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‘CODE DEFINITION VENTCLE IDENTIFICATION (ox 1) NATIONAL TYPE APPROVAL NUMBER A-unique code required by certain territories. Box 2) VEHICLE IDENTIFICATION NUMBER (VEN) eg Sterra 4-door saloon, manufactured fn Genk, West Germany during September 1989, Digit 1): Constant asterisk - (*) A) (Otgit 2 = 4): World Manufacturer Indicator Ford Werke A.G. - West Germany - WFO (European vehicles) - WF1 (Federal vehicles) BB ~ Satoon 3 door saloon AN ~ Escort Cosworth BAG) (Digit 5 & 11): Model Yariant: BF - Sierra 4 door satoon ©} WWigit 6 £7): Constant x 1) (Digit a): Product Source Company:- G ~ Ford of Germany ~ Own assenbly ED (Dtgft 9): Assembly Phant:- B ~ Genk £) (Digit 10): Model_Range:: A= Escort B ~ Sterra W)_(oigit 12): Date of Manufacture - Year:- — G ~ 1986 1987 J - 1998 k = 1989 i990 = 1991 We 1992 1993 1) (Digit 13): Date of Manufacture - Month JAN-FEB MAR APR__MAY UN vu G SEPT 1988 8 R a 6 c k D E L y s T 1989 a u 4 ’ 5 R A 6 ¢ K D é 1990 L y s 1 a u N P 8 Rg A 6 1991 c kK a E u Y s T a u 4 P 1992 8 R a 6 € K 5D E L y 8 1 1993 3 u " , 5 R a 8 c k a E 2) (Digit 14 ~ 18): Vehicle Sequence Wumber:- Five digits. (ight 19); Gonstant asterisk ~ (*) {Box 3) GROSS VEHICLE MASS Indicates maxtmun Tegal laden mass, in territories where this 1s required. (Box 4} GROSS TRAIN NASS Indicates the maximun conbined mass of vehicle and trailer or caravan. (Box §) PERMITTED FRONT AXLE LOADING Maximum permfssible load on the front wheels of the vehicle. (ox 6) PERMITTED REAR_AKLE LOADING Naxinun pernissible Toad on the rear wheels of the vehicle. March 1992 FORD SIERRA/ESCORT RS COSWORTH: SECTION 02-03COE DEFINITION iehicle Identification (VIN) Plate Location ‘The vehicle identification plate which is rivetted to the front upper cross-menber of each vehicle has ‘enbossed alpha-nunerical codes which are explained on the following page. These codes indicate details of vehicie specifications {n respect of type, permissible loading weights, engine, gear ratio, body paint colour, trim within the vehicle etc. they are therefore useful when procuring replacenent parts, During production the two-language plate was replaced by a four-language plate. Both versions are shown in Fig.l. irs ae C22] fe ple wy a R THEE WN AEG ERO COS-06-02 1 Figel VIN Plate Location (Both two and four-language versions shown ~ Sierra {Ilustrated) . 0392 — March 1992 FORD STERRA/ESCORT RS COSHORTH: SECTION 02-02FUEL CONSUMPTION oa Index Page Fuel Consumption «vse wee Simylated Urban Oriving ewe ee Consumption Data we eee 3 787 duly 1987 FORD STERRA RS COSWORTH: SECTION 04-01FUEL CONSUMPTION Legat requirenents in certain territories require that, for new passenger cars. official fuel consumption Figures are included in service literature intended for presentation to the first purchaser of the vehicle. Acopy of the official fuel consumption figures for Sterra RS Cosworth madeTs 48 published on page -03., ‘The fuel consumption of each class of car 1s determined in accordance with specified test procedures and three sets of data are given. a) Simulated Urban Driving (ECE 15 cycle, see below for details) b) Constant Speed Driving at 90 ke/n (56 mph) ©) Constant Speed Driving at 120 km/h (75 mph) A pastenger cor. prapared for testing shal? have bean run-in and driven for at Least, 3000 ba (1075 miles), it shat! be clean, nave Its windows and air intakes closed, have any manually controlled device on the carburettor inlet in the "Sumer" position, have in use only the equippent necessary for normal operation, have {ts heating system or air conditioner system switched off and have any terperature controlled radiator fan or any supercharger in the normal operating condition. The tyres shall be of atype normally fitted and inflated to the manufacturer's recomended pressures. In addition to the above, the driving weight of the car, the type of fuel used, the Tubricants used and ‘the anbfent air conditions during the test are controlled by the Regulations. SIMULATED URBAN DRIVING Vehicle kane, 60) 40| 30] w , Nf oie 2328 49~Bt Ca 143 155163 176 188195 waieaio Time - Seconds Fig.l. Simulated Urban Driving (ECE 15 Cycte) The test cycle shown in Fig.l. can be described as follows: Idle for 11 seconds, accelerate in Ist gear to 15 kn/h (9,4 miles/h) in 4 seconds, maintain this for 8 seconds, decelerate to rest in § seconds. Idle for 21 seconds, accelerate to 32 ka/h (20 nfles/n) tn 2'seconds (changing fron Ist to 2nd gear at 15 kev/h) hold this speed for 24 seconds, decelerate to, rest in ll seconds. Idle for 21 seconds, accelerate to 50 kn/h (31,2 miles/h) in 26’ seconds (changing fron ist to 2nd gear at 15 km/h and 2nd to 3rd gear at 35 km/h), hold this speed for 12 seconds, decelerate to 35 kavh (21,9 miles/hi in 8 seconds and hold this'speed for a further 13 seconds, ‘change to and gear and deceleraté to rest in 12 seconds. Idle for a final 7 seconds. This cycle should be carried out five tines to ensure that the vehicle 1s at normal operating temperature. The conplete fuel consumption test check comprises six consecutive test cycles, after the engine is at normal gperating temperature, carrted out without interruption. The totdl vast cycle ting {5 19,5 winutes, average speed is 19 km/h (11,9 miles/h) and the distance covered 1s 6,075 km (3,77 miles}. 787 duly 1987 FORD SIERRA RS COSWORTH: SECTION 04-02OWNER LITERATURE To comply with the requirements of certain territories, Owner Handbooks contain offfctal fuel consumption figures. FUEL CONSUMPTION FIGURES For reference purposes, the official fuel consumption figures for Sierra RS Cosworth vehicles are provided below. These figures were correct at the time of going to press. The consumption figures are ‘the sane for ail trim levels of a particular engine variant, except where otherwise stated. NOTE: AIT references to ‘gadlons‘ are {mperial gallons (1,2 U.S. Gallons). The results do not express or imply any guarantee of the fuel consumption of any particular car. Individual vehicles are not tested and there are inevitably differences between different cars of the same model. In addition, any car may incorporate particular modifications. Furthermore the driver's Style and road and traffic conditions, as well as the extent to which the car has been driven and the standard of maintenance, will all affect its fuel consunptfon. FUEL CONSUMPTION MODEL/ —-«BODY_«=«TAANS- FINAL TYRE EMIS. Mies per Gallon Litres per 100 kw ENGINE STYLE. «MISSION ORTYE SIZE LEVEL A Be a Be 2,0 Sierra Saloon Man S-sp 3,64 205/S0VRxLS 18:08 22,8 38,2 30,1 12,4 7,498 DOCH Turbo Hatch. 2,0 Sierra Saloon Man Susp 3,64 205/SOVRKI5 22,1 35,3 27,7 12,8 8,0 10,2 DOHC Turbo Hotch. 2,0 Sierra Seloon Man S=sp 3,64 205/S0VRK15 22,1 37,2 Wb 12,8 7,6 9,3 DOHC Turbo Notch. 4x4 2,0 Sierra Saloon Man S-sp 3,64 205/S0VRK1S 63 US 20,8 34,5 28,3 13,6 8,2 10,0 Bye Turbo Noten. Escort 2,0 Saloon Man S-sp 3,64 208/S0VRxIS 83 US 22,8 33,6 30,1 12,4 8,4 94 SoHE Turbo Hatch. x A ~ Simulated Urban Driving (ECE 15 cycte) 8 = Constant Speed Driving at 56 mph (50. km/h} C= Constant Speed Driving at 75 mph (120 km/h) 0302 Narch 1992 FORD SIERRA/ESCORT RS COSWORTH: SECTION 04-03PRECAUTIONS HEALTH AND SAFETY PRECAUTIONS Index Health and Sefety Precautions Acids and Alkatis Adhesives and Sealers sntifreeze 6 Brake and Clutch Fluids. Chenical Materials - Seneral Choro luracarbon (CFC) Corrosion Protection Materials busts ewe Electric Shock © weve Engine 011s eee we Exhaust Fumes 2 ee oe Fibre Insulation... « Mee First Aid Flurolastoner Foams - Polyurethane... fuels ee Gas Cylinders .. General Workshop Tools and Equipment legal Aspects sews Lubricants and Greases, Wise Paints ose Solder. an Solvents eee Suspended Loads Viton ss wee Welding se warning Symbols. 05 Page . 3 0302 Maren 1992 FORD STERRA/ESCORT RS COSWORTHS SECTION 05-01> HEALTH AND SAFETY PRECAUTIONS HEALTHC AND SAFETY PRECAUTIONS Many of the procedures associated with vehicle maintenance and repair involve physical hazards or other risks to health. This section Tists, alphabetically, ‘sone of these hazardous operations and the natertais and equipment associated with ‘thea. The precautions necessary to avold these hazards are identified. ‘The list {s not exhaustive and all operations and yrocedures, and the handling of materials, should Bevcarried’ovt with health aod WEALTH AND SAFETY PRECAUTIONS 0 NoTS Do _not mtx chemical matertals except in accordance ‘WIEN the manufacturers {nstructions; some Chemicals can form other toxic or harmful chemicals; give off toxfc or harmful funes; become explosive, when mixed together. Do not spray chemical materials, particularly ‘Those based on solvents, in contined spaces e.g. when people are inside a vehicle. Do not apply heat or flame to chemical matertals ‘xcept in accordance {th the manufacturers! Sone are highly inflaemable and se toxic or harmful funes. No not Teave containers open. Funes given off fan BUITd up to toxic, harmful or expiosive concentrations. ‘Sone’ fumes are heavier than air and wit] accumulate in confined areas, pits etc. Bo not transfer chemical materia?s to unlabelled ners. Do not clean hands or clothing with chemicals. Thenfcals, particularly solvents and fuels wil} Gry the skin and may cause irritation and dermatitis. Sone can de absorbed through the skin fn toxic ar harmful quantities. Do not use emptied containers for other materials ‘except when they have been cleaned under supervised conditions. Do not sniff or smelt chemical materials. Brief ‘Expoture to high concentrations of fumes can be toxic or harsful.. CCHLOROFLUOROCARBONS. (CFC) There is concern in the scfentific comunfty that GFC'S and Halons are depleting the upper ozone Vayer which fiters out haraful ultraviolet radiation. Decreased filtration of ultraviotet radiation may result in increases in skin cancer, cateracts and imune system suppression in humans, as well as decreased productivity of crops and aquatic systens. CFC's are used primarily as a refri vehicle air conditioning systems ani propelient. Halons are used as fire ‘extingui shants. rant in a5 an aerosol Ford supports worldwide elimination of CFC usage and it 1s recomended that Conpany subsidiaries and affflifates should phase out CFC usage as soon as acceptable substitutes are commercfably avai lable. CLUTCH FLUIDS - See Brake and clutch fluids. CLUTCH LININGS AKD PADS ~ See Asbestos. 0392 CORROSION PROTECTION MATERIALS - See Solvents, ire. Highly flanmable, flammable ‘These materials are varied and the manufacturers instructions should be followed. They may contain solvents, resins, petroleum products etc. Skin and eye contact should be avoided. They should only be sprayed in conditions of adequate ventfiation and not #n confined spaces. CUTTING ~ See Kelding DEWAXING ~ See. Solvents and Fuels (Kerosene) busts: Powder, dusts or clouds may be irritant, harmful for toxic. Avoid breathing dusts fron powdery chemical materials or those artsing from dry abrasion operations. Wear respiratory protection if ventilation {s fnadequate. Fine dusts of conbusttble material can present an explosion hazard in high concentrations and in the presence of sources of ignition. ELECTAIC SHOCK Electric shocks can result from the use of faulty electrical equipment or fron the misuse of equipment even in good condi tion. Ensure that electrical equipment {s maintained in good condition and frequently tested. Ensure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise danaged. Ensure that electric equipment 1s protected by a fuse of the correct rating. Never misuse electrical equipment and never use equipment which {s in any way faulty. The results could be fatal. Ensure that the cables of mobile electrical ‘equipment cannot get trapped and damaged, such as ina vehicle hoist. Use air operated mobile equipment where possible in preference to electrical equipnent. In cases of electrocution: + switch off electricity before approaching victim = if this 1s not possible, push or drag victim from source of electricity using dry non-conductive material ~ commence resuscitation 1f trained to do so = SUMMON MEDICAL ASSISTANCE ENGINE OILS ~ See Lubricants and Greases March 1992 FORD STERRA/ESCORT RS COSWORTH: SECTION 05-04HEALTH AMO SAFETY PRECAUTIONS EXHAUSTS Acids ~ See Acids and Alkalis Catalytic systems may be subject to the build up of a smal} anount of sulphuric acid inside the converter. Care should be taken when removing Converters so that no spillage occurs. Funes ‘These contain asphyxtating, harmful and toxic chemicals and particles such as carbon oxides, nitrogen oxides, aldehydes, lead and aromatic hydrocarbons. Engines should only be run under conditions of adequate extraction or general ventilation and nat in confined spaces. Systems Catalytic systems operate at extremly high temperatures. Care should be taken when handl ing these systems by the use of heat resistant gloves. Gasolene (petrol) engine There may not be adequate warning properties of odour or irritation before imediate and delayed toxic or harmful effects arise. Diesel engine Soot, discomfort and irritation usually give Adeqiate warning of hazerdous fune concentrations. FIBRE INSULATION ~ See Dusts Used in nofse and sound insulation The fibrous nature of surfaces and cut edges can cause skin irritation. This 1s usua}ly a physical and not a chenfcal effect. Precautions should be taken to avoid excessive skin contact through careful organisation of work Practices and the use of gloves. FIRE ~ See Melding, Foans, Legal Aspects Many of the materials found on or associated with the repair of vehicles are highly flammable. "Some give off toxic or harnful funes if burnt. Observe strict fire safety when storing and handling flammable materials or sotyents, particularly near electrical equipment or welding processes. Ensure before using electrical or welding equipment, that there is no fire hazard present. Haye a suitable Fire extinguisher available when using welding or fieating equipnent. 0392 FIRST ALD Apart from meeting any legal requirements, it 1s desirable for someone in the workshop to be trained in first aid procedures. Splashes in the eye should be Flushed carefully with clean water for at least ten minutes. Sofled skin should be washed with soap and water. Indtvidual's affected by fnhalation of gases, funes etc. should be renoved to fresh air immediately. Lf effects persist, consult doctor. If Tiguids are swallowed inadvertantly, consurt a doctor giving him the information on the Container or Tabet. Do not induce vontting unless ‘this action is indicated on the label. FLUOROELASTONER ~ See ‘Viton'. FOAHS ~ POLYURETHANE - See Fire Used in sound and noise insulation. Cured foams used in seat and trim cushtoning. Closed cet] rigid foam used in lower ‘A' piliars. Fotlow manufacturers instructions Unreacted components are irritating and may be harmful to the skfn and eyes. Wear gloves and goggles. Individuals with chronic respiratory diseases , astima, bronchial medical problems, or histories of allergic diseases, should not work with or near uncured matertais. The components, vapours, spray mists can cause direct irritation, sensitivity reactions and my be toxic or harmful Yapours and spray mists must not be breathed. These materials must be applied with adequate ventilation and respiratory protection. Do not renove respirator irmediately after spraying, wait until vapour/mists have cleared. Burning of the uncured components and the cured foams can generate toxic and harmful funes. Seoking, open flares or the use of electrical equipment during foaming operations and untit vapours/nists have cleared should not be allowed. Any eat cutting of cured foans or partialty cured foans should be conducted with extraction ventf lation (see Body Section 44 Legal and Safety aspects). March 1992 FORD SLERRA/ESCORT RS COSWORTH: SECTION 05-05<> WEALTH AND SAFETY PRECAUTIONS FUELS ~ See Fire, Legal Aspects, Chemicals ~ General, Solvents Avoid skin contact with fuel where possible. Should contact occur, wash the affected skin with soap and water. Gasolene (petrol) Highly flamable. Observe “NO SHOKING" signs. Swal toning can result in mouth and throat frrftation and absorption fron the stomach can result in drowsiness and unconsciousness. Smal} arounts can be fatal to children. Aspiration of Mauid into the lungs e-g. through vomiting, fs 3 very serfous hazard. Gasolene dries the skin and can cause irritation and dermatf tis on proionged or repeated contact. Liquid in the eye causes severe smarting. Motor gasolone nay contain appreciable quantities of benzene, which 1s toxic upon inhalation, and the concentration of gasolene vapours must'be kept very low. High concentrations will cause eye, nose and throat {rritation, nausea, headache, depression and syaptons of drunkentess. Very high concentrations wiN! result {n rapid toss of ‘consciousness Ensure there is adequate ventilation when handling and using gasolene. Great care must be taken to avotd the serious consequences of inhalation in ‘the event of vapour build up arising fron spitlages 1m confined spaces. Specia) precautions apply to cleaning and maintenance operations on gasolene storage tanks. Gasolene should not be used as a cleaning agent. Tt must not be siphoned by mouth. See First Aid. Kerosene {paraffin} Used also as heating fuel, solvent and cleaning agent. Flannable. Observe °NO SMOKING" signs. Irritation of the mouth and throat may result fron swallowing. The main hazard from swallowing arises if liguld aspiration into the lungs occurs. Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye may be slightly irritating. 