🏷️ Basic Information Identification Make: Ford Model: Sierra RS Cosworth Year: 1992-1996 Codes Chassis Code: GF/GL (Sierra facelift generation, 'Facelift'/'Sapphire' models) 👋 Introduction Market Position Positioning: Essential resource for owners and enthusiasts of the Ford Sierra RS Cosworth, catering to both routine maintenance and in-depth restoration. Competitive Analysis 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. Key Features 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 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Maintenance, Troubleshooting, Restoration Page Count Estimated Pages: Extensive (Specific count not provided, but described as 'highly detailed' and covering 'all major topics') Manual Type Type: Workshop Manual / Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Yes (Rebuild, troubleshooting, diagnostics) Cooling System: Yes Starting Ignition System: Yes Emission Controls: Yes Engine Controls: Yes (Including ECU diagnosis) Transmission Transaxle: Yes (Manual and potentially automatic variants) Exhaust System: Yes Fuel System: Yes (Including fuel injection) HVAC System: Yes Instrumentation Warning Systems: Yes Battery Charging System: Yes Audio Systems: Yes Lighting System: Yes Electrical System: Yes (Including extensive wiring schematics) Body Interior Exterior: Yes Suspension System: Yes Driveline: Yes (Including drivetrain components) Brakes System: Yes Steering System: Yes Procedures Included 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) Technical Depth Depth: Comprehensive (From general information to detailed component repair and electrical schematics) Level Of Detail: High (Includes substeps, notes, cautions, warnings) 📊 Manual Specifications File Format File Type: PDF Requirements: PDF Reader Searchable: Likely (Standard for modern PDF manuals, facilitating quick information retrieval) Printable: Yes (All pages are printable) Print Quality Quality: High (Implied by 'detailed illustrations, diagrams, wiring schematics') Binding Type Type: N/A (Digital format) Paper Type Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine 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) Performance 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 System Fuel Injection: Bosch Motronic Electronic Fuel Injection Fuel Type: Unleaded Premium (95 RON or higher recommended) 🔧 Transmission Standard Type: 5-speed Manual (M85 variant, typically from Getrag) Optional Type: Limited production automatic transmission variants may exist, though the manual is standard for the RS Cosworth. Features Drive Layout: Rear-Wheel Drive (RWD) with optional Limited Slip Differential (LSD) 📐 Dimensions Exterior Body Styles: Saloon (Sapphire), Hatchback (less common for RS Cosworth post-1987, but facelift models predominantly Sapphire) Weights Curb Weight: Approximately 1300-1350 kg (2866-2976 lbs) 🛡️ Safety Features Ratings 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. Active Features ABS: Yes (Standard on RS Cosworth models) Passive Features Seatbelts: Yes (Three-point inertia reel seatbelts) Airbags: Driver airbag typically optional or standard on later facelift models, not universal. 💡 Technology Features Infotainment Audio System: Factory Ford radio/cassette player, often with amplifier. Basic analog controls. Driver Assistance Cruise Control: Optional on many models, typically electronically controlled. Connectivity Connectivity Features: Limited to basic automotive electronics; no modern connectivity features like Bluetooth or USB were standard. 🔧 Maintenance Service Intervals 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. Fluid Specifications 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. Known Issues 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...