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Ford Escort RS Cosworth Ford Sierra RS Cosworth Complete Workshop Service Repair Manual 1992 1993 1994 1995 1996

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🏷️ Basic Information Identification Make: Ford Model: Escort RS Cosworth / Sierra RS Cosworth Model Variant: RS Cosworth Codes Model Code Escort: ECA Model Code Sierra: GBC Generation Escort Rs Cosworth Generation: First Generation (1992-1996) Sierra Rs Cosworth Generation: Second Generation (1990-1992), third generation (1993) 👋 Introduction Market Position Target Audience: Owners of Ford Escort RS Cosworth and Ford Sierra RS Cosworth, automotive technicians, performance tuning enthusiasts, restoration specialists. Competitive Analysis Value Proposition: Provides significant cost savings for owners by enabling self-maintenance and repair, comprehensive coverage far exceeding basic owner's manuals. Key Features Ease Of Use: Step-by-step instructions with clear imagery for simplified repair processes. Accessibility: Instant download and lifelong access, usable across various devices including PCs, Macs, tablets, and smartphones. Reliability: Customer satisfaction guaranteed, ensuring a high-quality, comprehensive resource. 📋 Manual Details Coverage Areas Coverage Scope: Complete Service Repair Workshop Manual for Ford Escort RS Cosworth and Ford Sierra RS Cosworth models. Models Covered: All models, engines, trims, and transmission types for the specified years. Page Count Estimated Page Count: Extensive (Detailed page count not provided, but described as 'complete' covering all procedures A-Z). Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital File (PDF compatible) 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical (YBT and YBP variants), fuel injection, ignition, cooling, lubrication, exhaust, turbocharging systems, engine management (ECU). Drivetrain Systems: Transmission (MT75, BorgWarner T-5), clutch system, differentials, driveshafts, CV joints, all-wheel drive system (Ferguson MaxTrac). Chassis Systems: Suspension (front MacPherson struts, rear multi-link), steering (power assisted), braking system (ABS included). Electrical Systems: Wiring diagrams, lighting, starting and charging systems, instrumentation, body electricals, infotainment, safety systems. Body And Interior: Body panel repair, interior trim, seating, HVAC system, body sealing, glass replacement. Procedures Included Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt inspection and replacement. Repair Procedures: Engine rebuild, transmission overhaul, brake pad/disc replacement, suspension component replacement, electrical component diagnosis and repair, bodywork repair. Troubleshooting: Diagnostic charts, common fault finding, symptom-based troubleshooting for all major systems. Specifications And Data: Torque specifications, clearances, fluid capacities, electrical data, wiring diagrams. Technical Depth Depth Of Coverage: Comprehensive, from basic maintenance and routine servicing to complex diagnostic and repair procedures, suitable for both DIY enthusiasts and professional mechanics. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Readability: Searchable text, zoomable images, easily navigable chapters. Print Quality Print Capability: Printable by chapter or entire document, allowing for physical copy creation. Binding Type Binding Type Digital: N/A (Digital Download) Paper Type Paper Type Digital: N/A (Digital File) Software Requirements Required Software: Adobe Reader or compatible PDF viewer (free download available). ⚙️ Engine Specifications Primary Engine Escort Rs Cosworth Engine: 2.0L Ford Cosworth YBT I4 (Turbocharged, Intercooled) Sierra Rs Cosworth Engine: 2.0L Ford Cosworth YBP I4 (Turbocharged, Intercooled) Performance Escort Rs Cosworth Horsepower: 227 PS (224 hp; 167 kW) at 6,250 rpm Escort Rs Cosworth Torque: 300 Nm (221 lb-ft) at 3,500 rpm Sierra Rs Cosworth Horsepower: 220 PS (217 hp; 162 kW) at 6,000 rpm (late models 230 PS) Sierra Rs Cosworth Torque: 300 Nm (221 lb-ft) at 4,500 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (Bosch Motronic or similar) with Electronic Control Unit (ECU). Fuel Type: Unleaded Premium (95-98 RON) Cooling System Cooling Type: Water-cooled, pressurized system with thermostatically controlled fan. Lubrication System Oil Type Recommendation: Synthetic or Semi-Synthetic 5W-30 or 10W-40 (refer to manual for specific OEM recommendations). 🔧 Transmission Standard Transmission Transmission Type: 5-speed Manual Transmission. Gearbox Escort Rs Cosworth: Ford MT75 Gearbox Sierra Rs Cosworth: BorgWarner T-5 (later Sierra models) Optional Transmission Optional Transmission Type: N/A (Exclusively manual transmission for RS Cosworth variants). Features Drivetrain Layout: All-Wheel Drive (AWD) system with Ferguson MaxTrac viscous coupling. Fluid Specification Manual Transmission Fluid: API GL-4 or GL-5 SAE 75W-90 Synthetic Gear Oil (refer to manual for specific capacity and PN). 📐 Dimensions Exterior Escort Rs Cosworth Dimensions: Length: 4,226 mm (166.4 in), Width: 1,732 mm (68.2 in), Height: 1,370 mm (53.9 in) Sierra Rs Cosworth Dimensions: Length: 4,435 mm (174.6 in), Width: 1,766 mm (69.5 in), Height: 1,365 mm (53.7 in) Weights Escort Rs Cosworth Curb Weight: Approx. 1,310 kg (2,888 lb) Sierra Rs Cosworth Curb Weight: Approx. 1,350 kg (2,976 lb) 🛡️ Safety Features Ratings Safety Rating Era: Vehicles of this era did not undergo standardized crash testing like modern vehicles (e.g., Euro NCAP, IIHS). Safety was primarily based on passive restraint systems. Active Features Anti Lock Braking System: Standard ABS (Anti-lock Braking System). Traction Control: N/A (Traction control not a standard feature on these models). Passive Features Seatbelts: Three-point seatbelts with pre-tensioners (front), three-point seatbelts (rear). Airbags: Driver airbag typically standard, passenger airbag optional or model-dependent. Body Structure: Reinforced safety cell, crumple zones. 💡 Technology Features Infotainment Audio System: Factory-fitted radio cassette players with...