0382 In noraat circumstances, the low volatility does not give rise ta harmful vapours. Exposure to nists and vapours from kerosene at elevated temperatures. should be avotded (mists my arise in dewaxing). Avoid skin and eye contact and ensure there {8 adequate ventilation. Gas-o11 (Diese? fuel) - See Fuels (Kerosene) Conbustibie Gross or prolonged skin contact with high boll ing s-D178 pay algo cause serious skin disorders including skin cancer. GAS CYLINDERS - See Fire Gases such as oxygen, acetylene, argon and propane are normally stored fn cylinders at pressures of lup to 2000 Tb/in2, (13,790 kn/me) and great care should be taken in handling these cylinders to avotd mechanfeal damage to them or to the valve gear attached. The contents of each cylinder’ shoutd be clearly identified by appropriate narkings. Cylinders should be stored in well ventilated enclosures, and protected fron ice and snow, or direct sunifght. Fuel gases (e.g. acetylene and Propane) should not be stored 14 close proximity ‘to oxygen cylinders. Care should be exercised to prevent leaks from gas cylinders and Vines, and to avoid sources of ignition. Only trained personnel should undertake work involving gas cylinders. GASES ~ See Gas Cylinders GASKETS (Flouroelastner} ~ See ‘Viton’ GAS SHIELDED WELDING ~ See Welding GAS WELDING ~ See Welding March 1992 FORD SIERRA/ESCORT RS COSWORTH: SECTION 05-06WEALTH AND SAFETY PRECAUTIONS GENERAL WORKSHOP TOOLS AND EQUIPMENT It is essential that all tools and equipnent are maintained in good condition, and the correct safety equipment used where required. Never use tools or equipment for any purpose other ‘than that for which they were designed. Never overload equipment such as hofsts, Jacks, axle and chassis stands or lifting slings.” Damage caused by overloading 1s not always inmediately apparent and may resuit in a fatal failure the next tine ‘that the equipment 1s. used. Do not use damaged or defective tools or equipment, particularly high speed equipment such ag grinding wheels. A damaged grinding »neel can Ulsintegrate without warning and cause serious njury. Wear suitable eye protection when using grinding, chiselling or sand blasting equfpnent.. Wear a suitable breathing mask when using abrasive blasting equipment, working with asbestos based ateriais or using’ spraying equipment. Ensure adequate ventilation to control dusts, nists and fures. SLES - See Adhesives and Sealers. HALON ~ See CFC's HIGH PRESSURE ATR, LUBRICATION AND OIL TEST EQUIPMENT. See Lubricants and Greases . Always keep Mgh pressure equipment in good condition, and regularly maintained, particularly at joints’ and unions. Never direct a high pressure nozzle, eg diese) injector, at the skin as the fluid may penecrate fo the nder-Lying tissue ate, and cause sertous injury. LEGAL ASPECTS. Many Jaws and regulations make requirements relating to health and safety in the use of materials and equipment in workshops. Sone of ‘these laws which apply in the U.K. are listed. Similar laws exist for other territories: # The Factories Act (1961) The Asbestos Regulations (1969) © Mighty Flammable Liquids and Liquified Petroleum Gases Regulations (1972) © Control of Pottution Act (1974) © Health and Safety at work Act (1974) 0392 4 The Class{ fication, Packaging and Labeling of Dangerous Substances Regulations (1978, 1981,1983, 1986) # Control of Lead at Work Regulations (1980) © Control of Substances Hazardous to Health (COSHH) Regulations (1989) © Abrasive Wheels Regulations (1970) Workshops should be faailiar, in detail, with ‘these and assoctated laws and regulations. Consult Tocal factory inspectorate If in any doubt. LUSRECANTS AMD GREASES Ayoid 211 prolonged and repeated contact with mineral oils. All lubricants and greases may be irritating to the eyes and skin. Used Engine Oils Prolonged and repeated contact with mineral of? Wil] result tn the removal of natural fats fron the skin, leading to dryness, freitation and dermatitis. In addition, used engine of1 contains potentially harmfu? contaminants which may cause skin cancer, Adequate means of skin protection and washing facilities must be provided. Do not employ used engine of1s as Tubricants or for any application where apprectable skin contact is likely to occur. ‘There are publications describing the problems and advising on preceuttonary measures. For the U.Kke a typfcal Health and Safety Executive pubifeatton ts: SiN 397 : Cautfonary Notice: Effects of mineral of1 on the skin. Health protection precautions # Avoid prolonged, excessive or repeated skin contact with used engine ofls ~ where necessary wear protective clothing ¢ Kear protective clothing, Including tapervtus gloves where practicable. #0 not pull oily rags in pockets. 4 Avoid contaminating clothes, particularly underpants, with of. Heavily soiled clothing and of1~impregnated Footwear should not be worn. Overalls must be cleaned reguiarly. 4 First Aid treatnent should be obtained immediately for open cuts. and wounds. 1 Use barrier creams, applying then before each work period, to help the removal of oi] from the skin, Wash with soap and water to ensure all of1 is renoved (skin cleansers and nail brushes wil1 help]. Preparations containing Tanolin replace ‘the natural skin oils which have been renoved. March 1992 FORD SIERRA/ESCORT RS COSWORTH: SECTION 05-07=> HEALTH AND SAFETY PRECAUTIONS LUBRICANTS AND GREASES (Cont'd) #0 not use gusolene (petrol), kerosene (paraffin), diesel fuel (gas'of1}, thinners or solvents for cleantng skin. © If skin discorders develop, obtain medical advice without delay. # iiera practicable, degrease components prior to handling. # ihere there is a risk of eye contact, eye protection should be worn, for exanpie, chemcat goggles or face shields; in adgitfon an eye wash Facility should be provided. Envtronmenta? Precauttons Burning used engine of1 in small space heaters or botlers can be recomended only for units of approved design. In the UK the heating system must meet the requirements of HM Inspectorate of Pollution for saall burners of Tess than 0,4 MM. If in doubt check with the appropriate loca? authority and/or manufacturer of approved appliance. Dispose of used of1 and used of1 filters through authorised waste disposal contractors to licensed waste disposal sites, or to the waste off reclamation trade. if in doubt, contact. the relevant Yocal authority for advice on disposal facilities. It 1s {legal to pour used of7 on to the ground, down sewers or drains, or into water courses. worse Sone operations e.g. sawing, discing, proximity to engines under load, or at high speeds, may produce high noise levels which could, in tine, damage hearing. In these cases, suitable ear protection must be worn. NOISE INSULATION MATERIALS = See Foans, Fibre insulation, "0" RINGS (Fluarolastoner} - See ‘Viton* PAINTS - See Solvents. Chemical Materials ~ General. Highly flamable, Flammable. signs. Observe "NO SMOKING” One Pack. Can contain harmful or toxic pigrents, ‘riers and other components as well as solvents. Spraying should only be carried out with adequate ventilation. TwocPack. Can also contain harmful and toxic ‘unreacted resins and resin hardening agents. The nanufacturers instructions should be followed and ‘the section on page 05-02 covering Resin Based Adhesives, Isocyanate containing Adhesives and Foams, should be consulted. 90392 Spraying should preferably be carried out in exhausted ventilated booths removing vapour and spray mists from the breathing zone. Individuals. working in booths should wear respiratory protection. Thase doing small scale repair work jim the open workshop should wear air-fed respirators. PAINT THINNERS ~ See Solvents PETROL ~ See Fuels (gasolene} PRESSURISED EQUIPMENT = See High Pressure Air, Lubrication and O11 test equipment. RESISTANCE WELDING ~ See Welding SEALS AND SEALERS - See Adhesives, Sealers and "Viton" SOLDER ~ See Yelding Solders are mixtures of metals such that the nelting point of the mixture 1s below that of the constituent metals (normally lead and tin). Solder application does not normally give Mse to toxic lead fumes, provided a gas/atr flame ts used. Oxy-acetyiene flames should not be used, as they are much hotter and will cause lead funes’ to be evolved. Sore fumes may be produced by the application of any flane to surfaces coated with grease etc. and inhalation of these should be avoided. Renoval of excess solder should be undertaken with care, to ensure that fine lead dust 1s not produced, which can give toxic effects {f inhaled. Respiratory protection may be necessary. Solder spillage and filing¢ should be collected ‘and renaved promptly to prevent general air contamination by Tead. High standards of personal hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust fron clotning. SOLYENTS ~ See Chemica} materials ~ General Fuels. (kerosene), Fire. e.g. acetone, white spfrtt, toluene, xylene, trlehleroethane. Used in cleaning materials, dewaxing, paints, plastics, resins, thinners etc. Sone nay be highty flanmable or flamable. March 1992 FORD STERRA/ESCORT RS COSWORTH: SECTION 05-08=> HEALTH AND SAFETY PRECAUTIONS SOLVENTS (cont'4) ‘Skin contact wil] degrease the skin and may result in irritation and dermatitis following Fepeated or prolonged contact. Sone can be absorbed through the skin in toxic or harmful ‘quantities. ‘Splashes in the eye may cause severe irritation and could lead to loss of viston. Brief exposure to high concentrations of vapours or mists will cause eye and throat trrdtation, drowsiness, dizziness, headaches and in the worst circumstances unconcfousness Repeated or prolonged exposure to excessive but Tower concentrations of vapours or mists, for which there might not be adequate warning indications, can cause more sertous toxic or harnful effects. Aspiration into the lungs (e.g. through vomiting) fe the most serfous consequence of syallowing. Avold splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary. Ensure good ventflation when in use, avoid breathing funes, vapcurs and spray mists and keep contatners tightly sealed. 00 not use in confined spaces. When spraying materfals containing solvents, e.g. paints, adhesives, coatings, use extraction ventilation or personal respiratory protection ‘in the absence of adequate general ventilation. Bo not apply heat or Flame except under spect fic and detailed manufacturers’ instructions. SOUND INSULATION See Fibre insulatfon. Foans. ‘SPOT WELDING - See Welding. SUSPENDED LOADS. There is always a danger when loads are lifted or suspended. Never work under an unsupported suspended or ratsed Toad e.g. suspended engine, etc. 0392 Always ensure that 1ifting equipment such as Jacks, holsts, axle stands, stings, etc. are Adequate and suitable for the job, in good condition and regularly maintatned. Never iaprovise Tifting tackle. UNDERSEAL ~ See Corrosion Protection. viTow In common with many other manufacturers vehic some components Fitted to the FORD range have '0) ings, seals or gaskets which contain a material known’as ‘Viton’. Viton is a fluorolastomer, that {s synthetic rubber type which containg Fluorine, It is emmonty used for. '0" rings, gaskets and seats of all types. Although Viton is the most well known fluorolastoner, there are others, including Fluorel and Tecmoflon. When used under design conditions flucroiastoners are perfectly safe. If, however, they are exposed to temperature tn excess of 400°C, the material wil] mot burn, but will decorpose, and one of the products Formed 1s hydrofluoric acid. This actd fs extremely corrosive end almost Imossible to renove once St hes contaninated the skin. 40" ings, seals or gaskets which have been exposed 6 very high temperatures will appear charred or as a black sticky substance. D0 NOT, under any efrcumstances touch then or the attached components. Enquiries should be made to determine whether Viton or any other fluorolastomer has been used in the affected 'O' ring, seal or gasket. If they are of natural rubber or’nitrile then there Is no hazard. If in doubt, assume the material may be Viton or another fluorotastoner. The affected area should be decontaninated before commencing any work. Disposable heavy duty plastic gloves should be worn at all times, and ‘the affected area washed down using wire wool and 2 Timenater (calcium hydroxide) solution to neutralize the acid before disposing of the residue. After use, the plastic gloves should be discarded carefully and safely. March 1992 FORD SIERRA/ESCORT RS COSWORTH: SECTION 05-09HEALTH AND SAFETY PRECAUTIONS WELDING ~ See Fire. Electric Shock. Gas Cylinders. Welding processes include Resistance Welding (Spot Welding), Are Helding and Gas elding. Resistance Heldin THE proceTs Toy cause particles of nolten neta? to be emitted at high velocity, and the eyes and skin aust be protected. Are Welding THIS process emits a high Tevel of ultra-violet radiation which may cause arc-eye and skin burns to the welder and to other persons nearby. Gas~ shielded welding processes are particularly hazardous in this respect. Personal protection rust be worn, and screens used to shield other people. Metal spatter will also occur, and appropriate eye and skin protection 1s necessary. ‘The heat of the welding arc will produce fumes and gases fron the metals being welded, the rods and Fron any applied coatings or contamination on the surfaces being worked on. These gases and fures may be toxic and {nhatation of these should be avoided. The use of extraction ventilation to renove the funes fram the working area may be necessary partfcularly in cases where the general ventilation is poor, or where considerable weldin work 15 anticipated. In extreme cases or confine Spaces where adequate ventilation cannot be provided, air-fed respirators may be necessary. Gas Welding (and cutting) Oxyoacetylene torches may be used for welding and cutting, and special care must be taken to prevent leakage of these gases, with consequent risk of fire and exploston. The process will produce metal spatter and eye and skin protection 1s necessary. The flame is bright, and eye protection should be used, dut the ultra-violet emission is much less than”that from arc welding, and lighter filters my be used. ‘The process itself produces few toxic fumes, but such funes and gses may be produced from coatings fon the work, particularly during cutting avay of damaged body parts, and inhalation of the funes should be avoided. 0392 In brazing, toxic fumes may be evolved from the metals in the brazing rod, and a severe hazard may arise 1f brazing rods contatning cadmium are used. In this event, particular care must de taken to avoid inhalation of fumes and expert advice may be required. SPECEAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELOING 08 CUTTING TAKES PLACE ON VESSELS WAICH HAVE CONTAINED CONBUSTIBLE MATERIALS, E.G. BOILING OR STEAMING OUT OF FUEL TANKS. WHITE SPIRIT ~ See Solvents. March 1992 FORD SIERRA/ESCORT RS COSWORTH: SECTION 05-10HEALTH AWD SAFETY PRECAUTIONS WARWING SYMBOLS Yehicle displaying the warning triangle and open book syrbol, Fig.1., advise consultation of the relevant section of the owners handbook before touching or attempting adjustments of any kind. ES ce-os 1 Fig.ts Warming symbol = consult handbook. sets eaping we wig eran ne Js Tehectrdetedé arcu and Qpon S004 symbol, "rig.2, sive narning of Components wth fnigrent oh foltagess"Wever touch these w/th'the engine ranwtag or the ignition tah en's cEt6-08-2 1 Fig.2. Warning symbol - high voltage ~ consul handaook.. Ford vehicles and replacement parts which contain asbestos are fdentified by a synbol, Fig.3. See Asbestos. WARNING ‘CONTAINS ASBESTOS ce14-05-3 1 Fig.3. Warning symbol on parts containing asbestos = consult handbook. 0392 Naren 192 FORD SIERRA/ESCORT RS COSMORTH: SECTION 05-11STANDARD PRACTICES STANDARD PRACTICES 06 Index Page Vehicle in Workshops, eee 2 Jacking up the Venicle : 2 Using Chassis Stands... 2 Jacking and Support Locations -. 3 Owner Jacking ene 4 Towing the Vehicle oe 4a Disconnecting the Battery. ee we 5 Reconnecting the Battery .. 5 Connect ing 2 STave Battery Using Jump Leads . 5 Battery Charging 6. ee wee 6 Component Cleaning... ve we 7 Component Inspection wwe ewe 7 Licence Plate Mounting 6. 1 ee 8 90392 March 1992 FORD STERRA/ESCORT RS COSWORTH: SECTION 06-01p> STANDARD PRACTICES VEHICLE I WORKSHOP When working on a vehicle in the workshop always ensure that: # The hand brake {s applied or the wheels are securely chocked to prevent the vehicle moving forwards or backwards. a If the engine is to be run, there is adequate ventilation, or an extraction hose ‘to renove exhaust gases. # There is adequate room to jack up the vehicle and remove the wheels if” necessary. # The battery fs disconnected if working ‘on the engine, underneath the vehicle, or if the vehicle is jacked up. 8 If using welding equipment on the vehicle, a suitable fire extinguisher is readily available. CAUTION: When electric arc welding on a vehicle, always disconnect the alternator wiring and the battery to prevent the possibility of a surge of current causing damage to the internal components of the alternator. It is not necessary to disconnect, electronic modules. JACKING UP THE VENICLE ~ GENERAL If possible always position the vehicle on a hard level surface, If the vehicle must be jacked up on a soft surface, use load spreading blocks under the jack, and the’axle or chassis stands. Always ensure that the jack {s of sufficient capacity to lift the load. Always securely chock the wheels remaining on the {ground to prevent the vehicle rolling Forwards or backwards. Do not rely on the hand drake as this may have to be released during the repair procedures. Always install suftable axle or chassis stands Defore working under a jacked up vehicle. When reversing onto some ramps, {t may be necessary to raise the frant of the vehicle to Prevent danage to the front spoiler and/or the exhaust flange connection. 