FORD SIERRA RS | COSwoRTH | and ESCORT RS |cosworTH Workshop Manual Volume | Volume IITis Morkshop Manual reproduces pages fron the Ford Sierra RS Cosworth and Ford Escort RS Cosnorth service microfiche and details techoical service information required for components not alreody covered in previously issued Oealer literature. Note that, unlike the previous issue, C6473, covering the Sterra RS Cosworth only, this manual does not include system test sections. For vehicle system tests, reference should be made to the appropriate Vehicle System Test Manual. The manual is designed prinarily for use by Ford dealerships and gives repair and adjustment procedures to-gether with conoonent illustrations, technical data ang detatis of special tools ar equipnent which way be required. The repair and adjustment procedures are intended as a quide for both the fully qualified and the: less experienced technician, The repair operations numbering sequence used n all Sections corresponds to that used in the Ford Cer Labour Time Scheaule. FOR AUL REPAIR OPERATIONS AND PROCEDURES WHICH ARE NOT DESCRIGED IN THIS MANUAL, REFERENCE SHOULD BE WADE TO THE FORD SIERRA ‘87 ONWARDS SERVICE MICROFICHE (C3144) , FORD STERRA RS COSWORTH SERVICE WICROFICHE (CG534) OR THE FORD ESCORT/ORTON ‘91 SERVICE MICROFICHE (CG15Z4) AS NECESSARY. OMNERS AND OPERATORS ARE ADVISED TO ALLOW ONLY AUTHORISED FORD DEALERSHIPS TO CARRY OUT THE MORE COMPLEX REPAIRS SUCH AS THE OVERHAUL OF A TRANSMISSION OR DIFFERENTIAL ASSEMBLY, PARTICULARLY THOSE REQUIRING SPECIALISED TOOLING AND KNOWLEDGE. REPLACEMENT PARTS Behind a11 FORD and MOTORCRAFT products are the vast resources of the worldeide Parts Supply Operattons which can supply replacenent parts made to the sane exacting standards as the original factory Fitted components. FOR THIS REASON, INSIST THAT ONLY GENUINE FORD OR MOTORCRAFT PARTS ARE USED AS SERVICE REPLACEMENTS. SPECIAL TOOLS. The Special Service Tool recognition chart given at the start of each section shows a! European sourced tools desirable or necessary to carry out a satisfactory repair. linen possible, i1Tustrations are given to assist in identifying the tool needed. Special Service Tools may be ordered Fron: V.L. Churehil1 Ltd, V. (éwener O.PLT.O.M, S.A. P.O, Box No.3 W 4018 Langenfela Povigona industriat Det Henares ‘London Road Postfach 2262 (Baap itacton) Daventry Industriestrasse 67 Parceta No. 58 Northants NAIL 4NF GERMANY 29080 Guadatajara ENGLAND SPAIN 492 Aprit 1992 FORD STERRA RS COSWORTH AND FORD ESCORT RS COSWORTH: INTRODUCTION-1FORD SIERRA RS | cosworTH| and ESCORT RS | cosworTH | Workshop Manual Volume |VOLUME T 00 ENTRODUCTION 01 FORMAT AND USAGE VEHICLE IDENTIFICATION FUEL. CONSUMPTION HEALTH AND SAFETY PRECAUTIONS ‘STANDARD PRACTICES APPLICATION AND USE OF SPECIFICATIONS SOLVENTS AND SEALERS ROAD OR ROLLER TESTING BRCRaee 11 WHEELS. AND TYRES, 12 BRAKING SYSTEN - ESCORT 12C BRAKING SYSTEM ~ STERRA 3A POWER ASSISTED STEERING - ESCORT ‘138 POWER ASSISTED STEERING - STERRA 4A FRONT AXLE AND SUSPENSION ~ STERRA 143.—FRONT AXLE, SUSPENSION AND DRTVESHAFTS - M175/4x4 14C_—FRONT AKLE”ANO SUSTENSTON ~ ESCORT 15 REAR AXLE, SUSPENSION AND DRIVESHAFT 6A MANUAL TRANSMISSION AND CLUTCH ~ BORG WARNER 168 MANUAL TRANSMISSION AND CLUTCH — MI75 VOLUME TI 21K Engine - Sierra 21B Engine - Sierra 4x4 2iC Engine - Escort 22 Ignition Systen 23 Fued System 248 Cooling System 243 Cooling System - &x¢ 258 Exhaust System 253 Exhaust System - 4x4 26 Starting system 29 Engine Hanagenent and Emission System - Sterrs 297 Engine Management ard Emission Systen - Sierra 4x4 294 Engine Management and Emission System - Escort 31 Charging System 22 Exterior Lights, Direction Indicators, Horn and Windscreen Wipers - Sierra 32k Exterior Lights, Direction Indicators, Horn and Windscreen Wipers - Escort 33 Interfor Lights, Instruments, Instrument Panel Controls - Escort 4A Heating and Ventilation - Sierra 4B Air Conditioning - Escart 43° Interior and Exterior Trim 54 Pre-Detivery and Maintenance Procedures For operations and sections not included in this