Ford Escort Cosworth Ford Sierra RS Cosworth Service & Repair Workshop Manual

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🏷️ Basic Information Identification Make: Ford Model: Escort Cosworth / Sierra RS Cosworth Codes Escort Cosworth Platform Code: SE9 Sierra Rs Cosworth Platform Code: GBC (for Sierra RS Cosworth 4x4) 👋 Introduction Market Position Market Niche: Performance homologation specials, rally homologation, enthusiast vehicles Competitive Analysis Key Competitors: Mitsubishi Lancer Evolution, Subaru Impreza WRX, Lancia Delta Integrale Key Features Manual Value Proposition: Provides professional-grade repair and maintenance information for highly sought-after performance vehicles, enabling owners to maintain, repair, and potentially restore them. Vehicle Appeal: Iconic rally-bred performance cars, celebrated for their driving dynamics and turbocharged power 📋 Manual Details Coverage Areas Primary Coverage: Mechanical, Electrical, Body, Troubleshooting, Maintenance, Repair Page Count Estimated Page Count: Hundreds (specific number not provided, but described as extensive) Manual Type Type: Factory Service & Repair Workshop Manual Language Language: English (assumed based on product description context) Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Engine mechanical, tuning, lubrication, cooling, fuel injection, ignition, emissions Transmission: Manual transmission (type and variant specific, e.g., MT75 for Escort Cosworth, MT75 or BorgWarner T-5 for Sierra Cosworth) servicing, repair, and troubleshooting Drivetrain: Driveshafts, differentials (including viscous coupling for 4x4 models), hubs, wheel bearings Suspension: Front and rear suspension components, geometry, alignment, shock absorbers, springs, bushings Brakes: Brake system hydraulics, ABS (if equipped), disc and drum brake servicing, parking brake Steering: Steering rack, column, power steering system, alignment Electrical: Battery, charging system, starting system, lighting, instrumentation, ECUs, wiring diagrams, sensors, actuators, body electrics Bodywork: Body panels, chassis, doors, windows, interior trim, body repairs, corrosion protection HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection/replacement Troubleshooting: Diagnostic procedures for common and uncommon faults, fault code interpretation (if applicable), symptom-based troubleshooting Repair: Step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs Diagnostics: Advanced diagnostic techniques, use of diagnostic tools, sensor testing, ECU diagnostics Installation: Component replacement and installation, including aftermarket upgrades if covered by factory procedures Technical Depth Depth: Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds. Includes detailed wiring diagrams and troubleshooting flowcharts. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Capability: Printable (single pages or entire manual) Binding Type Binding Type: Digital (not physically bound) Paper Type Paper Type: N/A (Digital PDF) Compatibility Device Compatibility: Computers (Windows & MAC), Tablets, Smartphones License Usage License: Lifetime use, unlimited installations ⚙️ Engine Specifications Primary Engine Escort Cosworth Engine: 2.0L I4 Cosworth YBT Turbocharged (and early YBP variants) Sierra Rs Cosworth Engine: 2.0L I4 Cosworth YBD Turbocharged (later 2.0L I4 Cosworth YBP Turbocharged for 4x4) Performance Escort Cosworth Power (Typical): 220-227 bhp (varies by market and specification) Sierra Rs Cosworth Power (Typical): 204 bhp (2WD), 220 bhp (4x4) Escort Cosworth Torque (Typical): 280-300 Nm (varies by market and specification) Sierra Rs Cosworth Torque (Typical): 275-290 Nm (varies by market and specification) Fuel System Injection System: Bosch Motronic Electronic Fuel Injection (EFI) with multi-point injection Turbocharger: Garrett T3/T04E (Escort Cosworth), Garrett T3 (Sierra Cosworth) with intercooler Engine Management ECU: Ford EEC-IV or EEC-V engine control unit 🔧 Transmission Standard Escort Cosworth Transmission: 5-speed Manual (MT75) Sierra Rs Cosworth Transmission: 5-speed Manual (MT75 for 2WD, BorgWarner T-5 for 4x4) Optional Optional Transmission: None (manual transmission exclusively) Features Drivetrain Type: Escort Cosworth: Permanent All-Wheel Drive (AWD). Sierra RS Cosworth: RWD (early models), AWD (later models) AWD System: Escort Cosworth: Ferguson Formula viscous coupling center differential. Sierra RS Cosworth 4x4: Ferguson Formula viscous coupling center differential. 📐 Dimensions Exterior Escort Cosworth Length: Approx. 4,216 mm (166.0 in) Escort Cosworth Width: Approx. 1,756 mm (69.1 in) Escort Cosworth Height: Approx. 1,385 mm (54.5 in) Sierra Rs Cosworth Length: Approx. 4,465 mm (175.8 in) Sierra Rs Cosworth Width: Approx. 1,750 mm (68.9 in) Sierra Rs Cosworth Height: Approx. 1,390 mm (54.7 in) Weights Escort Cosworth Curb Weight: Approx. 1,280-1,300 kg (2,822-2,866 lb) Sierra Rs Cosworth Curb Weight: Approx. 1,275-1,375 kg (2,811-3,031 lb) 🛡️ Safety Features Ratings Safety Ratings: Euro NCAP ratings not applicable for these era vehicles. Early models often lacked advanced safety features compared to modern standards. Active Features Anti Lock Brakes: Optional on some Sierra RS Cosworth models, standard on Escort Cosworth Passive Features Airbags: Driver airbag standard on Escort Cosworth, optional/later addition on some Sierra variants. Seatbelts: Three-point seatbelts with pre-tensioners (later models) 💡 Technology Features Infotainment Infotainment Systems: Basic Ford ETR (Electronic Tuning) radio and cassette player. Later models may have CD players. Aftermarket upgrades are common. Driver Assistance Traction Control: Not typically available or advanced by modern standards. Focus is on mechanical grip and driver skill. Connectivity Connectivity Features: Limited to basic audio inputs. No modern Bluetooth or smartphone integration from factory. 🔧 Maintenance Service...

