“The under shield is mounted onto a front bracket
supported by two aluminium side brackets, a centre support
fitted just ahead of the suspension crossmember, and two bolts
{nto the chassis rails. A foam pad should be fitted between the
‘undershield and the suspension cross member/sump.
Shields ae also available to protect the rear floor pan,
windscreen washer bottle, rear axle and production fuel tank.
(On gravel events mudflaps are recommended.
1 Undershield, Fro Kevlar 9095489
2 Undershied Support
Bracket, Front
3. Undershiel Support
4 Bracket, Sump
Shield, Side
5 Mudfap Froot LH
Mudap Front RH
6 Bracket - Mudlap
7. Modfap Rear LH
Madfap- Rear RH
8 Undersield, 7" Axle
9 Bolt- Axle
10 Foor Pan Shield LH
11 Poor Pan Shield RH
12. Kit- Pel Tank Guard
13. Shield - Washer Bote
9093504
9098697
9095503
‘90956
9005619
9085709
9085616
9085617
05014
9083217
TBE
THE
9095501
9092971
9052972
Finis Code Comments
‘Tarmac or Gravel
oie
Use wih standard 7 axe
Geavel use
Gravel use
For st, tank
Kevlar
BLT
Pace 4
Bopy SECTION - PROTECTION SHIELDS Mliusoor, >
{tis important to check the front and rear engine mounts
regularly on rough gravel events or where the car is jumping.
‘The standard engine mount heatshield must be fitted on
the RLS. near the turbocharger to avoid heat damage to the
rubber and consequential failure.
Engine mount failure can cause the driveshafts to pull out
Ensure the bolts to the engine block are as long as possible
and correctly torqued, as block castings can crack.
FS-35
Description Finis Code Comments
Insulator Engine Mount 9085171 “Seocted’
Insulator, Rear Dif. 9094679 “Selected
Insulator -Engine Rear 9004771 “Selected
Plate Assembly, Rear 9094799 Reinforced
‘Sospenson Steady
5. Reinforcement, Body 10 9094684 Weld o bodyshell
eur Crostmember
6 Inslotar-Rear Beam 90M6TB. “Selected?
Torques
1 Front Engine Mount to Arm 908m
2 Engine Moun to Front X MBR 55Nm
3 Re Axle Mount to Axle SONm
4. Re Axle Moant to Floor 25m
5 Transmission Mount X MBR 65m
6 Rear Beam Movatngs 88m
Bopvy Section - Mountincs Pace 5 (Melo, Gg
ENGINE
‘The basic engine is virtually a carry over from the Sierra
Cosworth 4x4, but witha larger turbo, and a water-cooled
intercooler. Water injection (SS) is also fitted to the first
2500 cars. This can only be activated withthe correct EPROM.
‘As the car was homologated with water injection, the
system MUST be fitted in the car to comply with group ‘N’.
Fit the recommended injectors, and spark plugs, map
sensor and fuel pump. Set the boost to 1.5 bar peak. Excessive
boost will raise the water temperature and shorten turbo and
‘gasket life, The turbocharger will normally last for 800km
between rebuilds, Ensure air filter element is replaced
regularly in dusty conditions or if wet. Seal gaps around
radiator/intercooler with tape.
“The EPROM board asy. 9095877 can be used with or
‘without a catalyst, but the production lambda (HEGO) sensor
‘ust be connected.
“The water temperature should be approx. 90°C at 20°C
‘ambient. In warm climates, restrict the intercooler pre-cooler
water flow and run the radiator fans continuously (fit an
override switch). The intercooler spray system (ISS) will
keep the plenum temperature at 40°C (ensure container is
filled at service points) The thermostat can be modified or
replaced. Use new cylinder head bolts at each rebuild, The
sump can be baffied to reduce oil surge.
INTERCOOLER,
Fu-2
Description Finis Code Comments ay.