0392 USING CHASSIS STANDS Chassis stands must alvays be used to support a Jacked up vehicle when working underneath it. e Figs.t- and 2 for correct positioning of Jacks, hotsts and stands. © Position the service jack centrally under the Jacking point to be ratsed, ensuring that the ‘jack saddle locates securely, and if it is a ‘troltey Jack, that the wheels are free to roll. Bp not Jack Vehicle under suspension arms, Tinks etc, © Securely chock the wheels at the other end of the vehicle. © Operate the jack to ratse the vehicle, keeping watch on the Jack saddle to ensure that $t Fenains correctly positioned and does not slip. © Place chassis stands in position ensuring that they locate correctly without foul ing other components, especially brake tubing or electrical wiring. Lower the jack carefully and ensure that all the Tegs of the stands remain Firmly in contact with the grovund and thetr heads remain correctly located. Only the correct design adjusting pins should be used in the chassis stands and these should be regularly checked for straightness and damage. Never use non-standard pins~or other materials fn Teu of the correct adjusting pins. MOTE: ATL workshop Jacking, hotsting and use of support stands is only acceptable with the vehicle at maxinun kerb weight or Tess, 1.e. no luggage or passengers. March 1992 FORD SIERRA/ESCORT RS COSMORTH: SECTION 06-02“sacking au supPoRT LOCATIONS Ww 887-08-1N 7 Fig.l. decking locations - Sierra c08-06-20 . Fig.2. Jacking locations - Escort. o3g2 March 1992 FORD SIERRA/ESCORT RS COSWORTR: SECTION 06-3,STANDARD PRACTICES OANER JACKING Wherever possible, ensure that the vehicle 1s on firm ground and that you are working from the kerb-side. Before attempting to jack up the vehicle, make sure that the ground is sufficiently solid £6 take the jack and ary additional supports used. Apply the handbrake and engage Ist or reverse gear. If jacking the vehicle on a stope cannot be avoided, both wheels on the opposite side of ‘the car must be securely chocked. Jwo Jacking points are provided on both sides of the car. Select the jacking point adjacent to ‘the wheel which 1s to be changed. Sierra Slide the arm of the owner jack into the Jacking point hole AS FAR AS POSSIBLE. Fig.1. Pivot the top of the Jack as close as possible to the side of the car and operate the Jack crank handle, Fig.2. NOTE: A stop Is provided on the Jack to prevent paintwork damage, when the Jack Ts operated. THE SIERRA RS COSHORTH JACK MUST NOT BE USED OW ANY OTHER MAKE OR MODEL OF VEHICLE. Escort The positions for iocating the omer jack are easily recognised as they correspond with indentical markings ion the rocker panel. ‘The channel in the head’of the jack locates on ‘the flange under the rocker panel, Fig.5. NOTE: Owner jacks oust not be used on any other part of the vehicle. SUPPORTS MUST BE USED WHEN WORKING UNDER THE VEHICLE. 0392 ‘Sioa 7 Fig.3. Slide the Sierra jack arm into the Jacking point as far as possible, S-06—2N w Fig4. Operating the Sierra owner jack- c0s-06-21 1 Fig.5. Locating the Escort owner jack. March 1992 FORO SIERRA/ESCORT RS COSHORTH:. SECTION 06-08TOWING THE VEHICLE When towing 15 necessary, the vehicle towing eyes should be used. The rope must be securely fastened to the towing eye and attached to the other vehicle such that the rope will not foul the bodywork. CAUTION: When the vehicle is being towed, the ignition switch aust be in position If (steering lock released and warning lights illustnated). Only then will the steering, direction indicators, horn and stop’ lights be operational . Alternatively the vehicle can be transported on a Low Loader. s-0eN Fig.4. Towing eyes (arrowed) A Escort = Sierra 90392 eos Waren 1992 FORD SIERRA/ESCORT RS COSHORTH: SECTION 06-04DISCOMNECTING THE BATTERY ‘STANDARD PRACTICES Atays stop the engine before dtscomecting the v battery: Always disconnect the battery before comencing repair operation which require: The vehicle to be Jacked up Work on the engine Work underneath the vehicle Arc-wal ding Always disconnect the battery negative (-) lead first. NOTE: Before disconnecting the battery ensure ‘that the radio keycode {s known and, on vehicles fitted with EEC IY ignition systens, make sure that no further data is required fron the modute as battery disconnection wi1l erase the ‘Keep Alive Memory’ (KAM) contained Fig.5. Battery Connections. in this system, It 1s not necessary to A's Posttive Terminal (+) Atscannect or renove electronic control B= Regative Terminal {-) nodules. RECONNECTING TRE BATTERY WARNING: If the battery has deen on bench charge the cells may be giving off explosive hydrogen gas. Avofd creating sparks, and if jn doubt cover the vent plugs or covers with damp cloth. Always ensure that al? electrical systens are switched OFF before reconnecting the battery, to’ avoid causing sparks or damage to sensitive electrical equipment. Aiways recomect. the battery positive (+) ead first and the negative (+) last, ensurig thet there 43 a good electrical contact end the battery terminals ave secures PEas-06-04 Restart the clock (where fitted) and set it to the correct time. Fig.9. dump tee connections to battery. A Slave lead clap. Re-enter the radio ‘pre-set! frequencies, B= Positive terminal if known. C= Engine lifting bracket we CONNECTING A SLAYE BATTERY USING JUNP LEADS. © Always ensure that the Jump leads are adequate for the task. Heavy cables must be used if the starter motor is, to be used, but light leads may be adequate 1f only testing electrical circuits. ¢ Always ensure that the slave battery is of the same voltage as the vehicle battery and is only connected in parallel. (Positive to positive and negative to negative terminals). ¢ Rways ensure that the electrical circuits are switched OFF before connecting jump leads. This reduces the risk of sparks occuring when the final connection is nade. CAUTION: The ‘flat battery* condition may have been caused by an electrical ‘short circuit’. If this condition exists there will be an apparently ‘Iive' circuit on the vehicle even when ali normal circuits are switched OFF. This can casue ‘arcing’ to accur when the jump leads are connected. WARNING: IF the slave battery has recently been charged and is ‘gassing’, cover the vent plugs or ‘covers with a damp cloth to reduce the risk of explosion should ‘arcing’ occur when connecting the Sunp leads. Always connect the Jump Teads in the fotlowing sequence: © Booster battery positive First then vehicle battery positive. 0392 March 1992 FORD SIERRA/ESCORT RS COSHORTH: SECTION 06-05CONNECTING A SLAVE BATTERY USING JUMP LEADS (Cont'd) # Booster battery negative next and then vehicle earth (at least 12 inches (300 mm) from the battery terminal, €.9. engine lifting bracket.) WARNING: Ensure that the ends of the Jump Teads do not touch each other, or earth (the vehicle body or chass1s frame), at any time while the leads are attached to the battery. A fully charged battery, if ‘shorted’ through junp leads, can discharge at a rate wet? above 1000 ams causing violent ‘arcing’, very rapid heating of the jump leads and terminals, and even cause the battery to explode. ‘# Always reduce the engine speed to idling before disconnecting the jump leads. ‘e Always disconnect the junp leads fn the reverse order to the connecting sequence and take great care not to ‘short’ the ends of the leads. CHARGING OF SEALED FOR LIFE BATTERIES (OFF THE VEHICLE) If a Sealed For Life Battery has @ Yow open circuit terminal voltage having been in stock for sone time or failed to crank an engine satisfactorily, it can be fast charged off the vehicle. The batteries selected for recharge mst be charged in an area which {s well ventilated and tt 1s recomended that the British Standard Code of Practice for the safe operation of starter battertes fs used as 2 guide. Constant Voltage Charging In order to avotd unnecessary supervision of the charge process, a nominally constant voltage charger snouTd be used so that the charge current is autonatically cut back as the battery's state of charge Improves. The charging equipment. should control the voltage maxinun limit to 14,4 * 0,5 volts and ximum current {s not greater than 25 anperes through any one battery'at any tine. ig equipment would, therefore be suitable for all the range of connon car battertes in use now and in the forseeable future. Charge should be terminated when the current rematns unchanged MOTE: Before disconnecting the charger, always switch the unit off, to avoid sparks. ‘This procedure will FULLY charge a battery in shout 2-3 days. However, it will rafse the state of charge from flat to a workable value within 3 hours if the battery 1s the normal car starter size. Constant Current Charging Constant Current Fast Charging {s possible but requires constant supervision, otherwise electro! AN Seaaat” and wilt feakFoae the: castng. ie Wo not rSeostanted eer uesorticas'¢°reguiae SharvTna Rete ee eee ie nein The charge should be started at 25 to 30 Amperes and adjusted so that voltage 1s 14,0 to 14,4 volts. It should then be adjusted to maintain a voltage of 14,0 to 14,4 volts as the battery's state of charge increases and ensures that tersinal voltage does not rise above 15,0 volts. The battery is ata workable state of charge when the current 1s accepted at the normal bench charge rate or less and the terminal yoltage is 14,4 volts. NOTE: Before disconnecting the charger, always switch the unit off, to avoid sparks. Batteries in storage, even on vehicles, must be charged at least once a month to prevent deterioration. Nhen charging a battery, the charger unit manufacturer's instructions should be followed. NEVER SMOKE OR IGNITE A NAKED FLAME near a battery which is being charged, as the charging process causes highly Inflanmable hydrogen gas to be gtven off. For this reason, the charging operation should e carried out off the vehicle, in a well ventilated area, to prevent a build-up of hydrogen. It Is safe to charge a battery on the vehicle provided the previous paragraph 1s observed during the charging period and for at Teast 15 winvtes after. It has the advantage that after charging, no Feconnection to vehicle systems 1s required (with current vehicles. this Inevitably causes a spark due fo radto semory, clock ete.) and therefore elininates the chance of an expfosion due to the conection being wade. 0392 March 1992 FORD SIERRA/ESCORT RS COSWORTH: SECTION 06-06> STAMDARD PRACTICES ‘COMPONENT CLEANING To prevent ingress of dirt, accumulations of loose dirt and greasy deposits should be renoved before disconnecting or dismantling components or assenblies. Conponents should be thoroughly cleaned before being inspected prior to reassembly. CLEANING KETHODS Dry Cleaning: Renove loose dirt with soft or wire brush. Scraping dict off with a piece of metal or wood. Wiping off with a rag or metal or wood. Blowing dirt off with compressed air, (Eye protection ‘Should be worn when using this method). 1up_ Extraction: Removal of dry dust using vacuum equtpment. This ‘ethod should always be used to renove friction Vining matertal dust, (asbestos particles). Steam Cleaning: ‘This method of cleaning can be used on most vehicle components except electrical assenbl fes. Exposed metal surface should be protected immediately after steam cleaning, to prevent corrosion. Solvent Cleantag: Yarious solvents are available which are suited! for component cleaning. Sone components such as brake hydraulic parts and electrical assenbl {es should be cleaned only with recommended solvents - refer to Section G8 or to the section of the manual relevant to the component. WARNING: Host solvents require careful handling and sone are harnful. Refer to Section 05 and to ‘the manufacturers literature for safety precautions. ‘COMPONENT INSPECTION CAUTION: The information contained in this section fs Intended as a general guide to inspection of components. It does not supersede the detatled information given in SPECIFICATIONS or in the text of REPAIR PROCEDURES which mst always take precedence. Components may be inspected during repair or overhaul for the following reasons: 8 To examine for damage © To measure wear © To assess whether the component is 1ikely to function satisfactortly until {ts next probable overhaul. 787 pause Damage should be assessed under the headings: Broken: The component. or a vital part of 1t may be fractured in such a way as to make ft unusable or trreparable. Distortec ‘The component may be bent, twisted, dented or satsalfgned, Scores The function of the component must be taken into account when assessing the effects of scoring on working surfaces. For instance mtnor surface scratches or |fght scoring will cause a brake hydraulic cylinder to fail, but will have 1strle effect in an engine cylinder bore. At the other extrene, robust, heavy duty components such 4s suspension spring bushes will still function satisfactorfly even with very deep scores in their surface. Cracked: In some conponents, cracks may be difficult to find, such as in a'cytinder head or block where ‘the rack way widen when the engine is hot, and close up agetn when cool. It may be necessary to use spectal equipment such as penetrant dye for magnetic flux to detect the presence and extent ‘of a suspected crack. Corroded, Eroded or Pitted: This 1s the detertoration of the surface of components usually as a result of chemical actton. Cheetcal action can also cause non-metallic materials to swell up or soften, such as brace hydraulic seals danaged by contaminated brake flutd. Torn or Cul Damage to non-metallic components such as of seals, gaiters, weatherstrips, etc. Wear Where the anount of wear allowable on a component is important, limits of wear will usually be given under SPECIFICATIONS in the relevant section of the manual. Where no wear Linits are glven, chen the ci it should be inspected with regard tc whether’ the amount of wed” apparent on the. working surfaces is such that it will seriously affect the function or operation of the conponent. duly 1987 FORD SIERRA ‘87: SECTION 06-07STANDARD PRACTICES ASSESSMENT OF THE FUTURE USEFUL LIFE OF A ‘COMPONENT If a component has been removed from a high mileage venicie and a further high mileage is anticipated, this factor shovid be taken into account when the component 1 inspected. lien the wear, damage or deterforation of a Component ts Such that it 1s likely to have only a ‘smfted future life, even after overhaul, it may be wore economical to renew {t. Where wear, damage or deterioration 1s apparent on a component which is critical to the safe ‘operation of the vehicle, such as brakes or steering, vo the oxtent that {ts future 1ife ts obviously Timited, then that component or assembly must be renewed and not overhauled. LICENCE PLATE MOUNTING The necessary parts required for fixing iicence plates to unregistered vehicles will be found tn a plastic bag placed in the vehicte glove box or Vuggage compartnent. All models have two guide bosses in the front Dunper and to pierced holes in the rear panel. Two waterproof plugs are fitted into the rear panel holes. FITTING INSTRUCTIONS U.Key GERMANY and territories not speci fied below Dri11_ or pierce front and rear licence plates, with two 6,5 mm holes, on the horizontal centre Vine symmetrically about the verticel and horizontal centre lines at 290 om between hole centres. Letters and nunerais should be arranged ‘on the itcence plate, where possible, to avoid ‘these holes. Front: - Fig.7A. DriTl two 3,80m holes 15 mm into the guide bosses in the front bumper. Fasten the licence plate to the bumper with two AB 10 x L6nm screws. fr Check to ensure that the waterproof plugs are firmly pressed into position in the body panel holes. ‘Fatlure to ensure a correct fit could lead ‘tw water leaks. Offer the licence plate to the ‘mounting plugs and plerce the sealing menbrane by screwing two AB 10 x 16 mm screws carefully into tthe plugs until the plate 1s secure. Fig.8. 787 8187-065 Fig.7. duly 1987 FORD SIERRA RS COSWORTH: SECTION 06-08STANDARD PRACTICES LICENCE PLATE MOUNTING (cont'd) Italy only Front: ~ Fig.78- Drf11 two 3,81 holes 15mm into the guide boss in the front bumper. Fasten brackets supplied to ‘the bumper with two AB 10 x 16 am screws. Dri1] the licence plate with 4,5 mm holes to coinctde with the holes fn the mounting bracket. Fix the plate in place by passing plastic, rivets ‘through the plate Into the bracket. Set the rivets by pusning the rivet stem Ftrmly to th rivet ody. Rear: As Us ++ Germany and others. France only Front:- Fig.7C. Drit] two 3,80 holes 1sm into the guide bosses 4n the front bumper. Fasten brackets supplied to ‘the bumper with two AB 10 x 16 en screws. Drill four 4,05 m holes in the licence plate to ‘Tine up with’ the two holes in each mounting bracket. NOTE: These holes must be offset vertically from ‘the horizontal centre line by rm, see Fig.8. Fasten Heence plate to brackets by passing four 4,8 mm blind rivets through plate and brackets and secure plate by setting rivets. Reart- Fig.9. Ensure plug is secure. Failure to do so could Tead to water leeks. offer the licence plate to the mounting area and dril1 two 4,85 em holes ‘through the plate and body panel/tailgate, symetrically along the horizontal line of the plate, avoiding letters. Fix plate by passing two £,8 mh Blind rivets through the plate and a, spacer washer into the body panel and setting in place, 787 $187.08. Fig.® $197-06.9 Fi9.9. duly 1987 FORD SIERRA RS COSWORTH: SECTION 06-09APPLICATION AND USE OF SPECIFICATIONS 787 APPLICATION AND USE OF SPECIFICATIONS Index Tightening Torques « Finishes apaiied to Standard Parts .. Bolt Head Identification Marks Strength Grade Identification of Prevailing Torque Nuts... we Basic Conversion Tables 7 Page duty 1987 FORD SIERAR RS COSWORTH: SECTION 07-01TIGHTENING TORQUES Metric Bolt Torques ~ Bolt Strength: Grade 8.8 Thread fitr 69 Finish: $ 72 zinc plate, chromate passivated plus lubricant stze a kon oft 6 2,5 to 3,0 0,2 to 0,3 1,8 to 2,2 15 510 ta 6.0 0,8 to 0,6 3,7 to 44 6 a5 to 10 919 to 1s 533 to 7.8 18 20 to 25 240 to 2,5 is to 18 mo 40 to 51 451 to 5,2 30 to 38 m2 70 to 90 Til to 92 to 65 me 116 to 146 1116 to 14,9 2 to 108 m6 475 to 220 1718 to 22,4 129 to 162 a8. 