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Sku: 450963

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Tags: Car Cars Escort Cosworth Ford Sierra RS Cosworth

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Escort Cosworth / Sierra RS Cosworth

Codes

Escort Cosworth Platform Code:

Sierra Rs Cosworth Platform Code:

GBC (for Sierra RS Cosworth 4x4)

👋 Introduction

Market Position

Market Niche:

Performance homologation specials, rally homologation, enthusiast vehicles

Competitive Analysis

Key Competitors:

Mitsubishi Lancer Evolution, Subaru Impreza WRX, Lancia Delta Integrale

Key Features

Manual Value Proposition:

Provides professional-grade repair and maintenance information for highly sought-after performance vehicles, enabling owners to maintain, repair, and potentially restore them.

Vehicle Appeal:

Iconic rally-bred performance cars, celebrated for their driving dynamics and turbocharged power

📋 Manual Details

Coverage Areas

Primary Coverage:

Mechanical, Electrical, Body, Troubleshooting, Maintenance, Repair

Page Count

Estimated Page Count:

Hundreds (specific number not provided, but described as extensive)

Manual Type

Type:

Factory Service & Repair Workshop Manual

Language

Language:

English (assumed based on product description context)

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanical, tuning, lubrication, cooling, fuel injection, ignition, emissions

Transmission:

Manual transmission (type and variant specific, e.g., MT75 for Escort Cosworth, MT75 or BorgWarner T-5 for Sierra Cosworth) servicing, repair, and troubleshooting

Drivetrain:

Driveshafts, differentials (including viscous coupling for 4x4 models), hubs, wheel bearings

Suspension:

Front and rear suspension components, geometry, alignment, shock absorbers, springs, bushings

Brakes:

Brake system hydraulics, ABS (if equipped), disc and drum brake servicing, parking brake

Steering:

Steering rack, column, power steering system, alignment

Electrical:

Battery, charging system, starting system, lighting, instrumentation, ECUs, wiring diagrams, sensors, actuators, body electrics

Bodywork:

Body panels, chassis, doors, windows, interior trim, body repairs, corrosion protection

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection/replacement

Troubleshooting:

Diagnostic procedures for common and uncommon faults, fault code interpretation (if applicable), symptom-based troubleshooting

Repair:

Step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs

Diagnostics:

Advanced diagnostic techniques, use of diagnostic tools, sensor testing, ECU diagnostics

Installation:

Component replacement and installation, including aftermarket upgrades if covered by factory procedures

Technical Depth

Depth:

Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds. Includes detailed wiring diagrams and troubleshooting flowcharts.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Capability:

Printable (single pages or entire manual)

Binding Type

Binding Type:

Digital (not physically bound)

Paper Type

Paper Type:

N/A (Digital PDF)

Compatibility

Device Compatibility:

Computers (Windows & MAC), Tablets, Smartphones

License

Usage License:

Lifetime use, unlimited installations

⚙️ Engine Specifications

Primary Engine

Escort Cosworth Engine:

2.0L I4 Cosworth YBT Turbocharged (and early YBP variants)

Sierra Rs Cosworth Engine:

2.0L I4 Cosworth YBD Turbocharged (later 2.0L I4 Cosworth YBP Turbocharged for 4x4)

Performance

Escort Cosworth Power (Typical):

220-227 bhp (varies by market and specification)

Sierra Rs Cosworth Power (Typical):

204 bhp (2WD), 220 bhp (4x4)

Escort Cosworth Torque (Typical):

280-300 Nm (varies by market and specification)

Sierra Rs Cosworth Torque (Typical):

275-290 Nm (varies by market and specification)

Fuel System

Injection System:

Bosch Motronic Electronic Fuel Injection (EFI) with multi-point injection

Turbocharger:

Garrett T3/T04E (Escort Cosworth), Garrett T3 (Sierra Cosworth) with intercooler

Engine Management

Ford EEC-IV or EEC-V engine control unit

🔧 Transmission

Standard

Escort Cosworth Transmission:

5-speed Manual (MT75)

Sierra Rs Cosworth Transmission:

5-speed Manual (MT75 for 2WD, BorgWarner T-5 for 4x4)

Optional

Optional Transmission:

None (manual transmission exclusively)

Features

Drivetrain Type:

Escort Cosworth: Permanent All-Wheel Drive (AWD). Sierra RS Cosworth: RWD (early models), AWD (later models)

AWD System:

Escort Cosworth: Ferguson Formula viscous coupling center differential. Sierra RS Cosworth 4x4: Ferguson Formula viscous coupling center differential.