1 Restrctor Tubo 9098484 36mm diameter gold 1
2 CHIRATubo Core 9005477 Balanced 1
3. Compressor Hsp. 9095446 Tout restrictor 1
4 Poel Injector 9085156 ‘Green’ 4
5 EPROM Board 9093877 Level PS
6 Adaptor Jet 9085677 1
7 Ja-135. s08sse4 1
5 Water Bag 9005552 1
9 Resistor [R22 Ohms 100W 1
10 Flow Vawe 9095871 1
11 Sparking Pig S0MBE4 AGP6OL 4
12 AirPresure Sensor 9092433 -3.0Bar 1
13 Cyl Head Gasket 082431 1
ONLY SUPER UNLEADED FUEL (98 OCTANE) SHOULD BE USED
Wantepae Senig ors.
Max, Boost 15 Peak (Overboost)
‘Fuel Pressure ile) 3Bar202
Engine O1 ‘Mobil 1 (Change afer
100%)
Inlet Timing (Max. openiog) uu ATDC
Exhaust Timing (Max. opening): 10° BTDC
(Crank Sensor Gap at Paley 11-13
Spark Pig Gap 5mm
Wasteyate Restctor 8mm
SPRAY
system
ee ee
}
co
=
Pace 6
ENGine SECTION ‘The standard froot ant roll bar is 29mm on the Escor.
‘The roll bar auls must be checked for tightness regularly. The
‘ends canbe drilled and fitted with ‘R’ pins for added security.
‘Tighten suspension bolts when car ison the ground to avoid
‘wind-up, inthe bushes.
‘Track control arms and upright castings must be changed
frequently - as any wear can cause failure ofthe T:C.A. tall
pin.
Front bubs should be checked regularly and renewed after
00am, Shotpecning will help to avoid fatigue cracking.
Front bumpstop length is critical to the handling ofthe car
(see spec. sheets)
Ensure the crossmember bushes (5) are fush with the
inside face ofthe crossmember or the TCA will jam in
position making removal difficult.
Description
Bush, Track Control
‘Arm Inner
Beh, Track Control
‘Am, Outer
‘Bush, An-Roll
‘Bar Mounting
‘Mounting, Front
‘Saspension, Upper
‘Bush, Crossmember To
“Track Control Arm
ody, Front Strut
Body, Front Seut
Inser, Fone Stet
Inser, Front Sit
Insert, Front Strut
Incr, Frnt Strut
Upper Spring Seat
Lower Spring Seat
‘Locking Ring. Lower
Road Spring, Front
Road Spring, Front
Road Spring, Front
Road Spring, Front
Bumpstop-Froat
Spacer-Bumpstop
Torgues
Hub Not
‘Top Mount
‘Ati Roll Bar to Chassis
Finis Code Comments ay.
sos2364
son2349
9002347
9095389
9008758
sonata
909468
005079
9098161
‘9004860
9095502
9093328
9093179
9095481
004856
094687
sose7ia
9085297
‘Ani Roll Bar 10 Track Control Arm
“Selected”
“Selects?
“Selects?
‘Suits 29mm sol bar
aan
Pret nto crossmember
Optimised camber 2
Gravel and tarmac (Alt)
Gravel 360/140
Gravel 3807160
“Terma 500200
Tarmac 325/150
Use with 9093328
85 Nim Tarmac
‘90 N/mm Tarmac (Alt)
Gravel, 72 Nh &
(Gravel, 80 Nim (Alt)
(Cutio eired length.
om
350
2m
97Nm
ON
Front Susrension Section
Pace 7 (Moluyoor, gm
‘When building up the rear suspension, cheek the tracking.
‘The rear beam and semi-trailing arms can be reinforced
which should be 3ram toe-in. If required, slot inner joint by the addition of material. Inthe case of the rear beam, any
‘mounting holes to achieve correct figure and weld reinforcing reinforcement must follow the original shape and be in contact
‘washers in correct location. The rear springs are designed to with it.