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Ford Escort RS Cosworth Ford Sierra RS Cosworth Complete Workshop Service Repair Manual 1992 1993 1994 1995 1996
🏷️ Basic Information
Identification
Make:
Ford
Model:
Escort RS Cosworth / Sierra RS Cosworth
Model Variant:
RS Cosworth
Codes
Model Code Escort:
ECA
Model Code Sierra:
GBC
Generation
Escort Rs Cosworth Generation:
First Generation (1992-1996)
Sierra Rs Cosworth Generation:
Second Generation (1990-1992), third generation (1993)
👋 Introduction
Market Position
Target Audience:
Owners of Ford Escort RS Cosworth and Ford Sierra RS Cosworth, automotive technicians, performance tuning enthusiasts, restoration specialists.
Competitive Analysis
Value Proposition:
Provides significant cost savings for owners by enabling self-maintenance and repair, comprehensive coverage far exceeding basic owner's manuals.
Key Features
Ease Of Use:
Step-by-step instructions with clear imagery for simplified repair processes.
Accessibility:
Instant download and lifelong access, usable across various devices including PCs, Macs, tablets, and smartphones.
Reliability:
Customer satisfaction guaranteed, ensuring a high-quality, comprehensive resource.
📋 Manual Details
Coverage Areas
Coverage Scope:
Complete Service Repair Workshop Manual for Ford Escort RS Cosworth and Ford Sierra RS Cosworth models.
Models Covered:
All models, engines, trims, and transmission types for the specified years.
Page Count
Estimated Page Count:
Extensive (Detailed page count not provided, but described as 'complete' covering all procedures A-Z).
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable Digital File (PDF compatible)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical (YBT and YBP variants), fuel injection, ignition, cooling, lubrication, exhaust, turbocharging systems, engine management (ECU).
Drivetrain Systems:
Transmission (MT75, BorgWarner T-5), clutch system, differentials, driveshafts, CV joints, all-wheel drive system (Ferguson MaxTrac).
Chassis Systems:
Suspension (front MacPherson struts, rear multi-link), steering (power assisted), braking system (ABS included).
Electrical Systems:
Wiring diagrams, lighting, starting and charging systems, instrumentation, body electricals, infotainment, safety systems.
Body And Interior:
Body panel repair, interior trim, seating, HVAC system, body sealing, glass replacement.
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt inspection and replacement.
Repair Procedures:
Engine rebuild, transmission overhaul, brake pad/disc replacement, suspension component replacement, electrical component diagnosis and repair, bodywork repair.
Troubleshooting:
Diagnostic charts, common fault finding, symptom-based troubleshooting for all major systems.
Specifications And Data:
Torque specifications, clearances, fluid capacities, electrical data, wiring diagrams.
Technical Depth
Depth Of Coverage:
Comprehensive, from basic maintenance and routine servicing to complex diagnostic and repair procedures, suitable for both DIY enthusiasts and professional mechanics.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Readability:
Searchable text, zoomable images, easily navigable chapters.
Print Quality
Print Capability:
Printable by chapter or entire document, allowing for physical copy creation.
Binding Type
Binding Type Digital:
N/A (Digital Download)
Paper Type
Paper Type Digital:
N/A (Digital File)
Software Requirements
Required Software:
Adobe Reader or compatible PDF viewer (free download available).
⚙️ Engine Specifications
Primary Engine
Escort Rs Cosworth Engine:
2.0L Ford Cosworth YBT I4 (Turbocharged, Intercooled)
Sierra Rs Cosworth Engine:
2.0L Ford Cosworth YBP I4 (Turbocharged, Intercooled)
Performance
Escort Rs Cosworth Horsepower:
227 PS (224 hp; 167 kW) at 6,250 rpm
Escort Rs Cosworth Torque:
300 Nm (221 lb-ft) at 3,500 rpm
Sierra Rs Cosworth Horsepower:
220 PS (217 hp; 162 kW) at 6,000 rpm (late models 230 PS)
Sierra Rs Cosworth Torque:
300 Nm (221 lb-ft) at 4,500 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (Bosch Motronic or similar) with Electronic Control Unit (ECU).
