chassis but extensively re-engineered. Distinct from the standard Ford Escort.

Homologation Basis:

FIA Group A rally regulations.

Rally Success:

While a homologation special, its direct rally predecessor was the Sierra RS Cosworth, paving the way for the Escort's motorsport heritage.

Production Years:

1992-1996

Production Location:

Ford's advanced vehicle manufacturing facility in Saarlouis, Germany.