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 (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...

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Sku: 584968

Collections: ALL Ford

Availability: In stock

Tags: 1985 1986 1987 Car Cars Ford Sierra Sierra RS

Product variants

Description

🏷️ Basic Information

Identification

Make:

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:

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:

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

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

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.