🏷️ Basic Information

Make:

Ford

Model:

Sierra RS Cosworth

Engine Code Escort Cosworth:

YBT (2.0L 16v DOHC Turbocharged)

Engine Code Sierra Cosworth:

YBD (2.0L 16v DOHC Turbocharged)

👋 Introduction

Target Audience:

Owners and technicians of Ford Escort RS Cosworth and Sierra RS Cosworth models seeking detailed repair, maintenance, and diagnostic information.

Uniqueness:

Vehicle-specific, dealership-equivalent information unlike generic repair guides. Provides exact procedures used by factory-trained technicians.

Comprehensiveness:

Covers all models and engines for both Escort RS Cosworth and Sierra RS Cosworth, offering a complete resource for repair and maintenance.

Ease Of Use:

Digital format allows for easy searching, printing of specific pages/diagrams, and enlargement of images. Eliminates the need for physical manuals.

Cost Saving:

Empowers owners to perform their own repairs, saving significant money on labor costs at dealerships or independent workshops.

📋 Manual Details

Systems Covered:

Engine Overhaul and Rebuilding, Brakes, Sunroof, Timing Belt Replacement, Wiring Diagrams, Troubleshooting and Diagnostics, Computer Diagnostic Trouble Codes, Engine Performance, Front End and Alignment, Suspension, Transmission Removal and Installation, Air Conditioning Service and Capacities, Transmission In-Car Servicing, Computer Diagnostic Codes, Firing Orders, Serpentine Belt Routings, Timing Belt Service Procedures, Brake Servicing Procedures, U-Joint and CV-Joint Service Procedures, Repair Procedures, Vacuum Diagrams

Total Pages:

> 1000

Type:

Service Repair Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Complete overhaul and rebuilding procedures, including piston and ring installation, cylinder head assembly, crankshaft and camshaft installation, and engine block preparation. Detailed specifications for all engine variants.

Engine Management:

Covers fuel injection, ignition timing, sensor diagnostics, trouble codes, and engine performance tuning. Includes diagnostic trouble tree charts and computer diagnostic codes.

Transmission:

Removal and installation procedures for both manual and automatic transmissions. In-car servicing, clutch replacement, and gearbox component overhaul detailed. Specific fluid types and capacities are provided.

Brakes:

Comprehensive brake servicing procedures including disc and drum brake repair, hydraulic system bleeding, component replacement (pads, rotors, calipers, master cylinder), and ABS system diagnostics.

Suspension Steering:

Detailed procedures for front end alignment, including camber, caster, and toe adjustments with specifications. Suspension component replacement (struts, shocks, bushings, control arms) and U-joint/CV-joint service included.

Electrical Lighting:

Complete wiring diagrams for all vehicle systems, including engine, chassis, lighting, and accessories. Troubleshooting guides for electrical faults.

Body Chassis:

Procedures for sunroof operation and repair, as well as general bodywork repair information. Vacuum diagrams for various vehicle systems.

Preventative Maintenance:

Factory maintenance schedules and charts, including recommended service intervals for oil changes, filter replacements, fluid checks, and timing belt replacement.

Diagnostics:

Extensive troubleshooting and diagnostics section covering common driving concerns, computer diagnostic trouble tree charts, and interpretation of diagnostic trouble codes.

Repair Overhaul:

Step-by-step repair procedures for virtually every component of the vehicle, from minor adjustments to complete engine and transmission rebuilds.

Specifications:

Complete torque specifications for all fasteners, fluid capacities and types, engine performance data, and alignment specifications.

Depth:

Comprehensive, dealership-level technical information suitable for both professional technicians and experienced DIY enthusiasts. Covers detailed internal component procedures and advanced diagnostics.

📊 Manual Specifications

File Type:

PDF

Searchable:

Yes (implied by PDF format, although explicit searchability isn't guaranteed without OCR)

Printability:

All pages are printable

Zoom Functionality:

Yes, zoom in/out is supported

Binding:

Digital (Downloadable)

Paper Type:

N/A (Digital Format)

Operating Systems:

Compatible with all versions of Windows (including 7, Vista 32/64, XP, ME, 98, NT, 2000) and Mac OS.

Reader:

Adobe PDF Reader required

Extractor:

WinZip or similar file extraction utility required

⚙️ Engine Specifications

Engine Type:

2.0L 16-valve DOHC Turbocharged Cosworth YBT/YBD

Bore Stroke Escort:

87.5 mm x 91.3 mm (approx.)

Bore Stroke Sierra:

87.5 mm x 91.3 mm (approx.)