252 to 217 25,7 to 32,3 186 to 233 N20 345 to 430 35,2 to 43,8 254 to 317 nee 470 to 590 47,9 to 60,1 347 to 435, Mea 600 to 750 61,2 to 76,5 443 to 553 Y Pipe Union and Connector Torques he kom oft Pipe Untons into Connectors: 6 rm tube to MIO thread 15 to 18 1,5 to 1,8 Li to 13 95m tube HI6 thread 30 to 34 Rl to 35 22 to 25 12 m tube Mi8 thread 45 to a9 446 to 5,0 33 to 36 Bundy Tube Untons and Connectors: 15 to 18 11 to 13 20 to 24 15 to 18 ube diameter M16 thread 27 to 31 20 to 23 tube diameter N16 thread 30 to 34 22 to 25 ‘tube diameter MIB thread 45 to 49 33 to 36 ww 787 duly 1987 FORD SIERRA RS COSORTH: SECTION 07-02FINISHES APPLIED TO STANDARD PARTS ote Finish Remarks s Plain Sone for 180 metric and inch parts Take care with ‘dentification. 38 Copper Plate Used only for exhaust system appl fcettons. sis Lead Plate Used only for battery connecttons. sn Zinc Plate - chromate ) Passtvated } Used on 150 metric parts. Identified by sr Zinc Plate - chromate 1 gotd or bronze colour. Passtvated - Plus Lubricant} sm Linc Plate = Black - Interior 35 Chrontun Plate ~ Bright ~ Extertor 376 Phosphate Coat - Plus Lubricant S78 Chromium Plate = Bright - Intertor 579 Zine Plate - Clear chromate} Passi vated } Used on inch parts to differentiate $80 Linc Plate - Clear Chronate ) from 150 metric. Pagstveted + Plus Lobricant } 381 Enamel ~ Black sae Linc Plate Used primartly in applications where limited corrosion resistance Is acceptable, Take care to identify whether 150 metric’ or inch parts. 383 Zinc Plate - Chronate Blue colour 4s intended’ primarily to distinguish bolts Passivated - Plus Lubricant and-screws of strength grade 10,9 and nuts of strength ~"blue Oyed or Lacquered grade 10 fron those of other grades. NOTE: Onty'mechanteal plating 1s permissible for bolts and screws. $06 Zine Plate - Chromate feg colour is intended prinarity to distinguish bolts Passivated - Plus Lubricant and screws of stregth grade 12,9 and nuts of strength shed’ Dyed or Lacquered grade 12 fron those of other arades. (OTE: Omly mechanical plating 1s permissible for botts and screws. s100 Special Finishes Series $200 Common Fintshes for Series ‘Spectal Purposes Sk Wax Sealer The Yetter "x! used es a suffix to other finish codes indicates the addition of a wax or thermoplastic material to provide a moisture resistant seal, on Nechanica) Plating The letter 'N! used as a suffix to other Finish codes indicates that mechanical plating only is perntssible. 187 July 1987 FORD SIERRA RS COSWORTH: SECTION 07-03Ze a x x ee g LY °° 1 oo'netefc Bole Standara Marking 2: 180 Metrie Bolt ateennetive Morting 43. 180 etric Bolt Strength Grade 10,9 ~ Coloured Blue 4. TSO Metric Bolt Standard Grade 12,9 - Coloured Red vevore Figs, Bolt Head Identification Marks ~ Standard Hardware (OX Genotes Manufacturers Identification Hark). pero Fig.2. strength Grade identification of Prevatling Torque Nuts Strength Grade Munber Indented into Face 2: eleck Facet Senet ttcatton ferks. Embossed on shoulders (Dot = 12 O'clock; Line = Strength Grade 3. ‘Clock Face’ Identification Marks Indented into Face 4. Number indented into one Hexagon Flat 787 duly 1987 FORD SIERRA RS COSWORTH: SECTION 07-06APPLIGATION AND USE OF SPECIFICATIONS BASIC CONVERSION TABLES Abbrev From To Multiply By Length ™ will inetres Inches 0,0394 in Inches MI1Timetres 25,400 a Netres Feet 3,28, ft Feet Metres. 0,304 km KiTometres Wiles 0,621 mi Mites Kilometres, 1,609 Area m2 witlimetres 2 Inches? 0,005 ine Inches? Wii Ymetres? 645.2 2 Hetres? Feet? 10,764 Ft Feet? hetres? 0,0828 Youne om Centinetres3 Inches} 0,061 (iquid capacity) ind inches Centinetres3 16,387 ane 1 Litres Pints 15760 Pe Pints Ltres 01570 1 Litres Gallons 9,220, sal Gal tons Litres 4,586 fas (Wetght) on Grams Ounces 0,035 oz ‘Ounces Grams. 28,350 k kilograms, Pounds 2,205 1 Pounds KTograms 0,458 t Tone Ton re Ton Ton Tone 0;907 Force kg kilograms Newtons 9,807 " Newtons Kilograms 0,102 oz Ounces Newtons, 0,278 N Newtons Ounces 36 Ib Pounds Newtons, ae N Newtons, Pounds > one Pressure/Stress. ka. KiTopascals Pounds/Inch® 0,145 Tb/ine Pounds /Iache Kilopascals 6,895 bar 8 Pounds /Inche 14,5038 eine Pounds/tnch2 Bar 006895 Torque Xo. Newton Ketres Pound Inches 8,85 ibin Pound. Inches Newtons Metres 0,11298 Nn Newton, Hetres Pound Feet 0173756 Thee Pound Feet Newton Netres 135582 Nn Newton Hetres Kilogran Metres 0,101972 kon Kilogram Metres Newton Metres 9, 80666 11 duly 1987 FORD SIERRA RS COSWORTH: SECTION 07-05SEALERS ‘SOLVENTS AND SEALERS 08 Index Page Solvents, Seelers and Adhesives wo 2 787 July 1987 FORD STERRA RS COSWORTH: SECTION 08-01‘SOLVENTS AND. SEALERS This section lists some of the solvents and sealers comonly used in the aintenance and repair of couponents and assenblies. The list fs not exhaustive and does not preciude the use of other brands or types of solvents or sealers provided that they conform to the Ford Specification. CAUTION: If in doubt about the suftability of any proprietary solvent or sealer for a particular application, contact the manufacturer of the product for information regarding storage, handling and appl ication. WARNING: Always handle al1 solvents, sealers and adhesive with extreme care. Some contain chemicals 9f give off funes which can be dangerous to health: Always fallow the manufacturers instructtons, Tt Fn doubt about ary substance, particularly a solvent, DO NOT use ft. Section 05 refers to some comonty used chemicals and materials, hazards assoctated with their use, and Safety measures to be taken. Sone of these chemicals may be included in the following Tist either in ‘their own right or as an ingredient in a sealer or adhesive. ‘Appi teation Ford Specification Manufacturer and Identification ANTE SEIZE COMPOUND RocoL KS_PAUL SAM IC 107A Foliac J166 PCD or PBC 492 Kluber Untaoly Tac 2 ‘GENERAL PURPOSE ADHESIVES Bostik PLUS PRODUCTS Grommets SM 2G 46328 - ‘8 2080 Rubber Parts SM 2G 46108 NE 186 A 1042 Mats ESEBN 26 10038, {IGA 516, A 1088 (AGA 95415 Weatherstrip ESEBM 26 100A 1320 - “*SUPERGLUE" LOCTITE Plastic/Rubber ete ‘SKM 26 95184 A18/426 Henkel Sicomet 8300 Plastic/Rubber/Metal SKM 26 95268 a5 . ‘THREAD LOCKING ANU SEALING LOcTITE Pipe unions SOM 4G 91020 575 (572) Studs and botts SOM 46 SLO7A 270 JOENTING COMPOUNDS LOCTITE setting SDM 4G 93054 276 - Non-setting ‘SPM 4G 9112F - Hylomar PL32M 787 duly 1987 FORD SIERRA RS COSWORTH: SECTION 08-02SOLVENTS AND SEALERS ‘Application Ford Specification Manufacturers Identification ‘BODY SEALERS BOSTIK WR GRACE/TEROSON Weld-through SH 4G 46368 P34 44S, - Caulking strips SH 4G 463208 323 General ESK-NAGZHE~A iK91PU General (Hi Ht Cure) EN 4G 69 106c 192 WINDSHIELD GLASS TO BOSTIX or —_W_R_GRACE/TEROSON WEATHERSTRIP. SEALER SH 4G 4631 EXPANDITE 1861 Bostic P sagas GLASS-TO-METAL ADHESIVE SYSTEM Loctite Aanesive ESF H2GIS3A 317 Activator ‘SH 97810034 736 787 uty 1987 FORD SIERRA RS COSHORTH: SECTION 08-03RORD OR ROLLER TESTING 9 Index Page Pre-test Checks ” 2 Starting the Engine . noe 2 Qn Road or Roller Test Checks we 4 After Conoletion of Test Checks 4 rer duly 1987 FORD STERRA RS COSWORTH: SECTION 09-01ROAD OR ROLLER TESTING ROAD OR ROLLER TESTING Road or rolter testing may be carried out for ‘the following reasons; © As part of requiar or scheduled maintenance procedures to check that all vehicle systems function correctly and perform sattsfactorfly. These procedures are detatled in GROUP 5 of the manual /nicrofiche. As part of a fault diagnosis procedure to ascertain or confirm a fault. Reference should be made to FAULT DIAGNOSIS in the relevant section/s of the manual/microfiche. ‘#8 After completion of repairs, to prove the effectiveness of the repair, and to check that the function and performance of the vehicle is satisfactory. This section follows a road or roller test procedure from pre-test checks, through engine starting and stopping, pre-driving checks, on-test checks 15 final checks on completion of the test procedure. Unless complete vehicle performance is being checked, the full road test procedure need not be carried out. Instead, those sections particularly relevant to the systex/s being checked can be extracted. It is suggested that pre-test checks, and functional tests of those systens/circuits which affect the safe and Tegal operation of the vehicle, such as brakes, lights, and steering should atways be carried ait. Vehicles fitted with four wheel drive should not be tested ana two wheel drive dynanoneter.. 989 PRE-TEST CHECKS: # Engine of7 level © Engine coolant level 4 Tynes, for correct oressures, conpatite types and tread patterns, and wear within Tiwi ts. # There is sufficient fuel in the tank to conpiete the test. #11 round the engine, transmission and under the vehicle for of, coolant, hydraulic and fuel leaks. Wake a'note of any apparent leaks and wipe off the surrounding area to make it easter to identify the extent of the leak on completion of the test. WARNING: If the brake system hydraulic flutd Tevel 15 tow or a hydraulic leak 1s found, do not attempt to road test the vehicle until the reason for the Tow level fs found or the leak 1s rectified. STARTING THE ENGINE Presstarting checks: With the ignition switch OFF, chect The handbrake 1s applied. @ The gear lever is in neutral. @ Instrunent gauges (except fuel gauge) read zero. © Fuel gauge registers a reading appropriate to the fuel level fn the tank. With the fonftion switch ON, check: ‘© Ignt tion controlled warning Tights come on. # Engine temperature gauge registers a reading conpatibie with the engine temperature. ‘© The operation of the handbrake warning Vight. and Fluid level warning indicator light. NOTE: a} On intial drive away from cold and within ‘the first 1,5 km (1 fle), do not depress accelerator beyond half travel untt] the vehicle has attained ¢ minimum speed of 25 km/h {15 miles/h), Never operate at high engine speed or full throttle whflst the engine 1s cold. September 1989 FORD SIERRA RS COSNORTH: SECTEON 09-02STARTING THE ENGINE (cont'd) STARTING A COLD PETROL ENGINE L. Fully depress the clutch. 2. without touching the accelerator pedal, turn the tgnftion key to posttion 111 to crank. the engine UNtIT HE starts. Once the engine starts, release the key, which will return to position II. 3. If the engine does not start after 10 seconds, turn the key to position 1, pause and repeat step 2. 4. 1€ the engine does not start after three attespts, wait 10 seconds and then proceed as described under STARTING A FLOODED PETROL ENGINE. STARTING A WARM PETROL ENGINE. 1. Slowly depress the accelerator pedal to about half its maximum travel, hold tt in this position and ‘turn the ignition key to position I] to crank the engine unti] it starts. 2. Once the engine starts, release the key, which will return to position 11. If the engine does not start after three attenpts, walt 10 second then proceed as described under ‘STARTING A FLOODED ‘PETROL ENGINE. STARTING A FLOODED PETROL ENGINE 1. Slowly depress the accelerator pedal to the floor and hold it in this position. 2. Turn the Sgnttion key to position II to crank the engine unti? 1t starts, then gradually re the accelerator pedal. 3. If the engine fails to start, proceed as described under ‘STARTING A WARN PETROL ENGINE’. 787 duly 1987 FORD SIERRA RS COSWORTH: SECTION 09-03=> ROAD OR ROLLER TESTING (ON ROAD OR ROLLER TEST ‘© Clutch pedal operation fs not stiff or heavy. fe Intttal gear engagement {s smooth and there is no evidence of clutch drag. Handbrake control operates smoothly and the handbrake releases quickly and completely. ‘4 Clutch takes up the drive smoothly, without slip or judder. CAUTION: If road testing, check the brake operation while still travelling at low speed before continuing with the test. If the brakes pull to one side or appear to be otherwise faulty, do not continue with the road test until the fault has been found and rectified. # Gear changing {s smooth, and there is no abnormal notse or vibration from the transmission. ‘8 The engine power output ts satisfactory, full poner is achieved, acceleration 1s snooth and pedal operation not stiff or heavy, and returns to idle position correctly. ‘e-There 4s no excessive or abnormally coloured smoke from the exhaust in normal driving, under heavy load or on the overrun. # Steering operation is sooth, accurate, not eccessively heavy or with excessive free play or vibration. Does not pull to one side and self, centres snoothly after cornering. © Speedoneter, coolant temperature gauge, fachonater register the correct readings or operate correctly. Switches and controls operate snoothly and positively, warning or indicator lights operate Correctly and the direction indicator control self cancels when the steering is returned to the straight ahead position. Heating and ventilation systems work correctly and effictentiy. 4 Brake operation and efficiency: 787 If the vehicle is betng tested on the road, brake testing should preferebly be carried out on a dry, clean and reasonably smooth level surface, with the vehicle laden to a minimum of 75% GYM. ‘Avoid brake testing on busy roads where 1 can cause inconvenience or danger to other road users. If the vehicle fs being tested specifically for performance and effictency of the brakes, install a suitable brake effictency eter in the vehicle prior to starting the test. NOTE: Brake testing which includes heavy brake applications shoutd not be carried out with new brake pads/discs,or Vinings/druns unt{? ‘the components have ‘bedded-tn'. New brake Friction components will not reach full efficiency until the ‘bedding-fa" process is conpiete. Test the brakes at several speeds within the normal operating range using both light and heavy pedal pressure. Note any tendency to snatch, pull a drag, and any undue devay 1m application or release Allow the vehicle to coast and note any tendency to pull to one side or evidence that the brakes are binding. After, stopping the vehicle (not tnnadiately after ‘a period of heavy braking), carefully checl ‘the brake drum temperature. A drum which feels hot, or appreciably hotter than the other, indicates the brake ts binding. WARNING: Avotd breathing the smoke or fumes from hhot brakes, this may contain asbestos dust which is injurious to health, see Section 05. ‘AFTER COMPLETION OF THE TEST CHECK FoR: «O11, coolant, hydraulic, afr and fuel Teaks. Abnormal temperature of any moving components or assemblies, e.g. wheel hubs, transmission, axle etc, which might indicate overtightness or lack of lubrication. duly 1987 FORD SIERRA RS COSWORTH: SECTION 09-04WHEELS AND TYRES a Index Page TECHNICAL DATA: ‘Tyre Pressures... Wheels ~ Tightening Forques .. +s ve ve Tyre Identification 0192 January 1992 FORD ESCORT/SIERRA RS COSWORTA: SECTION 11-1TECHNICAL DATA AECONMENDED TYRE PRESSURES (Cold - see Note 4) TYRE WORMALLY LADEN AND WORWAL USAGE | FULLY LADEN AND NORMAL USAGE SIZE (See Notes 1 and 3) (See Notes 2 and 3) Front Rear Front Rear 2 bar Ib/in? | dar Ib/in? bar 1b/in? | bar Ib/in [205750 Ris a1 2300 4 2300 2500 397 195/55 RIS Minter Tyre 225/45 7RI6 2,0 29 22 2 22 8 a6 35 205755 RIS Winter Tyre Temporary Spares Ties/80 Ris 95M 4,2 bar 62 Yb/in? Ti2s760 RIG 97K | (For all conditfons - Mex. Speed 80 kayh (50 mph) noves: 1. Normal Taden tyre pressures apply when vehicle 4s loaded with up to 3 additional passengers or the driver and 170 kg. 2. Fuily laden tyre pressures apply when vehicte 1s loaded in excess of the normal condition and up to the maximum rated Toaded condition, Normal usage {s defined as usage on ali roads at all speeds where high speed is not sustained for more than approximately 30 minutes at any one time. 4, The tyre pressures shown should be used when the tyre fs cold, {.e. when approximately at anbient ‘Tonperature (not warm to the touch as fs usual after operation). 5. hen operating at custeined soeeds above 160 Kn/h (100 mph) the folTowing tyre pressures must be TYRE WORMALLY LADEN AT FULLY LADEN AT SUSTAINED HIGH SPEED SUSTAINED HIGH SPEED SIZE (See Notes 1 and 8) (See Notes 2 and 5) Front Rear Front Rear | bar Tb/in2 | bar Yb/ind bar Ib/in? bar Yb/in? {—____j 205/50 VAIS 230 250° 9 26 38 30048 Winter Tyre 225/45 TAS 22 2 24 8 25 9 29° «3 205/55 RIS Winter tyre | o1s2 January 1992 FORD ESCORT/STERRA RS COSWORTH: SECTION 11-2> vHEcGs AnD Trees TECHNICAL DATA (cont'd) WHEELS: Sierra Cosworth Escort Cosworth Alloy wheels -. 7x15 Alloy wheels «Bx 16 Steel wheels =. 54 x 15 winter tyre Steel wheels. Sie x 15 winter tyre 3 x 16 tenporary spare NOTE: If Dunlop Performa 8000 tyres are fitted to the Escort Cosworth it must be noted that these tyres ‘are directfonal and must be fitted as indicated by green or red markings on the inside of the tyre. Avgreen marking indicates « right-hand side tyre anda red marking Indctates 2 left-hand side tyre. Tightening torques Me WBE Te Wheel nuts ~ steel/atioy wheels 100 " NOTE: Two types of wheel nut are used, one for steel wheels and another for alloy wheels. The nuts Used on alloy wheels incorporate a rotating conical washer to prevent wheel damage. Ensure that the correct nuts are used for each type of wheel as they are not fnterchangeable, Weel Salancing ‘The diameter of spigot required on the balancing machine is 63,25 mm to 62,28 mm and this diameter must project above the whee! mounting surface by 15 ma. The balance wetghts used for steel and alloy wheels differ in cross-section as they have been designed to match the contours of the specific wheel. It is therefore, important that the correct balance weights are always used. = The rear wheels should NOT be batanced on the vehicle, as the drive system used on such balancing equipnent could danage the viscous limited si1p differential. ‘Snow Chats For winter operation with snow chains, special 15 x 54 steel wheels should be used. On four wheel drive vehfcles snow chains should be fitted to all road wheels. If only two snow chains are available, for four wheel drive vehicles, they must be fitted to the front rosd wheels. On two wheel drive venfcles snow chains must only be fitted to the driving wheels, {.e. rear wheels on Sierra and front wheels on Escort. > Vehicle Jacking It 4s important that any vehicle Jacking compltes with Section 06 of this microfiche. Temporary Spare Certain Escort Cosworth varfants, depending on territory, carry a temporary spare. When the tenporery spare 1s {n use the following points must be adhered to: Drive with caution Do not exceed maximun speed limit of 80 kn/h {50 mph) ‘© Only use spare on a temporary basts © Replace temporary spare with normal whee! as soon as possible ‘8 Do not drive vehicle with more than one temporary spare at a time ois2 January 1992 FORD ESCORT/SIERRA RS COSWORTH: SECTION 11-3WHEELS AND TYRES TYRE OEWTEFICATION Tyre sizes are fdentif{ed by a combination of Tetters and numbers using both metric and inperial dinenstons. Fig.1- {Illustrates a wheel and tyre assembly with the information required to determine tyre size and type. “1145! weans the tyre 4s 145mm wide across its Ths dimension is with the tyre mounted on 4 specifically designed measuring rin. Actual width of tyre may vary if the size of fm being used on the vehicle ts different to the speci tic-measuring rin. An '/" after the tyre size (eg. 15/70) indicates the aspect ratio or height of the tyre, given as a percentage of max. width, i.e /70 = 708 of max, width. NOTE: Thfs {s not given on a1 tyres ~ the normal hetght is 82% of max. width, Other Conmon heightsare 708, 65% and GOL, these are ‘the so-called “low profile* tyres. <'R! Indicates that the tyre 15 of radial construction. 