manual, refer to either the Sierra 87 Microfiche or the Escort/Orion '91 Microfiche, as appropriate.FORMAT AND USAGE FORMAT AND USAGE or Index Page Format see Usage eee 187 July 1987 FORD SIERRA RS COSWORTH: SECTION 01-01FORMAT Groups wy The manual 1s divided into six main groups: 0 - Genera’ Information 2 = Engine 4 ~ Boy 1 ~ Chassis 3 - Electrical 5 ~ Maintenance Sections Each group is then sub-divided into section, eg: Group Z - Engine comprises 21 ~ Engine 23 - Fuel System 25 - Exhaust Systen 29 — Engine Management 22 - Ignition System 24 - Cooling Systen 26 - Starting System USAGE Section Contents Where applicable, each section comprises the following? Index This will be frare one of the section and is am itemised list ond page location of the content of the section. Tt also includes a list and page location of each operation covered in the section, Technical Data - A listing of essentia? information required during service and repeir operations, eg. Tightening torques, ignition timings, critica? dtnensions etc. ‘Special Service Tool Recognition - This is an (Ilustrated list of special tools and suitable equipment required to carry out the reoair procedures described. Service and Repair Operations - & series of procedures selected to give coverage of the norms! repairs undertaken in the ‘workshop. The renoval and installation of some components is not covered in detail because the procedure +s essentially simple and straight forward. Where a repair procedure is not covered, st may be for one ~ of the Following reasons: 1. The component may have heen introduced after the repair operations were issued. 2, The compnent may be classed as not repairabie due to the requirement for speciTist equipment to pngure its correct function and adjustment after repair. (Non-service [tem) 3. The component may be classed as not economical to repair, with renewal being less costiy than dismantiing and overhaul. A. The repate may be of specialist nature, possibly covered in another FORO cublication. For instance: Tyre repairs. fuel injection equipment testing, overhaul and calibration 787 duly 1987 FORD SIERRA RS COSHORTH: SECTION 01-02VEHICLE IDENTIFCATION oz Index Page Code Definition we 787 ausy 1987 FORD SIERRA RS COSWORTH: SECTION 02-01(CODE DEFINITION (cont'd) (Box 13) VERSION Provision for locally required codes by certain territories. (80x 14) eo0y coLouR A> Wisck 68 (40,632) Diamond White '73 (x80 691) Galaxy Biue $87 (XSC 21014) Burgundy ‘87 (KSC 20794) Navitine Blue ‘91 (¥SC 20094) Pacifica Blue (xsC 23600H) Tasman '86,(XSC 1903C) ‘Aqua Jade ‘91 (xSC 22600) Yerana Green '91 (XSC 2398C) Polaris Grey (XCS 2455C) Radiant Red ‘89 (XSC 251A) Mercury Grey "87 (xSC 20760) Flint Grey '89 [xSC 2228c) Crystal Slue ‘87 (xSC 2028¢) Strato Silver "91 (XSC 1056C) Spectal Vehtcles Aztec Gold ‘91 (XSC_2387C) Magenta '89 (xSC 21590) Biscayne Blue Mallard Green (xSC 2683 CH) Noonstone Siue "89 (xSC 1903C} Noondust Silver *9i (xSC 2431¢) 8 - Olmpte eokd ‘91 (x80 2231¢) For vehicles built in Britain the second digit of the paint code denotes the current model y For vehicles buflt on the continent the second digit of the paint code denotes the model year the colour was Introduced. Sox 15 EXHAUST EMISS70NS fo Exhaust Enfssion Level 33 US 0392 March 1992 FORD SIERRA/ESCORT RS COSWORTH: SECTION 02-05VENTCLE IDENTIFICATION (CODE DEF IIT CON «Box 7) sTEcRING code Tora Zor b Drive lefthand drive Right-hand drive (ox 8) ENGINE code NS Type DOWG/I-8 FFI Turbo Capacity | Titres 2.0 Power [ow (OI) 4x2 150,0 4x4 16120 (Box 9) TRANSMISSION Code 3 L 8 Type Man (5-speed) Man (5-speed) Yan (5 speed) Borg Warner TS Borg Karner MT-75 (Box 10) AXLE ‘code 3 u ‘axle ratio 3,68 3,62 (ox 41) INTERIOR TRIM Code a t % Colour Bluestone ‘Shadow ace Raven (Box 12) TYPE ist letter and Vetter ‘rd Tetter 4th & Sth letter 6th & 7th letter Year of y . - Yodel Body Type Nomotogation 20 = 2,0 litre A+ Escort. B= 3 Door 5 = 1986 Belgium & Identi fication B = Sterra F = 4 Door Luxemburg only not required 0392 Marach 1992 FORD SIERRA/ESCORT RS COSWORTH: SECTION 02-04