🏷️ Basic Information Identification Make: Ford Model: Sierra RS Cosworth Body Style: Hatchback (3-door) Generation Generation Name: Sierra RS Cosworth (Mk1/Mk2 overlap) Codes Engine Code: YBD (Cosworth YB Series) 👋 Introduction Market Position Positioning: The Ford Sierra RS Cosworth was a homologation special designed for Group A touring car racing, making it a highly sought-after performance variant of the standard Sierra. This manual serves the enthusiast and owner seeking to maintain or restore this iconic performance vehicle. Competitive Analysis Comparison: Competed against other homologation specials and performance sedans/hatchbacks of its era, such as the BMW M3 (E30), Mercedes-Benz 190E 2.3-16 Cosworth, and Audi Quattro. Key Features Distinctive Features: Unique aerodynamic body kit (including the iconic bi-plane rear spoiler), potent Cosworth YB turbocharged engine, advanced suspension for its time, and a significant racing pedigree. 📋 Manual Details Coverage Areas Model Years Covered: 1986, 1987, 1988, 1989, 1990, 1991, 1992 Page Count Estimated Page Count: Hundreds of pages Manual Type Type: Factory Service Repair Manual / Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete service, repair, and overhaul procedures for the Cosworth YB 2.0L Turbocharged engine, including cylinder head, block, pistons, crankshaft, camshafts, valvetrain, oil system, and cooling system. Fuel System: Detailed coverage of the Bosch L-Jetronic fuel injection system, fuel pump, injectors, fuel pressure regulator, fuel lines, and evaporative emission control system. Ignition System: Diagnosis and repair of the electronic ignition system, including coil packs, ignition control module, and spark plugs. Transmission: Service and repair of the T5 manual transmission, including clutch operation, gear shifting mechanisms, and fluid specifications. Drivetrain: Detailed information on the rear-wheel-drive system, including driveshaft, differential, and axle shafts. Suspension: Front and rear suspension component diagnosis and replacement, including shock absorbers, springs, control arms, bushings, and anti-roll bars. Steering: Service and repair of the power steering system, including steering rack, pump, and hydraulic lines. Brakes: Complete brake system overhaul, including front and rear disc brakes, calipers, master cylinder, brake lines, and ABS system (if equipped). Electrical System: Comprehensive wiring diagrams, fuse box layouts, component testing, and troubleshooting for all electrical systems, including lighting, instruments, and power windows. Body And Chassis: Body panel repair, structural integrity checks, door mechanisms, glass replacement, and underbody protection. Heating Ventilation And Air Conditioning: Service and repair of the HVAC system, including heater core, blower motor, and A/C components (if applicable). Emission Control: Diagnosis and repair of emission control systems, including catalytic converter, oxygen sensors, and EGR (if applicable). Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections, and lubrication points. Troubleshooting: Diagnostic procedures, fault code interpretation, and step-by-step troubleshooting guides for common and complex issues across all vehicle systems. Repair: Detailed instructions for the removal, installation, and adjustment of all mechanical and electrical components. Overhaul: Complete engine and transmission overhaul procedures with torque specifications and assembly sequences. Electrical Diagnosis: Testing of sensors, actuators, control modules, and wiring harnesses using multimeters and diagnostic equipment. Wheel Alignment: Specifications and procedures for checking and adjusting wheel alignment parameters. Recalibration: Procedures for recalibrating systems after component replacement (e.g., engine sensors). Technical Depth Depth: Comprehensive factory-level detail, suitable for professional mechanics and advanced DIY enthusiasts. Includes disassembly, assembly, torque specifications, diagnostic charts, and technical service bulletins (TSBs) if available within the original documentation. 📊 Manual Specifications File Format Format Details: Digital PDF format, compatible with all Windows and Mac operating systems. Requires Adobe PDF Reader and WinZip (free software). Print Quality Printability: Fully printable, allowing users to print specific pages or the entire manual for workshop use. High-resolution pages for clear text and illustrations. Binding Type Binding: Digital (N/A for printed manuals) Paper Type Paper Type: Digital (N/A for printed manuals) Accessibility Device Compatibility: Accessible on desktop PCs, laptops, smartphones, and tablets via web browser or dedicated PDF reader. ⚙️ Engine Specifications Primary Engine Engine Type: Cosworth YB Series DOHC Inline-4, 16-valve Displacement: 1993 cc (2.0 Liters) Bore X Stroke: 90.8 mm x 77.0 mm Compression Ratio: 8.2:1 (approx.) Turbocharger: Garrett T3 Turbocharger with Intercooler Engine Management: Bosch L-Jetronic Fuel Injection and Ignition System Performance Horsepower: 204 PS (150 kW; 201 hp) @ 6000 rpm (European Spec) Torque: 276 Nm (204 lb-ft) @ 4500 rpm (European Spec) Fuel System Fuel Type: Unleaded Gasoline (95 RON recommended) Fuel Delivery: Multi-point Electronic Fuel Injection 🔧 Transmission Standard Transmission Type: Ford T5 Manual Transmission (5-speed) Features Drivetrain: Rear-Wheel Drive (RWD) 📐 Dimensions Exterior Length: 4430 mm (174.4 in) Width: 1755 mm (69.1 in) Height: 1380 mm (54.3 in) Wheelbase: 2605 mm (102.6 in) Weights Curb Weight: 1295 kg (2855 lbs) 🛡️ Safety Features Ratings Crash Test Ratings: Euro NCAP ratings were not standard for vehicles of this era. Focus is on chassis design and passive safety features. Active Features Brake Assist: Optional Anti-lock Braking...