13' indicates the wheel diageter in ‘tnches. D~'74" indfcates the load index. This code relates to the maxtmun load the tyre can carry. E athe letter is a speed symbol - ft indicates: the max. speed at which the tyre can be used. Up to 130 km/h (81 mph) Up to 140 km/h (87 mph) Up to 150 km/h (93 mph) Up to 160 km/h (99 mph) Up to 170 ka/h (106 mph Up to 180 km/h (122 mph) Up to 190 kp/h (128 mph) Up to 210 km/h (230 mph) Up to 240 kayh (149 mph) Unspecified limits, high performance vehicles Nexdomoves F Around the edge of the tyre there may be a mark at regular tntervals, This mark could be an arrow, manufacturer's syabol or the Vetters ‘TMi. They indicate the position of ‘Tread Wear Indicators*, which a raised rubber sections across the tread of the tyre (See Fig.2.). If the tread wears down to the level of the ‘Tread Hear Indicator’ then the tyre should be replaced. o1ge BEIa-tt-01 Figel. Tyre tdenti fication marks. BEIa11-02 Fig.2. Tyre tread wear indicator. January 1992 FORD ESCORT/SIERRA RS COSWORTI SECTION 11-4BRAKING SYSTEM ‘BRAKING SYSTEM wz Index Page Technical Data we Spectal Service Too! Recognition... 3. Service and Repair Operations Contained 4m Page ‘Operation 12 141 0 Brake System 8leed we a 4 12 154 0. Brake Systen - Hydraulic Fluid - Replace . - 7 12 221.0 Brake Disc ~ Check Run-out (Both sides) Front and Rear re 2 12 2240 ise ~ Front Brake ~ Remove and Install rn’) 12 225 0 Disc - Rear Brake - Remove and Install (one side) soe 8 12 233.0 Disc Pads - Front - Replace (one side). wo eT 32 237.0 Disc Pads - Rear - Reptace (one side) . be 12 243.0 Caliper Assembly - Front = Renove and Instal? bo a 12 247 4 Piston - Front CeTiper = Remove and Instat! ee 8 32 263.0 Caliper Assenbly - Rear - Renove and Instalt ” re 6 12 253 8 Caliper Assembly - Rear - Overhaul - Caliper Removed 6, we = 8 12 259 4 Splash Shietd - Rear - Renove and install (Caliper Renoved) an oe 3 12 333.0 Brake Pedal - Remove and InstalT eB 12 341 0 Brake Fluic Reservoir - Renove and InstalT oe 36 12 580 0 Hydraulic Unit - Renove and Instal] : ee 9 12 5B1 0. Valve Block - Renove and Insta)? : 2 12 $82 0 Accunvlator - Renove and Instat woe 44 12 586 0 Hydraulic Punp and Motor Assenbly - Renove and instal? ae 45 12 589 0 Pressure Switch = Renove ard Install - Reprace ° : 48 12 590 0 High Pressure Hose ~ Renove ang Install re 49 12 591 0. Low Pressure Hose - Remove aod Install ee BO 12 662 0 Handbrake Cable - Adjust... ws Be 82 12 6440. Lever Assembly - Handbrake - Renove and Instali .. - 8 12 675 0. Cable Handbrake - Replace - 8 55 12 780 0 Wodule - Anti-lock Braking Systen - Remove and Instat] wore 7 32 7850. hee! Sensor - Renove and Install - Front 6. ene wee 12 7850. wheel Sensor ~ Remove and install - Rear : - 68 12 792.0 "8" Switch - Renove and Insta]. ee eo Exploded views Front caliper assenbly bo arene Rear caliper assembly) sete eB Hydraulic untt assembly S22 a8 04s April 1992 ESCORT RS COSWORTH: SECTION 12-1TECHNICAL DATA Escort RS Cosworth Front and rear disc brakes mm sretes Front disc diameter. be BB 10,85 New Front disc nominal thickness ve weve ewe we HIS Yorn front dise atscara tMekness tse ene ROR fear étse dtaneter 108 Mew rear disc nominal thickoess 6 eve ve sae 200 OTD Horn roar éise discard thickness # be 18,0 OTT Lubricants General grease. ve cee EHR Handbrake lever yoke/clevis pin and brake pedal shaft/bushes a we S-MLC-75A fut SAM-6C9103-A (DOT 4) Brake fluid eee ee er ESD-WECS7-A (Super DOT 4) Tightening torques to Dott Caliper anchor bracket to spindle carriers. sys. teat nee BL tL 37 to 45 Piston housing to anchor bracket hexagon bolts eee eee ene nee 20 HOB 15 to 19 Caliper anchor bracket to carrier plate (rear) 6. eee ewe SE ROL 37 to 45 Caliper piston housing stide in boit (rear) ewe rT) 23 to 26 ‘whee! nuts. wa tee ne 70 t0 100 50 to 74 Hydraulic Unit: (Teves Mk 11) Hydrauife unit to bulknead se AL tO 0 to 36 Accumulator to pump body etek 4 tO AB 2 to 34 Pump mounting bolt = kk cee tee TOD Sto7 High pressure hose banjo bolts = -. ws wy weve 16 8028 12 to 18 Reservoir mounting bolts. ss es teen BOG ated * When the discard thickness lias been reached the disc aust be replaced. Particular care must be taken when re-facing discs that the minimum thickness dimensions are not exceeded. as April 1992 FORD ESCORT RS COSWORTH: SECTION 12-2<=> BRAKING SYSTEM SPECIAL SERVICE TOOL RECOGNITION Escort RS Cosworth 12-006 Rear catiper piston wrench 12-007 Rear caltper spring compressor Wrench A.B.S. pressure switch 008 GeigeA..5s pressure tater som L Dial Indcaarhalagrixtare sone wetrhe ai) tnaator sage rs0t6 ial Piston spear oem o= Hexagon key adaptor ws De Medion a eapd patter (Swivel eas) vs00 age Apri 1992 FORD ESCORT RS COSWORTH: SECTION 12-3Escort RS Cosworth 32 161 0 BRAKE SYSTEN - BLEED SPECIAL SERVICE TOOLS REQUIRED: NONE CAUTION: If brake fluid is. sptlt on paintwork, ‘the affected area must be washed down with cold water iamediately. NOTE: When carrying out service bleed or, filling the syste from dry the following polits must be observed: © Always use brake fluid, to the correct ‘specification, from anew can. Never re-use brake fluid. © Top up reservoir as necessary during bieeding to prevent the hydraulic pump running dry. © Ensure brake bleed tube is {n good condition and secure when fitted to bleed valve. © The hydraulic punp motor running sound wiT? alter once fluid has purged through it from a high pitched buzz to a Tower pitched sound. (G0 NOT allow pump motor to run for more than 2 minutes. If pump does rin for more than 2 minutes, switch 'off", fgnftion position '0", and allow motor to cool for 10 minutes). Fig.2. Front caliper bleed valve. WARNING: | CARE MUST BE TAKEN WHEN BLEEDING THE REAR BRAKE CIRCUIT AS HYORAULIC FLUIO WILL BE ‘SUBJECTED TO EXTRENELY HIGH PRESSURE. 1, Disconnect oul tipiugs and renove reservoir cap. Top up reservoir, (Fig.1). 2. Open front left hand caliper bleed valve one full turn, (Fig.2). 3. Depress brake pedal to full travel and hold down. osg2 port 1992 FORD ESCORT RS COSKORTH: SECTION 12-8SYSTEM 12 141 0 Escort RS Cosworth 4, Close bleed valve, release brake pedal. 5. Repeat sub operations 2 to 4 until brake flufd flows air-free from bleed valve. 6, Bleed front right hand caliper in same manner as left hand caliper, (Fig.3)- 7. Open rear left hand caliper bleed valve one full turn. Fig.3. Rear caliper bleed valve. 8. Actuate foot brake. Retain foot brake 1n full travel position. 9. Switeh ‘on! fonttion, position ‘I1'. 10. Allow fluid to, flow from left hand bleed valve, allow fluid to continue to flow untt? air-free fluid flows. AL, Close bleed valve. 12, Release brake pedal and wait unt] hydraulic pump has stopped (switched ‘off'). 13. Actuate foot brake to half pedal travel and retain in this position. 14. Open rear right hand bieed valve one full] turn, leave in this ‘open’ pos{tion untiT fluid flows free of air. age Aprt 1992 FORD ESCORT RS COSHORTH: SECTION 12-5BRAKING SYSTEM 12 ato 15. Close bleed vaive. 16. Release brake pedal, wait until hydraulic punp has stopped (switched ‘ off"). 17. Top up reservoir to ‘max* mark on reservoir. 18. Switch ‘off’ ignition (position ‘0'). 19. Replace reservoir cap ensuring locating peg on reservoir is correctly located to reservoir cap. 20. Reconnect wiring connections, (Fig.4). ZL. Check for correct function of anti-Tock warning lamps. 22. Check system for leakages, function and efficiency. 492 Escort RS Cosworth ce1cos-12-8 Figst. Reconnect reservotr warning switch multiplugs. Aprit 192 FORD ESCORT RS COSMORTH: SECTION 12-6Escort RS Cosworth 12 V4 0 GRAKE SYSTEM - HYDRAULIC FLUID ~ REPLACE SPEGIAL SERVICE TOOLS REQUIRED: caliper piston expander... -GE-2031 Hexagon key adaptor To Ms-4 NOTE: This procedure details how old brake fluid ‘can de purged from the system by draining both front calipers circuits of fluid and replenishing with new fluid. Rear brakes can be replenished in the normai method as described in operation 12 161 0. Figel. Reservolr ‘Max! and ‘Min* markings, CAUTION: If brake fluid fs spilt on paintwork, ‘the affected area must be washed down with cold water mediately. WARNING: | CARE MUST BE TAKEN NHEN BLEEDING THE REAR GRAKE CIRCUIT AS HYDRAULIC FLUID WILL BE SUBJECTED TO EXTREMELY HIGH PRESSURE . 1. Open hood, #1t fender covers. Remove tgnition key. 2, Remove hydraulic unit fluid reservotr filer cap. 3. Jack up vebicle and fit chassis stands or raise on wheel-free hoist. 4. Connect bleed tubes to both front caliper bleed valves. Place other ends of tubes into suitable container to collect the purged fluid. Unscrew bleed valves one full turn, (Fig.2}. cB14008-12-6 a Fig.2. Front caliper bleed valve. 4g Aprit 192 FORD ESCORT RS COSWORTH: SECTION 12-742 154.0 Escort RS Cosworth 5. Depress brake pedal fully and allow ft to return quickly to rest. Continue to pump brake pedal untf] all fluid is purged from» calipers and air is being pumped into Containers, (pause between strokes to allow master cylinder to recuperate). 6. Remove both front road wheels. DEt«216 Fig.3. Front caliper retaining clip. 7, Rewove retaining clip from eft hand caliper housing, (Fig.3.). 8, Using 7 am hexagonal socket. Withdraw piston housing s11ding bol ts unti] piston housing 1s free from anchor bracket, (Fig.4). 9. Lift, cal per piston housing from anchor bracket and 14ft out brake pad fran piston, (leave opposite pad attached to piston housing). Fig.4. Using 7 ma hexagonal socket resove piston housing si {da bolts. DEH2-17 10. Fit piston expander into Jaw of piston housing. Actuate piston expander to fully retract piston, (Fig.5). Pump brake pedal unti? only air'ts being pumped out. Tighten bleed valve. NOTE: When first caliper has been purged, loosely refit brake pads.and fft to anchor bracket to prevent the piston being forced out of its housing when second side 1s being purged. LL. Repeat sub operations 7 to 10 for the right hand caliper. DEr248 Fig.5. Retract caliper piston using piston expander. o4g2 April 1992 FORD ESCORT RS COSWORTH: SECTION 12-8BRAKING SYSTEM 12 154.0 12. Postion bleed tube {nto clean glass Jar, containing a small quantity of approved brake flutd. Position Jar at least 300 mm above bleed’ nipple to ensure that the bleed valve itself 1s subjected to fluid pressure thereby preventing the possibility of air leaking past the threads of the bleed valve and into the brake system, (Fig.6). 13. FIV] reservotr with new fluid from a new container. Continue pumping the Drake pedal, pausing after each stroke unt] at rafree Hutd Js seen passing through the bleed tube. Hold brake pedal fully depressed and tighten bleed valves” Release brake pedal. 14, Top up reservoir. Carefully unscrew piston expander while applying the brake pedal, £0 moving the caliper piston to its fully extended position, (Fig.7). with the peda? still depressed unscrew bleed valve. Force calfper piston back to its fully retracted position by screwing fn the piston expander. 15, Retighten bleed vatve once piston fs fully retracted. Remove piston expander, refit pad. 16. Assemble piston housing to anchor bracket, Secure with 7 mm hexagonal slide bolts. Toraue, to spectficatton. Refit caliper retaining cl fp. 17. Repeat sub operations 14 to 16 for left hand caliper. 18. Top up reservotr to ‘max’ mark, continue to top up reservoir as required. 19. Open rear left hand caliper bleed valve one full turn, 0492 Escort RS Cosworth Fig.6. Position bleed jar at least 300 om above bleed valve. siene °o Fig.7. Caliper piston at fully extended position. prt 1992 FORO ESCORT RS COSWORTH: SECTION 12.12 154 0 Escort RS Cosworth 20. Actuate foot brake. Retain foot brake fn full ‘travel position. 21. Switch on ignitfon, position "IL". 22. Allow fluid to flow from left hand bleed valve, continue to allow fluid to flow untft clean air free Fluid flows. Fig.8. Rear caliper bleed valve. 2a, Clase bleed valve. s@ brake pedal and wait until hydraulic panp has stopped (switched ‘off'). 25, Actuate foot brake to half pedal travel and retain in this posttion. 26. Open rear right hand bleed valve one full turn, Teave in this open position until cleau fluid Flows free of air. 27. Close bleed valve. 28. Release brake pedal, wait until hydraulic pump has stopped (switched ‘off? 29. Switch "off ignition (position '0°], and top Up reservoir, DEM«2-19 Fig.9. Position bleed jar at least 300 mm above bleed valve. age Aprit 1992 FORD ESCORT RS COSHORTH: SECTION 12-1042 1540 Escort 85 Cosworth 30. Check for correct function of anti-lock warning lamps. 31. Refit front road wheets and tighten wheel nuts to speci fication. 32. Check system for Teakage, function and efficiency. 3, Remove fender covers and close hood. Lower vehicle. ong April 1992 FORD ESCORT RS COSNORTH: SECTION 12-11BRAKING SYSTEN 12 221 0 BRAKE DISC — CHECK RUN-OUT ~ FRONT AND REAR SPECIAL SERVICE TOOLS REQUIRED: Dial indicator holding fixture. 15-022 Metric diab Indicator gauge n 15-046 1, Jack up vehicle f1t chassis stands. 2, Remove front and/or rear road wheels. dise retaining clip before fitting wh nuts). Reftt wheel nuts to hold the discs in place on hub. Tighten nuts to specification. {Renove 1 Front brake disc check 3. Using dial gauge holding fixture, Special Service Tool No. 15-022 and gauge, attached to the steering ara measure disc run-out. This figure must be within 0,10 nm run-out of ‘total indicator reading. 4, Using a suitable microneter measure disc thickness at efght positions, 45° apart and 18 mm in from the outer edge of the disc, (Fig.16). If any of these readings vary by 0,01 am or more or, if the minirum thickness of the disc fs below 22,2 mm the disc should be replaced. See operation 12 224 0. age Escort RS Cosworth DEtt2-21 Fig.2. Measure dise thickness using suitable microneter, april 1992 FORD ESCORT RS COSWORTH: SECTION 12-12> BRAKING SYSTEM 12 210 \ Rear brake dsc check 5, Using dial gauge and holding Fixture attached to the lower arm measure disc run-out, (Fig.3). This Figure must be within 0,10 pm run-out of total indicator reading. Using sultable microneter measure disc thfekness at eight positions 45° apart and 15 min from the outer edge of the disc. If any of these eight readings vary by 0,01 m or sore or ff the readings are Yess than the specified wininue thickness, the dise w should be replaced. See operation 12 225. 7. Replace road wheels and torque wheel nuts to correct spect fication. Remove chassis stands and lower vehicle nse Apri 1992 Escort RS Cosworth Fig.3. Measure outer face of rear disc for run-out FORD ESCORT RS COSWORTH: SECTION 12-13Escort RS Cosworth Y 12 2240 DISC = FRONT BRAKE - REMOVE AND LUSTALL SPECIAL SERVICE TOOLS REQUIRED: NONE To Remove, A. Jack up venicle and fit chassis stands. 2, Remove road wheels. 3, Remove caliper retaining bolts, suspend Figel. Suspend caliper from tnner fender. caliper from inner fender to prevent damage to brake hose. vy 4, Mark disc and hub relative position. Remove disc securing clfp, and renove disc of f nub. To Instat NOTE: If orginal disc is to be refitted ensure ‘match marks are aligned. 5, Refit disc onto hub. Ensure hub and disc alignment marks are in line, 6. Relocate caliper onto spindle carrier, refit caliper retaining bolts and torque to specification. NOIE: Turn steering from lock to lock and check that brake hose does not twist up causing danage to hose by chafing. 7. Refit road wheels and tighten. 8. Remove chassis stands and lower vehicle. Apply foot brake to bring brake pads in the correct adjustment with disc. Fig.3. Dise removal. ~~ cage April 1992 FORD ESCORT RS COSWORTH: SECTION 12-14> BRAKING SYSTEM 12 25 0 DISC ~ REAR BRAKE - REMOVE AND INSTALL (one stde) SPECIAL SERVICE TOOLS REQUIRED: MONE WARNING: REAR BRAXE SYSTEM 1S SUBJECTED TO HIGH HYDRAULIC PRESSURE. 00 NOT APPLY FOOT BRAKE ONCE CALIPER HAS BEEN” REFOVED. To Remove 1, Slacken re whee? nuts. 2. dack up vehicle and fit chassis stands. 3. Remove road whee? and release handbrake. 4. Detach handbrake cable from lover arm retaining clip. 5. Remove caliper anchor bracket retaining bolts. Suspend caliper clear of disc preventing any stress to flexible hose, Fig.3. 6. Renove disc retaining clip from wheel stud. Wark dise and hub relative position, renove Escort RS Cosworth ise from hub. CE4COS-~12-22 Fig.3. Rear caliper shown suspended. ong Aprit 1992 FORD ESCORT RS COSWORTH: SECTION 12-15BRAKING SYSTEM 42 225 0 To Install NOTE: If original disc fs ta be refitted ensure match aarks are aligned. 7. Refit disc onto hub align match marks, refit clip. 8, Reposition caliper over disc and fit retaining bolts, torque to specification. 9. Relocate handbrake cable into lower arm clip ‘and secure. 