Horsepower Escort:

227 PS (224 bhp; 167 kW) at 6,250 rpm (typical for early models)

Horsepower Sierra:

204 PS (201 bhp; 150 kW) at 6,000 rpm (late model Sierra Cosworth 2WD), 220 PS (217 bhp; 162 kW) at 6,000 rpm (Sierra Cosworth 4x4)

Torque Escort:

300 Nm (221 lb-ft) at 3,500 rpm (typical for early models)

Torque Sierra:

275 Nm (203 lb-ft) at 4,500 rpm (late model Sierra Cosworth 2WD), 300 Nm (221 lb-ft) at 3,500 rpm (Sierra Cosworth 4x4)

Fuel Injection Type:

Multi-point fuel injection (MPI)

Turbocharger:

Garrett T3/T4 or Garrett T4 (depending on specific model/year)

🔧 Transmission

Type Escort:

5-speed Manual (e.g., MT75, MT75 4x4 for specific variants)

Type Sierra:

5-speed Manual (e.g., MT75 for 2WD, MT75 4x4 for 4WD variants)

Type:

Not typically offered with automatic transmissions in RS Cosworth variants.

Clutch Type:

Hydraulically actuated single dry plate clutch (specifics vary, manual details covered)

Gear Ratios:

Detailed gear ratios for all forward gears and reverse are provided within the manual for both models.

📐 Dimensions

Wheelbase Escort:

2,550 mm (100.4 in)

Wheelbase Sierra:

2,600 mm (102.4 in)

Track Width Escort:

Front: 1,470 mm (57.9 in), Rear: 1,470 mm (57.9 in) (approx.)

Track Width Sierra:

Front: 1,446 mm (56.9 in), Rear: 1,430 mm (56.3 in) (for 2WD), 1,452 mm (57.2 in) (for 4x4) (approx.)

Curb Weight Escort:

Approx. 1,275 kg (2,811 lb)

Curb Weight Sierra:

Approx. 1,270 kg (2,799 lb) for 2WD, Approx. 1,360 kg (2,998 lb) for 4x4

🛡️ Safety Features

Crash Test Era:

Vehicle models predate standardized modern crash test rating systems like Euro NCAP or NHTSA frontal impact ratings as commonly understood today. Early safety features and structural integrity are detailed in the manual.

ABS:

Anti-lock Braking System (ABS) available on many models, with diagnostic procedures covered.

Seatbelts:

Pre-tensioner seatbelts (on some later models) and standard 3-point seatbelts. Adjustment and repair procedures outlined.

Airbags:

Driver-side airbag standard on most Escort RS Cosworth, optional or standard on later Sierra RS Cosworth models. System diagnostics and replacement covered.

💡 Technology Features

Audio System:

Factory-fitted radio/cassette players or CD players from brands like Ford, Blaupunkt, or Pioneer. Wiring diagrams for audio systems are included in the manual.

ABS:

Anti-lock Braking System provides enhanced braking control. Diagnostic and service procedures are detailed.

Wiring Schematics:

Extensive wiring schematics for all vehicle electrical systems, crucial for diagnosing and repairing any electronic or sensor-related issues. Facilitates aftermarket upgrades and repairs.

🔧 Maintenance

Oil Change Interval:

Typically every 6,000 miles or 6 months, but refer to specific year/model maintenance schedule within the manual for exact Ford recommendations.

Timing Belt Interval:

Recommended replacement every 40,000-60,000 miles or 4-5 years, depending on model and operating conditions. Critical procedure covered in detail.

Engine Oil Type:

e.g., API SG/SH, ACEA A2/A3, Viscosity SAE 5W-30, 10W-40, 15W-40. Manual specifies exact grades based on temperature and model.

Coolant Type:

Ethylene glycol-based antifreeze. Manual provides specific mixtures and Ford-approved coolant types.

Brake Fluid Type:

DOT 3 or DOT 4 (refer to manual for specific model requirement).

Transmission Fluid Type:

Manual transmission oil (e.g., SAE 75W-90 GL-4 or GL-5, or specific Ford spec) and differential fluid. Manual provides exact specifications.

Crankshaft Bearing Failure:

A known historical issue in early Cosworth engines due to design tolerances under high stress. Proper maintenance and oil quality are crucial. Manual details inspection and repair.

Turbocharger Failure:

Can result from oil starvation, lack of proper cool-down, or carbon buildup. Manual provides maintenance and diagnostic tips.

Rust Corrosion:

Common in older vehicles, particularly in wheel arches, sills, and rear quarter panels. Manual may offer some bodywork guidance but focused on mechanicals.

📚 Vehicle History

Ford Performance:

Ford's legacy in rallying and performance vehicles, with the RS (Rallye Sport) badge signifying homologation specials and high-performance variants.

Sierra Cosworth Development:

Developed from the Sierra platform for Group A touring car homologation. Known for its distinctive large rear wing and potent Cosworth engine. Notable evolution includes 2WD and 4x4 variants.

Escort Cosworth Development:

Developed to homologate for Group A rallying, utilizing a modified Sierra Cosworth mechanical package (including engine and drivetrain) within the Escort Mk5/Mk6 body. Renowned for its aggressive styling and performance.

Sierra Cosworth Years:

1986-1992

Escort Cosworth Years:

1992-1996

🏆 Awards & Recognition

Rally Homologation:

Both models were developed primarily for homologation in Group A rallying and touring car racing, demonstrating their high-performance pedigree.

Motorsport Success:

The Cosworth engines and chassis configurations achieved significant success in international motorsport, cementing their legendary status.