🏷️ Basic Information Identification Make: Ford Model: Sierra RS Model Code: Sierra RS Cosworth / Sierra RS 500 Generation Generation Identifier: Sierra Mk III (often considered a significant evolution) Codes Production Code Range: 1992-1996 (specific to the manual's coverage, though the Sierra RS platform spanned earlier years) 👋 Introduction Market Position Market Segment: Performance Sedan/Hatchback, homologation special Competitive Analysis Key Competitors Era: BMW M3 (E30/E36), Mercedes-Benz 190E 2.3-16/2.5-16, Audi Quattro, Mitsubishi Lancer Evolution, Subaru Impreza WRX Key Features Defining Features: Cosworth YB engine, permanent all-wheel-drive, advanced chassis tuning, iconic styling, motorsport heritage Manual Utility Target User: Enthusiast owners, independent workshops, restoration specialists 📋 Manual Details Coverage Areas Coverage Breadth: Comprehensive mechanical and electrical repair and maintenance Page Count Estimated Page Count: 500+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: Cosworth YB 2.0L Turbocharged DOHC Transmission: Ford MT75 5-speed manual, BorgWarner T-5 (earlier variants covered implicitly) Drivetrain: All-Wheel Drive (4x4) system, viscous coupling unit, rear differential Suspension: Independent front (McPherson struts), Independent rear (multi-link), anti-roll bars, bushings Brakes: Front: Ventilated discs with 4-piston calipers (AP Racing on RS500), Rear: Solid discs with 2-piston calipers, ABS Steering: Power assisted rack and pinion Fuel System: Bosch L-Jetronic (early), Bosch Motronic M1.8, multi-point fuel injection, turbocharger, intercooler Electrical: Complete wiring diagrams, ECU, sensors, ignition system, charging system, lighting, accessories Bodywork: Chassis, body panels, aerodynamic aids (spoilers, splitters), interior trim, glass HVAC: Heating, ventilation, and air conditioning (if equipped) Procedures Included Maintenance Routine: Oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes Troubleshooting Diagnostics: Step-by-step diagnostic procedures for all major systems, fault code interpretation Engine Repair: Engine disassembly, assembly, head gasket replacement, piston ring replacement, valve guide replacement Transmission Repair: Clutch replacement, gear synchro replacement, bearing replacement, seal replacement Brake Service: Brake pad/disc replacement, caliper overhaul, brake line replacement, ABS system bleeding Suspension Component Replacement: Strut replacement, shock absorber replacement, bushing replacement, ball joint replacement Electrical Component Diagnosis And Replacement: Alternator, starter motor, ECU, sensor testing and replacement Turbocharger Service: Inspection, seal replacement, oil line maintenance Body Panel Alignment And Replacement: Door, bonnet, boot, fender adjustment and replacement Interior Trim Removal And Installation: Dashboard, door cards, seat removal Technical Depth Depth: Detailed overhaul procedures, factory specifications, torque values, diagnostic charts 📊 Manual Specifications File Format Digital Format: PDF Print Quality Image Clarity: High resolution, clear diagrams and photos Binding Type Binding: N/A (Digital) Paper Type Paper Quality: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Cosworth YB 2.0L Turbocharged Inline-4 Bore X Stroke: 90.8 mm x 77 mm Compression Ratio: 8.0:1 (standard RS), 7.5:1 (RS500) Valvetrain: DOHC, 16 valves, belt-driven camshafts Turbocharger: Garrett T4 (RS), Garrett T3/T04B (RS500) with intercooler Performance Horsepower: 220-225 PS (164-168 kW) for RS, 255 PS (189 kW) for RS500 Torque: 275-280 Nm (203-207 lb-ft) for RS, 360 Nm (266 lb-ft) for RS500 Redline: 6500 RPM Fuel System Fuel Delivery: Bosch L-Jetronic / Motronic, Electronic Fuel Injection (EFI) Fuel Type: Unleaded Premium (98 RON minimum recommended) Fuel Pump Type: Bosch high-pressure electric Engine Oil Recommended Oil Viscosity: 10W-40 or 15W-50 (synthetic recommended) Oil Capacity: 4.5 Liters (with filter) 🔧 Transmission Standard Transmission Type: Ford MT75 5-speed manual transaxle Optional Optional Transmission: None for RS variants, but earlier Sierras offered automatics Features Drivetrain Layout: Permanent All-Wheel Drive (RWD bias with front axle engagement) Gear Ratios Mt75: Typically: 1st: 3.15, 2nd: 1.94, 3rd: 1.36, 4th: 1.00, 5th: 0.77 Transmission Fluid Fluid Type: API GL-4 or GL-5, SAE 75W-90 (Synthetic recommended) Fluid Capacity: 2.0 Liters (MT75) 📐 Dimensions Exterior Body Styles: 3-door Hatchback, 4-door Sedan Length: 4431 mm (Hatchback) Width: 1715 mm Height: 1390 mm (Hatchback) Wheelbase: 2604 mm Weights Curb Weight: 1320-1450 kg (depending on body style and specification) Gross Vehicle Weight Rating: Approx. 1850 kg Wheel Tire Wheel Size: 15-inch (RS), 16-inch (RS500) Tire Size: 205/50 VR15 (RS), 225/45 VR16 (RS500) Wheel Bolt Pattern: 4x108 Offset: ET15 - ET25 🛡️ Safety Features Ratings Crash Test Performance: NCAP ratings not applicable to this era; performed well for its time but standards have advanced significantly. Active Features ABS: Standard (Bosch ABS II) Traction Control: Optional on some later models, not standard on all RS variants. Passive Features Airbags: Driver's airbag optional/standard depending on market and year. Seatbelts: Three-point inertia-reel seatbelts front and rear. Chassis Safety Features: Reinforced body structure, crumple zones. 💡 Technology Features Infotainment Audio System: Ford E.S.S. (Electronic Sound System) or aftermarket units common. Gauges And Displays: Comprehensive dashboard including boost gauge, oil pressure, oil temperature, voltmeter. Driver Assistance ABS System: Bosch ABS II with front and rear wheel speed sensors. Connectivity Diagnostic Ports: OBD I type connectors, specific Ford diagnostic protocols. 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles or 12 months, whichever comes first. Air Filter Replacement: Every 15,000...