10. Apply handbrake and refit road whee! /s. LL. Remove chassis stands, loner vehicle and fully tighten road wheels. 492 Escort RS Cosworth Apri 1992 FORD ESCORT RS COSWORTH: SECTION 12-16> BRAKING SYSTEM 12 233 0 DISC PADS - FRONT - REPLACE SPECIAL SERVICE TOOLS REQUIRED: Caltper piston expander Hexagon key adaptor GE-2031 8-94) Jo Remove 1. dack up front of vehicle, and fit chassis stands. 2. Remove road wheels. 3. Remove spring retaining clip from caliper housing. Using hexagon key adaptor 7 mm socket, unscrew bolts until piston housing is free fron anchor bracket. 5. Separate piston housing from anchor bracket, remove inner pad fron piston. Using caliper piston expander, carefully force piston back in to housing. 6. Remove outer brake pad from housing jaw. ons2 Escort RS Cosworth DeH12416 Fig.l. Remove cal fper spring cl1p. DEM2s7 Fig.2. Ustag 7 mm Hexagon key socket, renove slidesbolts. DeW298 Fig.3. Carefully force piston back into piston housing using piston expander. April 1992 FORD ESCORT RS COSWORTH: SECTION 12-17p> BRAKING SYSTEM 12 233 0 To Instat 7. Fit pad into caliper piston housing. Peel off sticky back paper from non piston pad and Jocate onto pad guide of anchor bracket. 8. Ensure pads and disc or dirt contamination. -@ free from any grea 9. Assenble pistons housing to anchor bracket, Secure with 7 om hexagon bolts. Torque to Spectficatfon. 10. Reconnect caltper pfston housing spring. Lb Refit road wheels remove chassis stands and lower vehicle. 12. Apply foot brake several times to ensure brakes are correctly adjusted before moving off. ong2 Escort RS Cosworth Figs4. Locate brake pads into piston housing. April 1992 FORD ESCORT RS COSHORTH: SECTION 12-18Escort RS Cosworth 32 237 0 DISC PADS - REAR - REPLACE tone side) SPECIAL SERVICE TOOLS REQUIRED: Piston wind back =... 12-006 CAUTION: Rear brake system is subjected to high hydraulic pressure. 00 NOT apply foot brake once caliper has been renoved from anchor bracket. DE112-28 To Remave 1. Slacken rear wheel nuts. Release handbrake. 2. Raise vahicle and fit chassis stands. Remove road wheels. 3. Detach handbrake cable From loxer arm retaining chip. 4, Remove forward bolt securing piston housing to carrier anchor bracket, Swing piston assenbly away fron brake disc. 5. Reswove brake pads from carrier bracket. 6. Using Special Service Toot 12-006 wind back piston clockwise into housing. NOTE: Ensure one slot in piston face 1s positioned so that it will engage with key on brake pad backing plate. Fig.3. Wind back piston using Spectal Service Tool 12-005. 0892 Aart) 1992 FORD ESCORT RS COSWORTH: SECTION 12-19BRAKING SYSTEM 12 2370 fo Instat 7, Position brake pads in carrier bracket. 8. Swing piston housing over disc. posi tionin: Slot tn piston over ey in brake pad baci ing plate. Ensure brake pad anti rattle springs are correctly positioned in piston housing, refit bolt to caliper anchor bracket si ide Pin, torque to specification. 9. Relocate handbrake cable into Tower arm securing clip. 10. Apply foot brake, to bring pads into contact with’ disc, ensuring correct adjustrent. AL, Refit road wheels, remove chassis stands and Tower ventcte. 12. Fully torque road wheels. 4g Escort RS Cosworth Ce14c08-12-11 Fig.4. Lower arm handbrake cable clip. ‘Apri 1992 FORD ESCORT RS COSWORTH: SECTION 12-20 weBRAKING SYSTEN 12 243 0 CALIPER ASSEMALY - FRONT - REMOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: Hexagonal tey adaptor =, MS-94 WARNING: SWITCH OFF_IGNITION (POSITION ‘O'), AND ‘APPLY FOOT BRAKE AT LEAST 20 TIMES OR UNTIL PEDAL BECOMES HARD TO DE-PRESSURISE THE ‘SYSTEM. NOTE: If brake fluid is spilt on paintwork the affected area must be washed down with cold water imediately. To Renove 1. Jack up vehicle, fit chassis stands and remove front wheels. 2, Renove clip securing brake pipe/flexible hose to front crossmember, (F1g.1). 3. Discomect brake pipe and flexible hose, fit blanking plugs to brake pipe and Flexid{e hose to prevent excessive fluid oss. 4. Remove spring retaining clip from caliper housing, (Fig.2}. 492 Escort RS Cosworth clip. DEHI216 Fig. Remove piston housing spring clip. Apri 192 FORD ESCORT RS COSHORTH: SECTION 12-2112 243 0 Escort RS Cosworth 5. Using hexagonal key adaptor 7 mm socket. Unscrew bolts until piston housing is free from anchor bracket. 6. Remove bolts securing anchor bracket to spindle carrier. ben47 7. Reaove brake pads and flexible hose from caliper piston houstng. Fig.3. Remove piston housing stfde bolts. To instal) 8, Secure anchor bracket to spindle carrier, torque bolts to 1 to 61 Nn. 9. Fit brake pad {nto caliper piston. Peel off sticky backing paper from non piston pad and secure onto housing jaw. AM, Reconnect Flexible hose to calfper housing and tighten, 11 Ensure pads and disc are free from any grease or dirt contamination. 12. Assenble piston housing to anchor bracket, secure with 7 mm hexagonal bolts, torque to 20 to 25 kin, Fig.5. Refit brake pads into piston housing. osg2 April 1992 FORD ESCORT RS COSHORTH: SECTION 12-2212 243.0 Escort RS Cosworth N13, Remove blanking plugs from hose connection and reconmect Flexible hose to brake pipe, Recl ip brake pipe to front crossnenber. 14, Bleed front brake circuit. Once brakes have been bled apply foot brake several times to ensure correct adjustment. sila Fig.6. Position bleed jar at Teast 300 my above bleed vatve. 15. Turn road wheels from lock to lock, checking that the Flextble hose dose not ‘wind-up’. 16. Refit front wheels, remove chassis stands and Tower vehicle. 17. Fully tighten road wheels. age April 1992 FORD ESCORT RS COSWORTH: SECTION 12-23Escort RS Cosworth Fig.7. Front caliper exploded view. A= Retaining bolts C= Retaining clip «E - Oust seal G = Piston B= Anchor bracket 0 = Brake pads F = Piston seal H - Piston housing 492 April 1992 FORD ESCORT RS COSNORTH: SECTION 12-24Escort RS Cosworth 12 247 4 PISTON = FRONT CALIPER - REMOVE AND INSTALL (Caliper piston housing removed) SPECIAL SERVICE TOOLS REQUIRED: NONE ‘To Renove 1. Apply Tow hydraulfe or low air pressure to caltper piston inlet port until’ piston 1s removed.” Use a suitable spacer (wood) between piston and piston jaw preventing damage to piston face. ennge52 NOTE: The piston dust cover cannot be renoved ‘until the piston {s removed. Fig.l. Piston housing assembly. A Dust cover C - Piston B= Piston seal 0 = Caliper 2. Hook out piston seal and dust cover. 43. Wash piston and cylinder bore fn comerctal alchol, methylated spirits. 4. Check piston and cylinder bore for sign of damage, scuffing, scores or corrosion. If cylinder bore body is corroded use wire wool to clean. Do not attenpt to clean piston surface. To Instat + Fig.2. Resove piston from piston housing using low aim pressure. 5. Lubricate cylinder bore and new piston seal with brake fluid, 6. Locate new piston seal in cylinder bore groove. 7. Stretch dust cover over piston and assenble piston into cylinder bore. 8. carefully push piston fully hoe into cyl tnder bore. Refit brake pads and assemble caliper assembly to anchor bracket. a Fig.3. Stretch dust cover over piston asseably and push piston into housing. o4g2 Aprit 1992 FORD ESCORT RS COSWORTH: SECTION 12425BRAKING SYSTEM 12 253.0 CALIPER ASSEMBLY ~ REAR INSTALL SPECIAL SERVICE TOOLS REQUIRE owe WARNING: SWITCH OFF IGNITION {POSITION '0"), ‘AND. APPLY FOOT BRAKE AT LEAST 20 TIMES OR WTI PEDAL BECOMES WARD TO DE-PRESSUATSE THE SYSTEN. NOTE: IF brake fluid is spilt on paintwork the affected area must be washed down with cold water immediately. To Remove 1. Open hood and fit fender covers. 2. Jack up vehicle and fit chassis stands. 3. Renove road wheels. 4. Release handbrate lever. 5. Disconnect flexible hose from brake pipe, fit blanking plugs to prevent excessive Fluid oss. 6. Remove caliper anchor bracket retaining bolts. 492 Escort RS Cosworth Fig.1. Disconnect flexible hose from brake pipe : Fig.2. Remove anchor bracket retaining bolts. April 1992 FORD ESCORT RS COSKORT SECTION 12-2612 2530 Escort RS Cosworth \ 7, Unhook handbrake cable from lever, 14ft out caliper assenbly. 8. Renove brake flexible hose from caliper. To Instat 9. Comect handbrake cable to caliper lever. Fig.3. Unhook handbrake cable from lever. 10. Nount calfper into position and secur Tighten mounting bolts. 11s Reconnect hydraulic flextble hose to brake pipe. 12, Bleed brake cfreuft and check for flutd leaks. 13. Refit road wheels renove chassis stands and Tower vehicle. 1M. Fully tighten road wheels. oag2 Apri 1992 FORD ESCORT RS COSWORTH: SECTION 12-27BRAKING SYSTEM Escort RS Cosworth DEL-2-32 Fig.5. Rear caliper, (exploded view). jston housing §—D = Slid = Locating washer = Piston assembly Bort = Retaining bolt C= Bleed valve oss K = Return sprin U7 Aandbrake ever April 1992 FORD ESCORT RS COSHORTH: SECTION 12-28BRAKING SYSTEN 12 253 8 CALIPER ASSEMBLY - REAR — OVERHAUL — CALIPER REMOVED SPECIAL SERVICE TOOLS REQUIRED: Rear celfper piston wrench Rear caliper Spring compressor .. To Dismantie 1, Throughly clean caliper body, removing a1] brake dust and road dirt. Remove slide pin bolts from anchor bracket and remove slide pins. 2, Mount caliper tn vice, use soft vice Jaw protectors. 3. Using Spectal Service Too! 12-006 pfston wrench, wind back caliper piston anti-clock wise until it protrudes approximately 20 om. Disengage piston protective cover gatter fron groove in piston. 4, Renove piston wind dack tool and reposition tool, winding piston fully out of engagement with adjuster nut. 5. Remove piston and protective gatter. Check conditton of piston seal contact area, if scored or corroded this must be replaced. Piston overhaul 6. Renove circlip from piston body, pull out adjuster nut with thrust washers, weve washers and thrust bearing. 7. Wook off seal from adjuster nut, noting direction of sealing Ifp. 8. Throughly ctean ali cal {per piston ‘components: @ Adjuster nut clutch surface @ Piston breather port in piston groove 15 clean and clear. o4g2 Escort RS Cosworth ver 9 c Fig.l. Using Spectal Service Too! 12-006 wind back piston. besa. Fig.2. Renove circlip from piston body. April 1992 FORD ESCORT RS COSMORTH: SECTION 12-29BRAKING SYSTEM 12 253.8 Cat iper body overhaul 9. Renove piston hydraulic seal from caliper be 10. Using Spectal Service Tool 12-007 spring compressor, screw spring compressor onto fast thread adister. Remove circlip securing spring cover housing. NOTE: 00 NOT over compress spring as damage to ‘spring cover housing will result. 11, Remove circlip retaining key plate, pull Adjuster fast thread and key plate’ from caliper body. Remove '0" ring from adjuster fast thread, 12. Renove handbrake strut fron bore. 13, Disconnect handbrake lever return spring from lever and remove. Remove stop bolt. AM, Slide lever and shaft from bore. seal using suf teb Remove shaft jever (screwdriver. 15. Throughly clean all caliper body components: ¢ Examine handbrake shaft, Tight corrosion on shaft nay be cleaned using wire wool. If heavily corroded or scored fit new tever assenbly. 16. If new lever fs to be fitted examine lever shaft bush for damage, if damaged remove bush using suitable Internal puller. o4g2 Escort RS Cosworth EN 12-38 Cc Fig.3. Reaove circlip from caliper body using Spectal Service Tool 12-007. Fig-4. Handbrake Yever assembly. April 1992 FORD ESCORT RS COSNORTH: SECTION 12-30BRAKING SYSTEM 12 253.8 To Reassenble 17, Fit new handbrake lever bush, ress into housing to a depth of 7,5 ma’from Tower seal lip, Ensure cutout in Side of bush is aligned with push rod bore. 18. Lightly coat surface of lever shaft and bush with brake grease. 19. Press in shaft seal into housing until tt, seats on shoulder. Slide lever into housing through seal ensuring seat Tip is not damaged during assembly. 20. Fit handbrake stop bolt and spring. 21. Locate handbrake strut into caliper bore, lubricate bore around strut with brake grease, 22. Fit new ‘0! ring seal ta fast thread adjuster. Reftt adjuster into caliper bore, Fit key plate, ensure dimple an plate is correctly Tocated in caliper dritling. Refit circlip. 23, Slide spring seating washer, spring and cover housing over adjuster thread. NOTE: Ensure cover housing tang feet are not. distorted or bent. 24. Using Service Tool 12-007 carefully compress spring and fit retaining circlip. NOTE: Care must be exercfsed when fitting circlips ‘Otherwise auto adjuster will fail to function. sez Escort RS Cosworth Del-12-61 1 Fig.5. Press in bush to a depth of 7,5 mm (xX) from seal Tower Vip. veriea7 Assenble fast thread adjuster and spring assenbly. April 1992 FORD ESCORT RS COSHORTH: SECTION 12-31=> BRAKING SYSTEM 12 253 8 25. Lubricate bore of caliper body with hydraulic Fluid and fit piston seal into groove. 26, Reassenble piston assembly, Fit new seal to adjuster out, ensure seal is correctly ed. 27. Lightly lubricate piston adjuster nut contact face with brake grease and assemble, fitting thrust bearing, washers and wave washer. Secure with circlip. 28. Fit piston protective gaiter into caliper body groove. 29. Stretch piston protective gatter over piston and start thread of adjuster aut onto fest ‘thread. 30. Using Service Tool 12-007 screw piston into caliper base. Locate piston protective cover ‘into piston groove. 31. Refit slide pins to anchor bracket locate gaiters in grooves. Lubricate slide pins and ‘gatters using specified: brake grease. 492 Escort RS Cosworth Fig.7. Ptston and adjuster nut assembly. & Fig.8. Guide pin assenbly. Apri 1992 FORD ESCORT RS COSKORTH: SECTION 12> BRAKING SYSTEN 12 259 4 SPLASH SHIELD ~ REAR - REMOVE AND INSTALL (Cal fper Renoved) SPECIAL SERVICE TOOLS REQUIRED: NS 100 Medium two legged puller {swivel Tegs) To Renove 1. Slacken rear hub nut. NOTE: Mud retaining nuts are handed. ‘thread on left hand side of vehicle and thread on right hand side of vehicle. 2, Remove spring clip retaining disc to hub. Wark hud and disc relative positions. 3. Remove rear hub aut and pull off drive Flange, Fig.2. 4. Renove four bolts securing splash shield and bearing carrier plate. osg2 April 1992 Escort RS Cosworth cEt4c0s-12-14 Fig.l. Remove spring clip retaining disc to hub. cEt4cos-12-16 Fig. | Remove splash shield caliper plate retaining bolts. FORD ESCORT RS COSWORTH: SECTION 12-33,BRAKING SYSTEM 12 259 4 To instal) 5. Ensure all contact faces are clean. Refit splash shield and caliper carrier plate. Torque retaining bolts. 6. Slide hub flange onto drive shaft spigot and Fit mut and torque to specification. 7. Refit brake disc and spring retaining clip. NOTE: Once vehicle brake assenbly 1s reassembled ‘and vehicle 1s lowered to the ground, check torque of hub retaining nut. oeg2 Escort RS Cosworth cE14c08-12-17 Fig.4. Splash shield assenbly. April 1992, FORD ESCORT RS COSWORTH: SECTION 12-34Escort RS Cosworth 12 333.0 BRAKE PEDAL - RENOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: NONE To Renove 1. Open hood fit fender covers and disconnect, battery earth lead. 2, Remove pedal cross-shaft circlip and brake pedal serva connecting rod retaining clip, Fig. 3. Remove brake light. switch/pedal position sensor from bracket, Fig.2. Refer to Section Fig.1. Remove underdash cover pane? 33 Operation 33 584°0. Disconnect mut2iphug before removing switch. 4. Push pedal pivot shaft out of pedal box assembly suffictent to release brake pedal. Remove pedal and spacers fron vehicle. To Insta 5. Examine pedal bushes and repla necessary. 6. Position brake pedal over servo connecting rod, replace spacers and push cross-shaft cEvai20a Through pedal and locate *0* section end in pedal box, see Fig.3, Fig.2. Remove brake Might switch/pedal position sensor. Fig.3. & Pedal pivot shaft 7. Replace cirelfp, servo connecting rod clip and brake Tight switch/peds1 position sensor (refer to Section 33, Operation 33 584 0). Recomect aultiplug. 8. Recomect battery, remove fender covers and close hood. Fig.3. Brake peda assembly. oas2 April 1992 FORD ESCORT RS COSWORTH: SECTION 12-36BRAKING SYSTEM 12 Hi 0 BRAKE FLUID RESERVOIR — REMOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: NONE NOTE: If brake fluid is sp{it on paintwork the affected area must de washed down with cold water inmediately. WARNING; SWITCH OFF IGNITION (Position '0"). Apply foot brake at leest 20 tines or until pedal becones hard to de-pressurise the systen. To Remove 1. Open hood fit fender covers and disconnect battery earth lead. 2. Ensure braking system pressure fs fully discharged. 43. Oetach brake flutd reservoir filler cap multi- plugs. “Remove filter cap. 4. Remove screw and clip securing reservoir to hydraulic unit. 5, Remove spring clip releasing low pressure pipe from electric pump. Drain Fydraulic fluid into sultable container. 6. Carefully reaove reservoir from hydraul fe unit. 7. Remove reservoir seals from hydraulic unit. 8. Remove low pressure hose from reservoir. soz Escort RS Cosworth CEv4COS-12-33, W Fig.2. Reaove spring clip releasing low pressure pipe. : April 1992 FORD ESCORT RS COSHORTH: SECTION 12-36BRAKING SYSTEM 123410 fo Instalt 9. Replace both reservoir seals. Ensure that rear sea) fs aligned correctiy in hydraulic ‘un't bores. 10. Refit low pressure hose to reservoir. 11. Lubricate seals and reservoir connections with brake fluid. Fit reservoir to hydraulic unit. 5 Secure reservoir to hydraulic unit with screw and clipe 13, Reconnect Yow pressure hose to electric hydraut fe pump, refit locking clip. NOTE: Ensure that hose elbow connections are finaly pushed {nto pump assendly before Titting lecking clip. 14. Top up reservotr with new brake fluid. 15. Reconnect battery. Ensure tgnition switch ts off (position ‘0 16. Bleed braking system, check for leaks. Reconnect fluid Tevel multiplug connections. 17. Remove fender covers and close hood. 18. Check operation of braking systen. 492 Escort RS Cosworth aprit 1992 FORD ESCORT RS COSNORTH: SECTION 12-37BRAKING SYSTEM Escort RS Cosworth CEVacos-12-31 Fig.6. Hydraulic unit assembly. As Reservoir and fluid C- Main valve F = Electric motor and W~ Pressure switch Vevel warning indicator 0 - Master cylinder hydraulic pressure pump 8 = Accumslator E = Push rod assembly G - Booster assembly. 