{give the lowest ride heights required. For some events it will
‘be necessary to fit one or more spacers (item 4) above spring,
tw avoid “bottoming out’ of the suspension.
‘The production semi trailing arms on the Escort are
stronger than Sierra and fitted with uniball joints. On rough
‘gravel events check regularly for bending and cracking around
anges. Similarly, check rear hubs. Shotpeening will help
prevent fatigue cracking.
Description
Road Spring, Rear
Road Spring, Rear
Upper Spring Seat
‘Space, Upper Spring Seat
Shock Absorber, Rear
‘Shock Absorber, Rese
Shock Absorber, Rear
Insert, Damper
Insert, Damper
Damper Top
Spherical Bearing, Rear
Damper
‘Cirlip, Rear Damper
Bump Stop
Bump Stop
Spacer, Bump Stop 6mm
‘Torques
Hub Nuss
‘Trliog Arm to Beam,
Damper Mountings
Finis Code
sons
‘so8sa3
088861
‘sonsare
9093519
‘sonst6s
084859
‘092545
9093257
‘s9286
son2eis
9092536
‘9092517
9095298
Comments a.
Geavel, 78 Nl
“Tarmac, 85 Nim
Boit wo bodyshell
(Optional, for 15mm
Fide height increase
“Tarmac 4001170
‘Tarmac 3401160
Gravel 330/130
Lower inner
‘Top & lower outer
‘Use with recommended.
shock abiorbers
Use with 9092816
Off oad use 75am
“Tarmac ote SOmm
300m
95m
95m
Pace 8
REAR SusPENSION SECTION _ tito ee
FORD MOTORSPORT VEHICLE BUILD SPECIFICATION
EVENT ‘TARMAC GRAVEL
SPECIFICATION FRONT FRONT REAR
‘SUSPENSION
Springs 85. Nim 85.N/mm 72.Nienm 78Nimm
Dampers ‘500/200 400/170 380/160 350/130
Bump Rubbers Tomm + 6mm 50mm ‘94mm + 6mm. 75min + 6mm
‘Anti-Roll Bar 829mm 92mm 29mm 22mm
Blade Position - - = =
CASTOR 30" - 3°30"
‘CAMBER 300 2°00" 225 100
TOEIN 2mm 3mm. 2mm 3mm
RIDE HEIGHT 160mm 170mm 215mm 220mm
BRAKES 278mm 9273mm 9 278mm 9 273mm
Master Cylinder Disconnect ABS Disconnect ABS
[Brake PAd Material Blue Carbon Red Carbon Red Carbon Blue Carbon
CLUTCH V2" Paddle 9A" Paddle
WHEELS 8x16" 8x16" Tx16" Tx16
Tyre 9 620x 225mm 9 620x 225mm 2 660mm © 660mm
‘Compound ~ = 5 .
Pressure 2.0Bar 2.0Bar 20Bar 2.0 Bar
GEARBOX SPEC, NUMBER sos468
‘CENTRE DIFF. CHAIN RATIO. 34% Front 66% Rear 50 Nm VC.
FRONT AXLE. 9095165
REAR AXLELSD 9095164 180.Nm V.c.
NOTE: Front ride height is measured from centre line T:C.A. joint to ground on recommended tyre (A), Rear ride height is
‘measured from steady plate mounting face to ground on recommended tyre (B). Camber/castor figures quoted are
in production tolerances of #1°, Ride heights should be increased by 10 ~ 15mm on rough gravel or bumpy tarmac.
SUSPENSION SPECIFICATION Pace 9 (Mleuypor,- i
“The standard wheel size fitted to the Ford Escort RS
Cosworth is 8° x x16" with 25mm offset.
For gravel, 6" x 16" or 7” x 16" is recommended with a unrestricted. Longer studs are available to suit competition
‘maximum tyre size of 660 diameter.
For Tarmac 7° x 16" or 8* x 16" is recommended with a
tyre diameter of 620mm. Maximum tyre width in 1993 is
wheels, if required.
