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Ford Sierra RS 1985-1987 Service Repair Manual
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🏷️ Basic Information Identification Make: Ford Model: Sierra RS Model Variant: RS Cosworth Production Years Covered: 1985, 1986, 1987 Codes Platform Code: Ford Sierra (GBC, GBG, GB4) Engine Codes: YBD...
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🏷️ Basic Information
Identification
Make:
Ford
Model:
Sierra RS
Model Variant:
RS Cosworth
Production Years Covered:
1985, 1986, 1987
Codes
Platform Code:
Ford Sierra (GBC, GBG, GB4)
Engine Codes:
YBD (2.0 OHC), YBG (2.0 OHC Injection), YBJ (2.0 OHC Injection), YBP (2.0 DOHC Cosworth - Turbocharged)
👋 Introduction
Market Position
Segment:
Compact/Mid-size Performance Hatchback/Saloon
Target Audience:
Enthusiasts, motorsport fans, owners seeking in-depth maintenance and repair knowledge
Competitive Analysis
Key Competitors:
Volkswagen Golf GTI, Peugeot 205 GTI, Opel Kadett GSI, BMW 3 Series (E30)
Key Features
Vehicle Appeal:
Rear-wheel drive dynamics (RS Cosworth), aggressive styling, powerful turbocharged engine (RS Cosworth), homologation special for rallying.
Manual Value Proposition:
Provides essential, factory-level information for maintaining and repairing the iconic Sierra RS models, especially the sought-after RS Cosworth.
📋 Manual Details
Coverage Areas
Primary Coverage:
Ford Sierra RS (including RS Cosworth variants)
Secondary Coverage:
Standard Sierra models (non-RS) with compatible components
Page Count
Estimated Page Count:
800+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
2.0 OHC (Pinto), 2.0 DOHC Turbocharged (Cosworth YBP), Cooling System, Lubrication System, Fuel System (Carbureted & Injection), Ignition System, Emission Control Systems
Transmission:
5-Speed Manual (T9, MT75), Limited Slip Differential (LSD) for RS variants
Drivetrain:
Front Wheel Drive (FWD), Rear Wheel Drive (RWD) for RS Cosworth
Suspension:
Front Independent (McPherson Strut), Rear Independent (Semi-Trailing Arm), RS specific tuning and components
Brakes:
Front Discs (Vented for RS), Rear Discs, ABS (Anti-lock Braking System) for select models
Steering:
Rack and Pinion, Power Steering (optional/standard on RS)
Electrical:
Battery, Charging System, Starting System, Lighting, Instrumentation, Fuses and Relays, Wiring Diagrams, ECUs (Engine Control Units)
Body:
Body Structure, Exterior Panels, Interior Trim, Sealing, Doors, Hood, Trunk, Glass, Body Repairs, Corrosion Prevention
Heating Ventilation Air Conditioning:
HVAC System Operation and Repair
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Spark Plugs, Belts, Hoses
Engine Repair:
Engine Removal/Installation, Cylinder Head Overhaul, Piston and Connecting Rod Replacement, Crankshaft Rebuild, Timing Belt/Chain Service
Transmission Repair:
Transmission Disassembly/Assembly, Clutch Replacement, Gearbox Overhaul, Differential Service
Brake Service:
Brake Pad/Disc Replacement, Caliper Overhaul, Brake Line Flushes, ABS System Troubleshooting
Suspension Steering Service:
Shock Absorber/Strut Replacement, Bushing Replacement, Ball Joint Service, Tie Rod End Replacement, Wheel Alignment Procedures
Electrical Diagnostics:
Troubleshooting Electrical Faults, Wiring Harness Repair, Sensor Testing, ECU Diagnostics
Body Repair:
Panel Replacement, Dent Repair, Welding Procedures, Rust Repair, Interior Component Installation/Removal
Fuel System Service:
Fuel Pump Replacement, Injector Cleaning/Replacement, Carburetor Adjustment/Rebuild (where applicable)
Troubleshooting:
System-Specific Diagnostic Flowcharts, Symptom-Based Troubleshooting Guides
Technical Depth
Depth:
Comprehensive - from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures.