92 FORD ESCORT RS COSHORTH: SECTION 12-38 Apri 1992<> BRAKING SYSTEH 12 580 0 HYDRAULIC UNIT = REMOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: NONE Not If brake flutd is spttt om paintwork, the ‘affected area must be washed down with cold water immediately. WARMING: SWITCH OFF IGNITION (position '0"} Apply foot brake at least 20 times or untiT the brake pedal becomes hard to de-pressurise the systen. To 1. Open hood, Fit fender covers and disconnect battery earth Yead. WARNING: Ensure braking system pressure is fully dtscnarged. 2, Disconnect electrical connections from hydraulic unit, (pressure sw{tch, main valve, reservoir fTlér cap, electric hydraulic punp and earth connection) 3, Disconnect hydraulic pipes from hydraulic unit valve body, fit blanking caps to prevent dirt ingress. 4. Remove under dash trim panel fran around the brake pedal, where applicable. 5. Rewove brake pedal push rod clip. 6. Renove hydraulic unit mounting nuts. NOTE: The aid of a second technician shoutd be ‘used to support the hydraulic unft when Femoving mounting nuts. 492 Escort RS Cosworth Fig.1. Disconnect electrical connections from hydraulic unit. unit. . Fig.3. Renove tydraultc unit mounting nuts and pedal push rod clip. April 1992 FORD ESCORT RS COSWORTH: SECTION 12-3942 580 0 Escort RS Cosworth Lift out nydraulic unit from vehicle and drain reservoir. NOTE: D0 not 1éft hydraulic unit by its hoses, reservoir or push rod. DO NOT ATTEMPT TO ACTUATE HYDRAULIC UNIT BY PUSHING PUSH ROD. 8. Remove sealing gasket material from hydraulic untt and body fixing. Fig.4. Brake pipes. To Install 9. Fit new sealing gasket materiel to hydraulic unit and body avotding Fixing studs. 10, Ftt spherical ball to push rod. carefully install hydraulic untt into vehicle ensuring push rod enters brake pedal. Care should do taken not to force push rod from its natural position. 11. Support hydraulic unit while second technician secures hydraulic unit and with four nuts. Torque to specification. 12. Reconnect brake pedal to hydraulic unit push rod clip. 13. Remove blanking caps and reconnect brake pipes to hydraulic unit, Figs 4 and 5. WARNING: ENSURE BRAKE PIPES ARE CONNECTED TO CORRECT PORTS. SEE FIG.5. (CEMCOS-12-30 Fig.5. Brake pipe comections. vase April 1992 FORD ESCORT RS COSWORTH: SECTION 12-40BRAKING SYSTEM 12 5800 16, Reconnect electrical aultiplugs to main valve, pressure switch electrical hydraulic pump and earth connection. 15. FAM reservoir with new brake fluid. 16. Bleed front brake circuits. 17. Reconnect battery. 18 Switch ‘on’ ignition and check pump operation. NOTE: Do not allow electrical hydraulic pump to operate for more than 2 minutes. (If pump does run for nore, switch ‘off! tgnftion posttton '0' and allow motor to cool for 10 minutes. 19, Bleed rear brake circuit check system for fluid Teaks. 20. Refit under dash trim panel, where applicable. 21. Reconnect reservoir fluid filter cap mu} tiplugs. 22. Remove fender covers and close hood. 23. Check operation of boost and anti-lock function. gaz Escort R5 Cosworth Fig.7. Top up reservotr to ‘Max' mark. April 1992 FORD ESCORT RS COSMORTH: SECTION 12-41> BRAKING SYSTEM 42 S81 0 VALVE PLOCK - REMOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: NONE To Remove L. Remove whee. Remove 3 retaining nuts from under wheelarch, Fig.1. 2, Detach 6 brake pfpes from underneath valve block, Fig.2. 43, Disconnect multiplug and carefully Lift and repove valve block assembly, Fig.3. ong Escort RS Cosworth Figel. Valve block bracket retaiatng nuts. beMcos-1234 ~ aoe 7 Fig.2. Yalve block brake pipe unions. Fig.3. Valve block miltiplug and assembly. Aprit 1992 FORD ESCORT RS COSWORTH: SECTION 12-42> BRAKING SYSTEM 12 581 0 4. Locate valve block assenbly {na vice to remove pressure control regulator valve, Figed, (where required) 5, Renove 3 torx bolts, detach and remove valve block from bracket. To Install 6. Fit valve block to bracket and secure with 3 torx bolts, Locate and fit PRY to valve block assenbly in a vice and tighten to secure, (where required). 7. Locate valve block assembly into position in engine compartment. 8. Locate and secure brake plpes to valve block, Fig.5. 9. Secure valve block assembly to wheelarch with 3 nuts and refit multiplug. 10. Bleed entire braking system and check operation of anti-lock function. ase Escort RS Cosworth ce14c08-12-87 Figs4. PORY removal. a ‘CEiacos-1235 Fig.5. Valve block brake pipes. April 1992 FORD ESCORT RS COSHORTH: SECTION 12-43Escort RS Cosworth 42 502 0 ACCUMULATOR - REMOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRE! Hexagon Key adaptor... MS-94 WARNING: SWITCH OFF IGNITION {posi tfon '0') Apply foot brake at Teast 20 tines or until the brake pedal becones hard to de-pressurise the systen. NOTE: If brake flutd is spilt on paintwork, the affected area rust be washed down with’ cold water (mediately. Fig.l. Slacken accumlator, cover base of accumulator with cléan cloth. To Remove 1. Open hood, Fit fender covers and disconnect, battery. 2. Ensure braking systen pressure ts fully atscharged. 3. Carefully venove accumulator from hydraulic unit using the hexagon key adaptor. Cover base of accumlator with a clean rag to prevent any dirt ingress. To Install 4, Ensure ‘0' ring Is fitted and in good DEI-12-49 1 condition. Fig.2. Fit new '0" ring seal to accumulator. 5. Fit accumulator to hydraulic unit and torque ‘to spect fication. > 6. Reconnect battery. 7. Switch on ignition and check accumlator charge tine, (should be less than 60 seconds). 8. Bleed braking system in accordance with Operation No. 12 1410, Check for leaks. 9, Reove fender covers and close hood. 10. Check operation of boost and anti-Tock function. ong2 ‘april 1992 FORD ESCORT RS COSWORTH: SECTION 12-84<> BRAKING SYSTEM 32 566 0 HYDRAULIC PUMP and MOTOR ASSEMBLY - REMOVE AND. INSTALL SPECIAL SERVICE TOOLS REQUIRED: Mexagon Key adaptor ., 45-94 WARNING: SWITCH OFF IGNITION (position °0") Apply foot brake at Teast 20 tines or until the brake pedal becones hard to de-pressurise the system. NOTE: If brake Fluid is sptt on paintwork, the affected area must be washed down with’ cold water immediately. To Renove 1, Open hood, fit fender covers and disconnect battery. 2, Ensure braking system pressure ts fully discharged. NOTE: It may be necessary to rewove the hydraulic unt following Op. No. 42 580 0. 3. Undo pipe nuts securing high pressure pipe to punp body and remove pipe. . 4. Using hexagon key adaptor remove accumulator Fron’ purp body. 5, Disconnect mul t{plug connection from pressure switch, Fig.3. 6. Disconnect mul tiplug from pump motor, Fig.3. vege April 192 Escort RS Cosworth CEI4.COS-12-27 Fig-L. Remove high pressure pipe auts. CEN4COS-12-38 1 Fig.2. Renove spring clip releasing tow pressure pipe from nydrauiie pump. Fig.3. Pressure switch (A) and pump (8) multiplug. FORD ESCORT RS COSWORTH: SECTION 12-45> 12 686 0 7. Remove pump housing to hydrauiic unit. mounting bolt 8. Renove pump housing assembly fror hydraul ¢ unite WARING: Do not use anything other than properly designed and manufactured hose Clamp. Unseen damage to the fabric of the hose will result if unsuitable tools are used. 9, Remove spring clip to release Tow pressure pipe from hydraulfe pump. Clamp low pressure hose using suttable hose clamp to prevent excessive Fuld Toss. 10. Renove pressure switch from pump housing. 11, Prise out punp mounting insulators and tubes from pump body. Zo Install 12. Fit mounting tubes and insulators to pump housing. 13. Refit pressure switch into pump housing, ensure sealing ‘0' ring fs in good condition, Adjust plastic collar so that drain tube 1s facing pump motor. 14. Connect Yow pressure hose and secure with spring cifp. Locate pump onto hydraulic unit. Pass mounting bolt through bushes and torque to specification. 15. Reconnect high pressure pipe. 16. Fit new '0' ring onto accumilator and Fit to pump housing tighten accumator. o4g2 BRAKING SYSTEM Escort RS Cosworth 9E1-12-69 Fig. Purp housing mounting assenbly. DEI 12-49 Fig.5. Fit new accumator ‘0' ring. Aprit 1992 FORD ESCORT RS cOSNORT SECTION 12«42 586 0 Escort RS Cosworth 17, Reconnect multi plugs to punp and pressure switch ensure sealing boots are correctly fitted. 18. Top up reservolr with new brake fluid. 19, Reconnect battery. Switch ‘on' ignition, check for nydraul te Fluid Teaks allow pump to run unt i? switch "oft. Fig.6. Top up reservoir to ‘Max’ mark. Do not allow hydraulic _punp te operate for more than 2 minutes (if pump does run for more switch 'off* ignition position '0' and allow pump motor to cool for 10 minutes}. 2. Bleed brake systen, 22. Remove fender covers and close hood. 23. Check operation of ant{-lock system. osg2 April 1992 FORD ESCORT RS COSWORTH: SECTION 12-47> BRAKIN G SYSTEM 12 509 0 PRESSURE SWITCH ~ REMOVE AND INSTALL REPLACE SPECIAL SERVICE TOOLS REQUIRED: Pressure switch wrench ., 12-008 WARNING: SWITCH OFF IGNITION (position '0") Apply foot brake at least 20 tines or until the brake pedal becomes hard to de-pressurise ‘the syster. NOTE: If brake flufd is spilt on paintwork, the ‘affected area must be washed down with’ cold water timediately. To Remove 1. Open hood, Fit fender covers and disconnect, battery, Ensure braking system pressure is fully discharged. 3. Disconnect pressure warning switch mul tiplug. 4. Using Special Service Tool 12-008 remove Pressure warning switch. To Instat 5. Fit new '0' ring seal to pressure warning switch. 6. Screw in switch and tighten using Special Service Tool 12-008, Adjust plastic band until drain tube in'band is facing pump body. 7. Reconnect pressure warning switch aul tiptug. 8. Reconnect battery, switch on ignition and check switch and pump operation. 9. Bleed brake system {n accordance with Operation No. 12 141 0, 10. Remove fender covers and close hood. 0892 Es Figs. Disconnect multiplug. Spectal Service Tool-12-008 cart RS Cosworth shown in place. April 1992 FORD ESCORT RS cOSHORTH: 2 SECTION 12-48BRAKING SYSTEN 12 590 0 WIGH PRESSURE HOSE - RENOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: NONE WARNING: SNITCH OFF IGNITION (position '0"). ‘Apply foot brake at least 20 times or until the brake pedal becomes hard to de-pressurise the system. NOTE: If brake fluid is spiTt on paintwork, the affected area must be washed dosn with cold water immediately. To Renove 1. Open hood, fit fender covers and disconnect battery 2. Ensure braking systen pressure fs fully discharged. NOTE: 1t may be necessary to remove the hydraulic unit following Op. Wo. 12 580 0. 3. Undo high pressure pipe nuts and remove pipe from hydraulic unit. To Instat) 4, Fit high pressure pipe to hydraulic unit. 5. Reconnect battery. 6. Bleed braking system fm accordance with Operation No. 12 141 0, and check for hydraulic fluid leaks. 7. Remove fender covers and close hood. ase Escort RS Cosworth Figel. Renove high pressure pipe nuts. April 1992 FORO ESCORT RS COSWORTH: SECTION 12-49> BRAKING SYSTEM 12 S91 0 LOW PRESSURE HOSE = REMOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: NONE WARNING: SNITCH OFF IGNITION (posttion '0"). Apply foot drake at least 20 times or untfl the brake pedal becones hard to do-pressurise the systen. NOTE: If brake Flutd fs spflt on paintwork, the affected area mst be washed dawn with’cold water immediately. To Renove 1. Open hood, fit fender covers and disconnect battery. 2, Ensure braking system pressure ts fully discharged. NOTE: {t may de necessary to remove the hydraulic unft foilowing Op. No. 12 580 0. 3, Remove spring clip to retease low presture pipe from hydraulic punp. Allow hydraulic fluid to drain into suitable container. 4. Puld off hose from reservoir filter connection. 492 Escort AS Cosworth CEMCOS-12-33 u FigeL+ Remove spring clip to release low pressure hose from pump body. Fig.2. Renove low pressure hose from reservoir. Apri 1992 FORD ESCORT RS COSHORTH: SECTION 12-5012 591 0 Escort RS Cosworth To Instalt 5. Connect Tow pressure hose to reservoir filter connection push on fully. 5. Connect hose ta hydraulic pump, secure with spring clip, once fitted check security of hose in pump. DEH12-48. 7. Top_up reservoir with new brake fluid check -Fig.3- Top up reservotr to 'Max' mark. or Beaks. 8, Reconnect battery. 9. Bleed braking system and check for hydrautic fluid Teaks. 10. Renove fender cover and close hood on92 ApriT 1992 FORD ESCORT RS COSNORTH: SECTION 12-61Escort RS Cosworth 12 662 0 HANDBRAKE CABLE ~ ADJUST SPECIAL SERVICE TOOLS REQUIRED: MONE To Adjust 1. Raise vehicle on ramp or jack up and fit shassis stands. Release handbrake lever. 2, Remove locking pin from adjuster. Stacken ijuster Vocknut and adjuster untiT both handbrake Tevers on caliper have fully cetacos.12.18 returned to stop. Fig.l. Handbrake adjuster assenbly. A ~ Locknut B- Adjuster 3. Paint alignment white Tine on Tever and caliper body. ~ 4. Adjust handbrake cable adjuster against body abutnent bracket until efther handbrake caliper lever starts to move from the alignment line. 5. Apply handbrake to equalise cable. 6. Tighten handbrake cable Tocknut onto adjusting sleeve, finger tight, then using suitable yrench, tighten lockhut to ¢ mininun of three clicks" and a maximum of six ‘clicks’. Finally 1 @ new adjuster locking pin. NOTE: One complete turn of the adjuster represents six ‘clicks'. 7. Lower vehicle to ground. Fig.2. Caliper handbrake lever adjustment alignment marking. one April 1992 FORD ESCORT RS COSWORTH: SECTION 12-52> BRAKING SYSTEM 12 644 0 LEVER ASSENBLY — HANDBRAKE - REMOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: KONE To Remove 1. Ratse vehicle on ramp or jack up and fit chassis stands. 2. Open hood Fit fender covers and disconnect, battery. 3, Discomect equaliser yoke from handbrake actuating rod. Ranove circlip and clevis pin, 4. Renove sections of centre consote where necessary. 5. Disconnect handbrake warning switch mu? tiplug. 6. Remove handbrake mounting bolts, Tift out handbrake lever and reaove handbrake warning switch, ong Escort 85 Cosworth Fig.l. Disconnect handbrake equaliser yoke. Fig.2. Handbrake lever assembly. April. 1992 FORD ESCORT RS COSWORTH: SECTION 12-53

BRAKING SYSTEM 12 644.0 To Install 7. Refit handbrake warning Tight switch to handbrake lever. 8. Locate handbrake push rod through rubber Floor gaiter and secure. Reconnect warning tight multiplug. 9. Refit centre consote where applicable. 10. Reconnect handbrake cable equaliser yoke to actuating rod. 11. Lower vehicle, Reconnect battery, remove Fender covers and close hood. 42 Escort RS Cosworth Apri 1992 FORD ESCORT RS COSHORT! SECTION 12-54<> BRAKING SYSTEM 12 675 0 CABLE WANDBRAKE ~ REPLACE SPECIAL SERVICE TOOLS REQUIRED: NONE To Remove 1, Raise vehicle on ramp or Jack up vehicle and fit chassis stands. 2, Remove both rear wheels. 3, Slacken handbrake adjuster Tocknut and adjuster. 4, Remove circlip and clevis pin From handbrake equaliser yoke. Detach handbrake cable from both calipers, remove cable from caliper guide sieeve. 6. Prise open lower arm cable clip. Renove ctrcti| adjuster side} Fixings. securing outer cable (non and remove cable from body 8. Pull cable through Tower ara rear axle sub- Frame, Remove cable from vehicle. age Escort RS Cosworth Ce14C08-12-48, Figel. Slacken handbrake cable adjuster and Tockaut. A= Lockout 8 - Adjuster Fig.2. Detach cable from rear caliper. April 1992 FORD ESCORT RS COSWORTH: SECTION 12-55> BRAKING SYSTEM 12 6750 To Install o 10. a a. Be ue 18. 6. Reposition cable, ensure cable is correctly Tocated througn fever arm rear axle sub-frame. Route cable over lover arms and slide end of cable through caliper cable guide sieeve. Attach cable to caliper handbrake levers. Locate outer cable {nto body location fit Clrcl ip to secure non-adjuster side of cable to body. Reconnect cable equaliser yoke to handbrake Tever vod, fit clevis pin and ctrciip, ‘Adjuster cable as described below: © Paint alignment Tine onto cal {per body end lever. © Ensure both caliper handbrake levers are fully returned to their stops. © Adjust handbrake cable adjuster against body abutnent bracket until efther lever starts to nove from the aligneent line. © Apply handbrake to equaise cable. © Tighten handbrake cable Jocknut onto adjusting sleeve finger tight, using a suitable wrench tighten Tocknut to a Minimum of three ‘clicks’ and a maximum Of six ‘clicks’. Secure outer cable to lower arm retaining clips. Refit road wheels and tighten wheel nuts. Lower vehicle to ground, oe92 Escort RS Cosworth Y Fig.3. Reconnect equaliser yoke to handbrake lever rod. vy Fig.4. Lower arm retaining clips. April 192 FORD ESCORT RS COSKORTH: SECTION 12-56BRAKING SYSTEM 12 780 0 MODULE ~ ANTI-LOCK BRAKING SYSTEM ~ REMOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: MONE To Remove 1. Remove load space trim panel as described In Operation Ho. 43 746 0. 2. Renave 3 module retaining nuts and carefully ease madule asserbly anay, Fig.l. 3. Pull locking lever away, Fig.2, and disconnect miltiplug. Renove top bracket from aodute. To_Instalt 4, Refit top bracket to module. Reconnect. ultiplug and secure by Yowering Yocking ever 5. Locate module assembly and secure with 3 retaining nuts. 6. Refit load space trim panel as described in Operation. No. 43 745 0. 04g Escort RS Cosworth i c€14008-1 Figel. Module retaining nuts. Geracos-12-2 Fig.2- Multiplug removal. april 1992 FORD ESCORT RS COSHORTH: SECTION 12-57Escort RS Cosworth 12-785 0 WEL SENSOR — RENGVE AND TKSTALL — FRONT SPECIAL SERVICE TOOLS REQUIRED: NONE To Remove 1, Jack up vehicle and fit chassis stands. 2. Open hood, and fit fender covers. 3. Unclip from chassis side rail. Disconnect, wheel sensor mul tiplug. Fig.1. Front wheel sensor Toon multiplug. 4. Remove bolt securing wheel sensor ta spindle carrier. Carefully pull out sensor. 5. UncTtp sensor loom from cable supports. To Instat Before refitting, ensure wheel spindle sensor carrier bore and’sensor mounting face 1s clean and free from rust, or rough edges. 