🏷️ Basic Information Identification Make: Ford Model: Escort RS Cosworth Model Generation: Mk4 / Sierra Cosworth platform (often referred to as 'Mk5' Escort by enthusiasts due to its distinct design and performance) Production Years Covered: 1992, 1993, 1994, 1995, 1996 Codes Chassis Code: GBA (Escort) 👋 Introduction Market Position Market Niche: High-performance homologation special, rally icon, enthusiast-focused performance vehicle. Competitive Analysis Comparative Vehicles: Competed with cars like the Lancia Delta Integrale, Toyota Celica GT-Four, Mitsubishi Lancer Evolution, and Subaru Impreza WRX/STI of the era, though it was based on a front-wheel-drive platform with a converted all-wheel-drive system. Key Features Performance Focus: Designed for motorsport homologation, featuring aggressive styling, advanced aerodynamics, and a powerful turbocharged engine. Manual Advantage: Provides comprehensive, factory-accurate information for maintenance and repair, enabling cost savings and empowering owners to maintain their specialized vehicle. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service, repair, and maintenance for the Ford Escort RS Cosworth (1992-1996). Page Count Estimated Page Count: Hundreds of pages (exact count not specified, but implied to be extensive). Manual Type Type: Official Full Factory Service Repair Workshop Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine: Engine service/repair, engine control system, fuel injection, fuel system, emission system. Transmission: Transmission service/repair, differential/drive, axle. Brakes: Brake system. Electrical: Wiring diagram, electrical system. Suspension Steering: Suspension, steering. Cooling Heating Ac: Cooling system, heater/air conditioning. Body Interior: Chassis/body, interior, restraint system. Procedures Included Maintenance: General maintenance, periodic lubrication, preventative maintenance. Troubleshooting: Troubleshooting diagnostics and solutions. Repair Rebuild: Step-by-step instructions based on complete disassembly and reassembly of components. Technical Depth Depth: Comprehensive, covering basic maintenance to advanced repair procedures, suitable for DIYers and experienced mechanics. 📊 Manual Specifications File Format Compatibility: All versions of Windows and macOS. Access Method: Downloadable PDF, accessible via web browser on PC, smartphone, and tablet. Software Requirements: Adobe PDF Reader and Winzip (both free). Print Quality Printability: Printable (entire manual or specific pages). Binding Type Binding Type: N/A (Digital PDF Format) Paper Type Paper Type: N/A (Digital PDF Format) ⚙️ Engine Specifications Primary Engine Engine Code: YBT Configuration: Inline 4-cylinder, 16-valve, DOHC, turbocharged Displacement: 2.0 Liters (1998 cc) Performance Horsepower Ps: 225 PS @ 6250 rpm (early models), 220 PS (later models). Torque Nm: 300 Nm (approx. 221 lb-ft) @ 2500 rpm. Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) with Cosworth-designed turbocharger (Garrett T3/T04B). Engine Management ECM Type: Ford EEC-IV with specific Cosworth calibration. 🔧 Transmission Standard Type: 5-speed manual transaxle Optional Type: N/A (Manual transmission only) Features Drivetrain: Permanent All-Wheel Drive (AWD) with a Ferguson viscous coupling and a 50:50 torque split (variable under load). Fluid Specifications Gearbox Oil Type: API GL-4, SAE 75W-90 (specific Ford specification WSD-M2C200-B). 📐 Dimensions Exterior Length Mm: 4340 mm Width Mm: 1770 mm Height Mm: 1370 mm Wheelbase Mm: 2600 mm Weights Kerb Weight Kg: Approx. 1320 kg Gross Vehicle Weight Kg: Approx. 1750 kg 🛡️ Safety Features Ratings NHTSA Rating: Not officially rated by NHTSA in the US market as it was not sold there. Active Features Braking System: AP Racing 4-piston front calipers with 330mm ventilated discs, 280mm ventilated rear discs. ABS: Anti-lock Braking System (ABS) - standard. Passive Features Airbags: Driver airbag standard; passenger airbag optional or standard depending on market and year. Seat Belts: Three-point inertia-reel seatbelts front and rear. 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette player, optional CD player in later models. Basic sound systems for the era. Driver Assistance Features: ABS, limited-slip differential (in some configurations or aftermarket). No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist. Connectivity Features: N/A (No built-in connectivity features like Bluetooth or USB as per modern standards). 🔧 Maintenance Service Intervals Oil Change: Every 10,000 km or 12 months, whichever comes first. Spark Plugs: Replace every 20,000-30,000 km depending on type (e.g., copper vs. platinum). Check manual for specific interval. Timing Belt: Replace every 80,000 km or 5 years (crucial due to interference engine design). Fluid Specifications Engine Oil Type: Ford WSS-M2C153-E or ACEA A3/B3 compliant synthetic oil, SAE 5W-30 or 5W-40 recommended. Coolant Type: Ford specification ESE-M97B44-A (or equivalent green ethylene glycol-based antifreeze). Brake Fluid Type: DOT 4 (Ford specification WSS-M6C57-A). Known Issues Common Problems: Turbocharger wear/failure, oil leaks (rocker cover, oil cooler), coolant leaks, clutch wear, differential whine, electrical gremlins, turbo lag (inherent to some tuning stages). Performance Considerations: Requires regular maintenance due to high-performance nature; sensitive to fuel quality and proper warm-up/cool-down procedures. 📚 Vehicle History Brand Heritage Motorsport Legacy: Ford's rich motorsport history, particularly in rallying, directly influenced the development of the RS Cosworth models. Model Evolution Development Basis: Developed by Ford Europe in collaboration with Tickford and Cosworth Engineering. Based on the Ford Escort Mk5 platform but extensively re-engineered with a Sierra Cosworth drivetrain and chassis components. Production Manufacturing...