📐 Dimensions

Exterior

Escort Cosworth Length:

Approx. 4,216 mm (166.0 in)

Escort Cosworth Width:

Approx. 1,756 mm (69.1 in)

Escort Cosworth Height:

Approx. 1,385 mm (54.5 in)

Sierra Rs Cosworth Length:

Approx. 4,465 mm (175.8 in)

Sierra Rs Cosworth Width:

Approx. 1,750 mm (68.9 in)

Sierra Rs Cosworth Height:

Approx. 1,390 mm (54.7 in)

Weights

Escort Cosworth Curb Weight:

Approx. 1,280-1,300 kg (2,822-2,866 lb)

Sierra Rs Cosworth Curb Weight:

Approx. 1,275-1,375 kg (2,811-3,031 lb)

🛡️ Safety Features

Ratings

Safety Ratings:

Euro NCAP ratings not applicable for these era vehicles. Early models often lacked advanced safety features compared to modern standards.

Active Features

Anti Lock Brakes:

Optional on some Sierra RS Cosworth models, standard on Escort Cosworth

Passive Features

Airbags:

Driver airbag standard on Escort Cosworth, optional/later addition on some Sierra variants.

Seatbelts:

Three-point seatbelts with pre-tensioners (later models)

💡 Technology Features

Infotainment

Infotainment Systems:

Basic Ford ETR (Electronic Tuning) radio and cassette player. Later models may have CD players. Aftermarket upgrades are common.

Driver Assistance

Traction Control:

Not typically available or advanced by modern standards. Focus is on mechanical grip and driver skill.

Connectivity

Connectivity Features:

Limited to basic audio inputs. No modern Bluetooth or smartphone integration from factory.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 10,000 km (6,000 miles) or 12 months, whichever comes first. Refer to manual for specific engine variant and oil type.

Spark Plug Replacement:

Recommended at approx. 30,000-40,000 km (18,000-24,000 miles), depending on plug type and driving conditions.

Timing Belt Replacement:

Crucial for Cosworth engines. Typically 60,000-80,000 km (36,000-48,000 miles) or 4-5 years. Failure leads to catastrophic engine damage.

Fluid Specifications

Engine Oil Specification:

API SG/SH, ACEA A2/A3 rated oil, viscosity typically 5W-30, 5W-40, or 10W-40 depending on temperature. Consult manual for precise OEM recommendation (e.g., Motorcraft).

Coolant Specification:

Ethylene Glycol based antifreeze/coolant, mixed 50/50 with distilled water. Ford specification (e.g., Motorcraft Super Plus 50/50). Blue or green coolant typically used.

Brake Fluid Specification:

DOT 3 or DOT 4 brake fluid.

Transmission Fluid Specification:

MTF 94 for MT75 transmission. Check manual for specific type and capacity.

Known Issues

Rust And Corrosion:

Common issue in wheel arches, sills, and rear panel areas, especially on Sierra models.

Turbocharger Wear:

Potential for wear or failure on high-mileage vehicles, requiring rebuild or replacement.

Suspension Bushings:

Wear in suspension and steering bushings can lead to imprecise handling and noise.

ECU Failures:

EEC-IV/V ECUs can be prone to failure over time, affecting engine performance and starting.

Oil Leaks:

Common on aged engines from various seals and gaskets (e.g., cam cover, crankshaft seals).

📚 Vehicle History

Brand Heritage

Ford Motorsport:

Ford has a long and successful history in rallying and motorsport, which heavily influenced the development of these models.

Model Evolution

Sierra Cosworth Development:

Developed as a Group A homologation special for rallying, evolving from the naturally aspirated Sierra XR4i and the turbocharged Sierra XR4i.

Escort Cosworth Development:

Developed as a direct successor to the Sierra Cosworth for Group A rallying homologation, utilizing the Escort Mk5 platform but with significant mechanical and aerodynamic enhancements.

Production

Sierra Cosworth Production Years:

1986-1992 (approx. 29,000 units)

Escort Cosworth Production Years:

1992-1996 (approx. 7,145 units)

Manufacturing Locations:

Sierra Cosworth: Germany (Ford-Werke AG). Escort Cosworth: Belgium (Ford Belgium, assembly by Karmann)

🏆 Awards & Recognition

Recognitions

Motorsport Success:

Both models were highly successful in international rallying (WRC) and circuit racing, contributing to their legendary status.

Enthusiast Acclaim:

Widely regarded as modern classics and desirable performance cars, consistently praised for their driving experience and unique character.