Description
Wheel 16° 27"
Wheel 16° 6°
Wheel 16° 8°
Wheel Si
Wheel Ns
Wheel Brace
Steeing Track Rod
‘Tye Pressures:
Torques
Wheel Nurs
‘Tack Rod lar Joint
‘Track Rod io Sig. Arm
Steering Rack Mounting
Flais Code Comments
TBE
667997
9095118
9095122
095344
Std, (Tarmac)
‘Longer than sd,
Use with 9095498
{Shown on page 3)
HD. oint
90Nm
S8Nm
30Nm
45Nm
NOTE: Remove sterng lock from stering column.
Pace 10
Wheers, Tyres AND STEERING Manger” >
‘Two grades of carbon brake pads are now available. Blue
‘carton has the higher friction, The ‘red’ carbon material is less
‘prone to brake ‘grab’ and not so aggressive to the discs. A
‘change in balance can be achieved by using different material
front and rear (i.e. red atthe rear on Tarmac will avoid rear
brake lockup.)
‘To bed in: Make a few gentle stops to remove high spots,
then several hard applications from high speed down to 30 kph
with recovery in between. Continue until fade is no longer
apparent. Drive until brakes cool down. Bed new dises with
used pads and vice versa. Check discs regularly during events.
Disconnect ABS module inside car.
For additional cooling the optional lower grille end
shields and duct covers should not be fitted.
(Catiper Mounting Hott:
BRAKES SECTION Pace 11 Mdliigooey,- ep
‘5 The Motorsport front and rear axles have been dismantled,
crack tested, shotpeened and carefully reassembled to improve
heir service life. In normal rally conditions the axles should be
‘overhauled after 600km, but ifthe car has had a puncture or
‘broken shaft the axle should be changed as soon as possible.
‘The rear VC. can be overhauled by F-F.D. at Coventry.
‘Crack test all gears at each rebuild and change casings
after 1200km to avoid fatigue cracks, See workshop manual for
rebuild procedures, Note thatthe front R.H. driveshaft joint is
‘normally retained inthe axle by a circlip.
‘The optional case for the front axle is selected for
‘maximum wall thickness to give added security on gravel
events,
Rear
Description Finis Code Comments Qy.——_Deseription Finis Code Comments Oy.
1 From Axle Assembly 9085165, 1S RearAdle Assembly” 9095164 Selected t
Complete
Service Pars for 9095164 Include:
Service Parte for 9095165
Differential Assembly 9094797 Selected gears 1
2 Crown Wheel and Pinion 9094796 Selected and shorpened 1 (Reat) Includiog
‘Set, Front Diferetat Viscous Coupling, 180 Non seing
3 Differemial Assembly, 9094798 Selected gears 17 Crown Wheel and Pinion 9094794 Selected and shotpeened 1
Pront 362:1,
4 Case- Prot Axle 9095239 Selected thickness
(ot incuded in 9095165)
——
Pace 12 Drive Line AND TRANSMISSION SECTION aaa exe
‘The Escort RS Cosworth transmission is very similar to
the Sierra 4x4, but witha slightly longer output shaft to suit
the new rubber propshaft coupling.
‘Considerable attention has been paid to gears to ensure
reliability, and the Motorsport gearbox is now fitted with the
highest quality production gears available. The centre VC. is
set at SOnm.
‘The recommended service interval is $00 km stage
mileage in normal conditions. At each rebuild cracktest all
‘gears, replace 3rd gear bearing and sleeve (6152807). Warm
sleeve before fitting to shaft. Check selector forks for wear ot
bending. Tighten countershaft bearing housing while rotating
‘transmission, unt] shaft is locked, then slacken off by one
tooth to ensure bearing preload,
‘Use a good quality synthetic gear oil. For full repair
procedure see the workshop manual (MT7S transmission
publication No. CG1S02/EN).
Check driveshaft and propshaft joints regularly and
repack with grease. When building the car, check front
You might also like