Diagnostics:
Advanced diagnostic procedures, wiring diagrams, fault code interpretations (for EFI models)
Special Tools:
Identification and usage of special Ford tools required for specific repair procedures
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Fully searchable text for quick information retrieval
Printability:
Printable for workshop use
Print Quality
Image Resolution:
High-resolution scans of original diagrams and photographs
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated 2.0L OHC (Pinto)
Displacement:
1993 cc (2.0 Liters)
Bore X Stroke:
93.7 mm x 72.5 mm
Compression Ratio:
9.5:1 (typical for injection models)
Power Output:
Approx. 115-125 PS (85-93 kW) for fuel-injected variants
Torque Output:
Approx. 170-185 Nm (125-136 lb-ft)
Performance
Rs Cosworth Engine Type:
2.0L DOHC Turbocharged Cosworth YB
Rs Cosworth Displacement:
1993 cc (2.0 Liters)
Rs Cosworth Bore X Stroke:
90.8 mm x 77.0 mm
Rs Cosworth Compression Ratio:
8.0:1
Rs Cosworth Power Output:
204 PS (150 kW) for early models
Rs Cosworth Torque Output:
290 Nm (214 lb-ft)
Fuel System
Carbureted Models:
Weber or Solex carburetors (e.g., 2.0 OHC)
Injection Models:
Bosch L-Jetronic or Ford EFi
Rs Cosworth Fuel System:
Bosch Motronic Fuel Injection with Turbocharger
Ignition System
Ignition Type:
Distributor-based electronic ignition (various types depending on engine and year)
Cooling System
Coolant Type:
Ethylene Glycol based antifreeze (e.g., Ford Super Plus Coolant or equivalent)
Lubrication System
Oil Type:
API SG or SH, SAE 10W-40 or 15W-40 (check specific engine variant)
Oil Capacity:
Approx. 4.5 - 5.0 liters (4.7 - 5.3 US qt) with filter
🔧 Transmission
Standard
Standard Transmission:
5-speed manual (Ford T9)
Optional
Optional Transmission:
3-speed Automatic (C3 or C5, less common on RS)
Features
Rs Cosworth Drivetrain:
Rear-wheel drive with viscous coupling Limited Slip Differential (LSD)
Transmission Fluid Type:
Manual: SAE 75W-90 or 80W-90 GL-4/GL-5; Automatic: MERCON or Type F (check manual)
📐 Dimensions
Exterior
Body Styles:
3-door Hatchback, 5-door Hatchback, 4-door Saloon, 5-door Estate (Wagon)
Wheelbase:
Approx. 2605 mm (102.6 in)
Length:
Approx. 4200-4400 mm (165-173 in) depending on body style
Width:
Approx. 1700 mm (67 in)
Height:
Approx. 1380-1430 mm (54-56 in) depending on body style
Weights
Curb Weight:
Approx. 1100-1300 kg (2425-2866 lbs) depending on model and specification
Rs Cosworth Curb Weight:
Approx. 1250 kg (2756 lbs)
🛡️ Safety Features
Ratings
Crash Test Data:
Limited official Euro NCAP data for this era; often based on contemporary consumer testing.
Active Features
ABS:
Optional on many models, standard on later RS Cosworth variants.
Traction Control:
Not typically available on 1985-1987 models.
Passive Features
Seatbelts:
Three-point front seatbelts, lap belts in rear (some models).
Crumple Zones:
Designed with front and rear crumple zones for energy absorption.
Roll Cage:
Internal roll cage structure for RS Cosworth models for chassis rigidity and safety.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio cassette players, often with optional upgraded speakers or amplifiers.
Digital Displays:
Analog gauges for speedometer, tachometer, fuel, and temperature. No digital infotainment systems of the modern era.
Driver Assistance
ABS:
Available as an option, providing enhanced braking stability.
Cruise Control:
Rarely fitted, typically an aftermarket or very late model option.
Connectivity
Connectivity Features:
None; vehicles of this era predate modern connectivity standards.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km (6,000 miles) or 12 months, whichever comes first.
Air Filter Replacement:
Every 20,000 km (12,000 miles) or as needed based on driving conditions.
Spark Plug Replacement:
Every 40,000 km (24,000 miles), check gap regularly.
Timing Belt Replacement:
Every 80,000 km (50,000 miles) or 5 years for OHC engines; Cosworth YB has a timing chain system (check manual for specific chain maintenance).
Fluid Specifications
Coolant Capacity:
Approx. 7.0 - 8.0 liters (7.4 - 8.5 US qt) for the cooling system.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
Ford specification power steering fluid or ATF Dexron II/III (check manual).
Known Issues
Rust:
Common rust points include wheel arches, sills, rear spring mounts, and around windows.
Cosworth Yb Engine Gaskets:
Head gasket failure, particularly on heavily modified or poorly maintained engines. Oil leaks from rocker cover and front/rear crank seals.
Suspension Bushings:
Wear in control arm bushings, anti-roll bar bushes, and trailing arm bushings leading to imprecise handling.
Electrical Gremlins:
Older wiring can degrade; issues with headlight motors, central locking, and intermittent dashboard warning lights are not uncommon.
Gearbox Selector:
Worn gearbox linkage bushes can result in vague gear selection.
📚 Vehicle History
Brand Heritage
Ford Performance Legacy:
Ford's long history in motorsport and performance road cars, including the Escort RS series.
Model Evolution
Sierra Introduction:
Introduced in 1982 as a replacement for the Ford Cortina/Taunus, featuring a distinctive aerodynamic shape and rear-wheel drive (later front-wheel drive on some variants).
Rs Cosworth Development:
Developed in conjunction with Cosworth, a legendary British motorsport engineering company, for Group A touring car homologation.
Rs Cosworth Variants:
Series 1 (1986-1987) featured RWD and the iconic 2.0L Cosworth YB engine; Series 2 and 3 followed with AWD and different styling cues.
Production
Manufacturing Locations:
Europe (e.g., West Germany, Belgium, UK)
Rs Cosworth Production Volume:
Approx. 5,545 units for the Series 1 RS Cosworth.
🏆 Awards & Recognition
Recognitions
Motorsport Success:
The Sierra RS Cosworth achieved significant success in Group A touring car racing and rallying, solidifying its performance credentials.
Performance Car Acclaim:
Regularly featured in automotive magazines of the era for its handling, performance, and value proposition in the hot hatch/performance sedan market.
Collectible Status:
Highly sought-after modern classic, particularly the RS Cosworth variants, appreciated for their engineering and motorsport heritage.