Fuel Type:
Unleaded Premium (95-98 RON)
Cooling System
Cooling Type:
Water-cooled, pressurized system with thermostatically controlled fan.
Lubrication System
Oil Type Recommendation:
Synthetic or Semi-Synthetic 5W-30 or 10W-40 (refer to manual for specific OEM recommendations).
🔧 Transmission
Standard Transmission
Transmission Type:
5-speed Manual Transmission.
Gearbox Escort Rs Cosworth:
Ford MT75
Gearbox Sierra Rs Cosworth:
BorgWarner T-5 (later Sierra models)
Optional Transmission
Optional Transmission Type:
N/A (Exclusively manual transmission for RS Cosworth variants).
Features
Drivetrain Layout:
All-Wheel Drive (AWD) system with Ferguson MaxTrac viscous coupling.
Fluid Specification
Manual Transmission Fluid:
API GL-4 or GL-5 SAE 75W-90 Synthetic Gear Oil (refer to manual for specific capacity and PN).
📐 Dimensions
Exterior
Escort Rs Cosworth Dimensions:
Length: 4,226 mm (166.4 in), Width: 1,732 mm (68.2 in), Height: 1,370 mm (53.9 in)
Sierra Rs Cosworth Dimensions:
Length: 4,435 mm (174.6 in), Width: 1,766 mm (69.5 in), Height: 1,365 mm (53.7 in)
Weights
Escort Rs Cosworth Curb Weight:
Approx. 1,310 kg (2,888 lb)
Sierra Rs Cosworth Curb Weight:
Approx. 1,350 kg (2,976 lb)
🛡️ Safety Features
Ratings
Safety Rating Era:
Vehicles of this era did not undergo standardized crash testing like modern vehicles (e.g., Euro NCAP, IIHS). Safety was primarily based on passive restraint systems.
Active Features
Anti Lock Braking System:
Standard ABS (Anti-lock Braking System).
Traction Control:
N/A (Traction control not a standard feature on these models).
Passive Features
Seatbelts:
Three-point seatbelts with pre-tensioners (front), three-point seatbelts (rear).
Airbags:
Driver airbag typically standard, passenger airbag optional or model-dependent.
Body Structure:
Reinforced safety cell, crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory-fitted radio cassette players with basic AM/FM, sometimes with CD changer compatibility on later models. Aftermarket upgrades common.
Driver Assistance
Cruise Control:
Optional on some trims, but not a primary feature.
Connectivity
Connectivity Features:
Very limited by modern standards. Primarily basic electrical systems, no integrated Bluetooth or navigation 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 recommendations).
Timing Belt Interval:
Every 60,000 miles (96,000 km) or 5 years, critical for Cosworth YBT/YBP engines.
Spark Plug Replacement:
Every 30,000 miles (48,000 km) or as specified by OEM (e.g., NGK PFR7B for performance).
Fluid Specifications
Coolant Specification:
Ford Super Plus 2000 or equivalent ethylene glycol-based coolant with anti-corrosion additives.
Brake Fluid Specification:
DOT 4 or DOT 5.1.
Known Issues
Turbocharger Reliability:
Proper warm-up and cool-down procedures are essential to prolong turbocharger life. Oil starvation can be critical.
Rust And Corrosion:
Common to vehicles of this age, particularly wheel arches, sills, and rear valence on Sierra models. Escort Cosworth more robust but still susceptible.
Suspension Bushings:
Wear in suspension bushings can lead to handling degradation and clunks.
Ignition System:
Coil packs and distributorless ignition systems can be sources of misfires if not maintained.
📚 Vehicle History
Brand Heritage
Cosworth Legacy:
Ford's partnership with Cosworth Engineering dates back to iconic engines like the DFV V8 and BDA, symbolizing high-performance motorsport heritage.
Model Evolution
Sierra Rs Cosworth Evolution:
Originally a 2-door saloon (1986), evolved into a 4-door (1988) and then the Sierra RS Cosworth Sapphire (1990-1992). The Escort RS Cosworth (1992-1996) was a radical redesign based on the Escort platform but heavily engineered with a Cosworth YBT engine and AWD.
Production
Escort Rs Cosworth Production Years:
1992-1996
Sierra Rs Cosworth Production Years:
1986-1992 (original Sierra RS Cosworth), 1990-1992 (Sierra RS Cosworth Sapphire)
Manufacturing Locations:
Escort RS Cosworth: Karmann factory, Osnabrück, Germany. Sierra RS Cosworth: Genk, Belgium (Ford plant).
Homologation Purpose
Motorsport Homologation:
Both models were developed with Group A World Rally Championship (WRC) and touring car racing homologation in mind.
🏆 Awards & Recognition
Recognitions
Motorsport Success:
Both models achieved significant success in rallying and touring car championships, cementing their legendary status.
Performance Car Acclaim:
Widely acclaimed as iconic performance cars of their respective eras, celebrated for their handling, power, and rally-bred pedigree.
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