6. Liberally coat sensor spindle carrier bore and hanfer with wheel bearing grease. 7. Ft new ‘0° ring to wheel sensor. 4, Coat sensor with grease and push sensor Firmly into spindle carrier bore until flush. Secure with bolt and washer. 9. Bef sensor Yom int cable suport. 10 Reconnect sensor toon to main toom and secure to side rail clip. Ensure connector '0' ring is correctly seated, AX. Remove fender covers, and close hood. 12. Lower vehicle and check anti-lock operation. DEI-4-22 Fig.2. Remove whee? sensor. age April 1992 FORD ESCORT RS COSWORTH: SECTION 12-58> BRAKIKG SYSTEN 12 785 0 WIEEL SENSOR - REMOVE AND INSTALL — REAR SPECIAL SERVICE TOOLS REQUIRED: NONE CAUTION: Rear brake system 1s subjected to high hydraulic pressure. 00 HOT apply foot brake once caliper has been removed fron anchor bracket. To Renove 1, Jack up vehicle and fit chassis stands. Renove road wheels. 3, Release handbrake cable lever. 4, Remove two torx bolts and rear seat cushion, Fig.l. 5. Disconnect whee! sensor plug from mata Voom, Fig.2. 6. Prise out gromet and pass sensor cable ‘through Floor pane?, Fig.3. 7. Renave handbrake cable froa lower arm securing clip. 8. Remove forward bolt of caliper slide pin, swing caliper up and retain in positicn. 9. Renave bo}t securing wheel sensor to mounting bracket, carefully renove wheel sensor. a2 Escort RS Cosworth Fig.3. Sensor loom gromet, Apri] 1992 FORD ESCORT RS COSNORTH: SECTION 12-59BRAKING SYSTEM 12 785 0 To Instat Before refitting wheel sensor, check bore area around sensor mounting for damage, rust or ough edges. Rotate road wheel and check toothed wheel for darage. 1G. F#11 whee? sensor mounting bracket bore with wheel bearing grease. 11. Fit new '0" ring to wheel sensor, 12. Coat wheel sensor with grease and push sensor Firmly into nounting bracket bore until flush, secure with boit and washer, Fig.4. NOTE; Sensor agunting bolt and washer are untque (wolt 26 mm Tong and washer 1,5 thick). 13. Refit caliper mounting bolt and torque to speci fication. 16. Secure handbrake cable into Tower arm bracket, Fig.5. 16. Route whee! sensor cable along suspension Jower arm and clip in position, feed thread through Foor panel and refit gromet, F1g.6. 16. Reconnect, wheel sensor Toom to main Tom. Ensure 'O' ring in comector ts correctiy Yocated and pushed fully hone. 17. Refit seat cushion and secure with 2 torx bolts. 18. Apply handbrake, refit road wheels. 19. Lover vehicle and check operation of enti jack. ase Escort RS Cosworth CE14COS-12-44 F1g.6. Sensor loom clips. Apert] 1992 FORD ESCORT RS COSWORTH: SECTION 12-60Escort RS Cosworth 12 792.0 'G" SWITCH ~ REMOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: NONE To Remove L. Slide the front right-hand seat back to its maximum travel . / Sa ceucsaa Figel. '6' switch location and retaining screws. (seat renoved) 2, Remove the two screws holding the 'G’ switch to the floor and renove it fron the vehicle, Fig.d. 3. Remove the nult{plug from the switch. To Instat 4. Refit the multiplug. 5. Locate the "6" switch in position and secure it with the two screws. 6. Check for correct operation of the ASS. warning Tight. vane Aprit 1992 FORD ESCORT RS COSNORTH: SECTION 12-61BRAKING SYSTEM Anti-Lock Brake System (ABS) 12 Index Page Technical Data ee se eee 2 Spectal Service Tool Recognition .. +. 1 4 Service and Repatr Operations Contained sa Page Operation 12 1410 Brake System- Bleed we eee 12 154 0 Brake System - Hydraulic Fluid - Replace. eee 12 22.0 Brake Disc - Check Run-out - Front and Rear . ws re) 12 224 0 Disc - Front Brake - Renove and Install ce 10 12 225 0 Rear Brake - Remove and Install... Ba 12 2330 Disc Pads - Front - Replace Bo rT 12 237 0 Oise Pads - Rear - Replace = « Soe 1“ 12 243.0 Caliper Assembly - Front - Remove and Install. yew 16 12 247 4 Piston Front Caliper - Remove and Install es 16 12 26 0 Caliper Assembly - Rear - Romove and Instal? : toe ow 12 393.0 Brake Pedal - Remove and Install BB 12 341 0 Brake Fluid Reservotr ~ Remove and instar? ee aD 12 580 0 Hydraulic Unit = Remove and Install... eos = 2 12 581 0 Yatve Block - Remove and Install Be 8 12 $82.0 Accumulator - Remove and Instat] oon oe oF 12 586 0 Hydraulic Punp and Motor Assembly - Renove and Install... = weve 28 12 509 ¢ Pressure Switch - Renove and Install fon to 12 591 0 Low Pressure Hose ~ Remove and Install 8 12 755 0 Brake Pressure Control Valve - Remove and instal] 4» ee = ewe 12 780.0 Module Anti-lock Brake System - Remove ard Install rr re? 12 785.0 Wheel Sensor - Renove and Install = Front... ee ee ee ee 8 12 185.0 Wheel Sensor - Remove and Install - Rear se eee 990 September 1990 FORO SIERRA RS COSHORTH: SECTION 12-1TECHNICAL DATA System see ae neve ae Teves: mark 2 electronic anti-lock system. Dual circuit with front/rear split. Type ws ve weve ae Front: Twoswheel drive = ventilated discs with four piston calipers Four-wheel drive = ventilated discs with single piston calipers Rear: Two-wheel drive - sotid discs with single piston calipers Four-wheel drive ~ ventilated discs and single Piston calipers. Handbrake te vs vege ee Manual Tever, located between front seats, operating on rear wheeis only. Nanual cable adjustient. Lubricants General greese wee Mea Handbrake lever yoke/ctevis pin and brake pedel shaft/bushes =... SeMIC-75A Brake pad backing plates to carrier plate ol frakote grease Brake Fluid Brake flutd (amber). sve ve SAM-6C9103-8 . Anti-lock Braking System Accumulator Pressures bar lydrautic pressure pump switch 'off" pressure. 160 to 190 Hyéraulte pressure pump switch ‘on* pressure -. 130 to 150 ABS warning ight switch ‘on’ pressure «110 to 100 990 September 1990 FORD SIERRA RS COSWORTH: SECTION 120-2BRAKING SYSTEN TECHATCAL DATA Front disc brakes - ventilated in Dise diameter (Two-wheel drive) «ves 288.0 1a (Fourewheel drive) 0. v) tL 2780 10,95 Disc runout wee 0,15 0,006 Nintaum disc thickness ee 28 08 Maximun thickness vartation . +. ++ ve 0,01 00008 Rear disc brakes mm in Dise diameter (Two-whee? drive) ” 10,75 {Four-whee! drive) 10475 Dise runout ewe we we ” 0,006 Minimum disc thickness (Two-wnee! drive) 0,35 (Four-wnee? drive) on Maxinua thickness variation... 0,006 Tightening torques tin Kata dota caliper (front) se eve ues SL OL Syl to G17 to a5 Caliper (front) caliper bolts (M9). «sto 22,0 4 25 18 to 19 Rear caliper anchor bracket bolts. + SL to 61 81 to 6,1 37 tos Rear caliper slide pin bolts...) to 3831 to 3,5 23 to 26 fydrauiic unfons sss weave G8 O95 08 tO.0,9 5 BOT Bleed valve ws 10,2 Lo 7 Hydraulic Actuation Assenbly: lydravlie Actuation Asserbly to bulkhead... 14 to Sl 41 to 51 30 to 37 ‘Accumulator to pump housing . +. ss we AAG 3A tO AG 2 to Pump mounting bolt seve ewe tO 8 OT 09 5 tT Nigh pressure pipe union «. ss ewe tO12 OT to 125 to 9 Wheel sensor fixing bolt - front. + +s 88 toll 0,85 tol 6 to B rari. 1) 1) iS toll 085 tod = 6 to 8 990 September 1990 FORD SLERRA RS COSWORTH: SECTION 120-3 iORAKING SYSTEM SPECIAL SERVICE TOOL RECOGNITION Toot Toot Wane \ Bear caliper piston wrench 12-006 a ranch AB.5. pressure seth 12-008) pressure tester 12-009 SS b Dial Indicator holding Fixture 15-0224 Metric dial Indicator gauge 15.046 787 July 1987 FORD SIERRA RS COSWORTH: SECTION 120-4BRAKING SYSTEM 12 141 0 BRAKE SYSTEM - BLEED SPECIAL SERVICE TOOLS REQUERED: NONE CAUTION: 1f brake flutd ts spf1t on patntwork, ‘the affected area rust immediately be washed down with cold water. NOTE: When carrying out service bleed or fi]ling the system from dry, the following points must, be observed: ‘e Always use recomended brake flufd fron a new can. Never re-use brake fluid. ‘© Top up reservoir as necessary during bleeding to prevent the hydraulic pump running dry. # Ensure brake bleed tube {s in good condition and secure when fitted to bleed valves. ‘© The Hydraulic, punp motor running sound wit] alter from a high pitched buzz to a lower pitched sound once’ Mufd has purged through ‘te (D9 NOT allow pump motor to run continuously for more than 2 minutes. If pump does run for nore than 2 minutes, switch ‘off! ignition, position ‘0, and alo motor to cool for i0 minutes). WARNING: CARE MUST BE TAKEN WHEN BLEEDING THE REAR BRAKE CIRCUIT AS HYDRAULIC FLUID WILL BE SUBJECTED TO EXTREMELY HIGH PRESSURE. 1. Open hood and Fit fender covers. Using Ford recommended brake fluid top up reservoir. 2. Open front left hand caliper bleed valves fone full turn. 3. Pump brake pedal to full travel and hold down. 787 COS-120-2 ° Fig.2. Front caliper bleed valves. uly 1987 FORD SIERRA RS COSWORTH: SECTION 12¢-5BRAKING SYSTEM 12 ta 0 4. Close bleed valves, release brake pedat - 5. Repeat sub operations 2 to 4 until brake Fluid flows air froe fron bleed valves. 6, Bleed front right hand caliper in sane manner as left hand caliper. 7. Open rear left hand caliper bleed valve one full turn. . 8. Actuate foot brake. travel position. Retain foot brake in full 9, Switch ‘on' ignition, position ‘13. 10. Allow fluid to Flow fron left hand bleed valve, for at least 15 seconds, ensuring air free Huid flows. 11. Close bleed valve. 12. Release brake pedal and wait unt? hydraulfe punp has stopped (switched ‘off"). 13. Open rear right hand bleed valve one full turn, 14. Actuate foot brake to half pedal travel and retain in this position. Allow fTuid to flow until air free for at least 18 seconds. 787 DeI-12-27 Fig.3. Rear caliper breed valv Fig.4. Using suftable tool, fully depress brake pedal. uly 1987 FORD SIERRA RS COSWORTH: SECTION 12¢-6BRAKING SYSTEM 12 141 0 15. Close bleed valve. 16, Release brake pedal, wait until hydraulic pump hhas stopped (switched ‘off'}. 17, Switch ‘off* ignition (posttion * 18. Top up reservoir to "rax’ mark on reservotr. 19. Replace reservoir cap ensuring locating peg on reservoir cap is correctly located in reservoir. Reconnect wiring connections. 21. Check for correct function of anti-lock warning lamps. 22. Check braking system for leakages, function and efficiency. 787 Fig.5. Reconnect reservoir warning switch ru} ti plugs. A= ABS mul tiptug B- AMS multiplug duly 1987 FORD SIERRA RS COSWORTH: SECTION 12¢-712 1540 BRAKE SYSTEM - HYDRAULIC FLUID REPLACE SPECIAL SERVICE TOOLS REQUIRED: NONE This operation should be used in conjunctton with ‘the Brake System Bleed, Operation No. 12 141 0. To purge the brake system, continue to actuate ‘the brake pedal until al1old brake fluid fs pumped out and new clean brake fluid can be seen entering the bleed jar. CAUTION: If brake fluid is spilt on paintwork, the affected area rust imiediately be washed down with cold water. NOTE: When carrying out service bleed, purging, ‘or filling the system fron dry, the following points must be observed: # Alvays use recomended brake flufd from a new can, use brake fluid. © Top up reservotr as necessary during bleeding to prevent the hydraulic pump running dry. Ensure brake bleed tube fs in good Gondition and secure when Fitted to bleed valves. © The tydrsutic pump motor running sound will alter from a high pitched buzz to 2 lower Pitched sound once fluid has purged through it.” (U0 NOT allow punp rotor to run continuously for more than 2 minutes. If puap daes run for more than 2 minutes, switch ‘off' ignition, position ‘o', and allow motor to cool for 10 minutes) | If difficulty is experienced with purging ‘the hydraulic actuation assenbly, apply faot brake and release with ignition ‘ON’. Continue to apply. foot brake until pup motor running sound changes. WARNING: CARE MUST BE TAKEN WHEN BLEEDING THE REAR BRAKE CIRCUIT AS HYDRAULIC FLUID WILL ‘BE SUBJECTED TO EXTREMELY HIGH PRESSURE. 787 duly 1987 FORD SIERRA RS COSKORTH: SECTION 120-812 @21 0 BRAKE DISC ~ CHECK RUN-OUT FRONT AND REAR SPECIAL SERVICE TOOLS REQUIRED: Dial indicator holding fixture .. 15-022 Metric dial Indicator gauge I 15-046 1. dack up vehicle and fit chassis stands. 2. Remove front and/or rear road whe cos- 120-04 Fig.l. Check front disc run-out. Front brake disc check 3, Using ofa gauge holding fixture, Spectal YS Service Tool No, 15-022 ané gauge, measure isc run-out. The total dial gauge indicator reading should be less than 0,15 mm vartation. 4. Using @ suitable micrometer, measure disc thickness at eight positions, 45° apart at mid-pad contact area, 15 sm in from the outer edge of the disc. If any of these readings vary by 0.01 qm or more, or 1f the minimum thickness of the disc 15 below 22,8 ma, the disc shoutd be replaced. Rear brake disc check cos-12¢-05 5. Using dial gauge and holding fixture attached ‘to the Tower arm measure, disc run-out. Fig.2. Measure thickness vartation at eight equally. spaced positions. ‘The total dla) gauge indicator reading should be tess than 0,15 mm variation. 6. Using sultable micrometer, measure disc thickness at eight positions, 45° apart at wid-pad contact area 15 1m in from the outer edge of the disc. If any of these eight readings vary by 0,01 mm or more, or 1f the readings are less than the permissible minimun thickness of the disc (8,9 mm), the dise should be replaced. 7. Replace road wheels and torque wheel nuts, to specification. 8 Remove chassis stands and lower vehicle. Fig.3. Check rear disc run-out. 990 Septenber 1990 FORD SIERRA RS COSWORTH: SECTION 12¢-9> BRAKING SYSTEN 12 224-0 DISC ~ FRONT BRAKE - RENOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: NONE To Renove 1. Slacken wheel outs, Jack-up vehicle and fit chassis stands. 2, Remove front road wheels, (note position of wheels on hubs). 43, Remove caliper to knuckle retaining bolts. Release drake pipe clip from suspension strut ‘and suspend caliper to prevent damage to flexible hose. 4. Remove disc to hub retaining clips and renove sc NOTE: if original disc 1s to be refitted, mark osition of hub and disc to ensure original al ignnent. Jo Instat 5, Thoroughly clean hub and disc mating faces ensuring no dirt or corrosion is present before refitting. 6, Recal ign-disc to hub (if original is to be refitted) and secure disc to hub using spring clips. Reposition catiper onto knuckle assenbly, refit bolts and torque to specification. 8, Reclip brake pipe to suspension strut. 9. Refit front road wheels, renove chassis stands and lower venice. Torque wheel nuts Yo correct specification. 10. Apply foot brake to ensure front brake pads are correctly auto-adjusted. 990, Fig.l. Remove front caliper retaining bolts. (Two-wheel drive illustrated) cos-2c-08 Fig.2. Disc retaining clips. F153, decannect brake pipe to strut retaining clip. September 1990 FORO SIERRA RS COSNORTH: SECTION 12¢-10BRAKING SYSTEM 12 @25 0 DISC ~ REAR BRAKE - REMOVE AND TASTALL SPECIAL SERVICE TOOLS REQUIRED: NONE To Remove 1, Slacken road whee? nuts, jack-up rear of vehicle and renove road wheels. 2. Release handbrake and detach handbrake cable from lower arm clip. Renave cal per anchor bracket retaining bolts and lift off calfper. Suspend caliper clear of disc, preventing ‘any stress to flexible hose. 3. Remove disc retaining clip from wheel stud and resove disc. Mark d{sc and hub 4f original disc is to e refitted. To Instat 4. Throughly clean disc and hub mating faces, ensure both are clean and free from dirt or corroston. 5. Recposition disc onto hub and refit retaining clip. NOTE: If original disc 1s to be refitted, align ‘mating marks. Refit caliper and secure anchor bracket to mounting ptate, torque bolts to specification. 7, Re-apply handbrake, refit road wheel and Tower vehicle. 8. Torque road wheel muts, release handbrake and then apply foot brake to ensure disc pads are correctly auto-adjusted. 990 DEI-2-26 Fig-1- Remove caliper retaining bolts. Fig.3. Lift caliper assembly clear and renove disc. September 1990 FORD SIERRA RS COSWORTH: SECTION 12C-11§ BRAKING SYSTEM 12 233 0 DISC PADS - FRONT - REPLACE (one side) SPECIAL SERVICE TOOLS REQUIRED: NONE. ‘Tworkhee! Orfve Variants To Renove 1, Shacken wheel nuts, jack-up front of vehicle and fit chass{s stands. 2. Rewove front road wheels. 43. Using suftable thin pin punch, remove lower brake pad retaining pin. 4, Remove brake pad anti-vibration clip. 5, Remove upper brake pad retaining pin. 6. Carefully extract the brake pads fron piston housing. Lever back pistons Into caliper piston housing. Care should be taken not to damage piston dust gatters. To Instalt 8, Clean dust and any dirt contamination from ‘caliper housing. 9. Locate brake pads into caliper piston housing. 10. Fit upper brake pad retaining clip, Tocate gnttevibration clip Yo upper retalning cl fp. Push clip towards brake pads and refit lower retaining pin. 11. Once a11 brake pads have been installed, apply foot brake to bring brake pads into contact with the disc. Fig.1. Remove lower pad retaining pin. Insert - retaining pin 12, Refit road wheels and tighten whee? quts, lower vehicle and torque wheel nuts to correct specification. Fig.3. Renove brake pad from caliper piston body. 990 Septenber 1990 FORD SIERRA RS COSWORTH: SECTION 120-12> BRAKING SYSTEM 12 233 0 Four-wheel Drive To Remove 1, Slacken wheel nuts, Jack-up front of vehicle and renove road wheels. 2. Remove caliper spring clip, Fig.4. 3. Remove protective plugs and slacken piston housing retaining Allen bolts untf1 piston housing is free from anchor bracket, Fig.5. 4. Remove pad from caliper piston and, using a suitable tool, Yever Fixed pad off ‘caliper housing fingers, Figs To Insta 5. Clean dust and dirt from caliper piston housing, observing safety precautions relating ‘to dust ‘generated from friction surfaces. 6. Push piston fully back into housing. Locate ew brake pad in piston. Renove backing paper from fixed pad and locate in caliper housing. 7, Refit caliper piston housing to anchor bracket. Tighten Allen bolts and replace pump. Refit caliper spring clip. 8. Apply footbrake vigorously to bring pads into contact with disc. 9, Refit road wheels and tighten wheel nuts. Loner vehicle to ground and fully tighten wheel nuts. 990 sane Figs. Remove caliper spring clip. Fig.6. Remove pads from caliper piston housing. Septemer 1990 FORD SIERRA RS COSWORTH: SECTION 12-13=> BRAKING SYSTEM 12 237 0 DISC PADS ~ REAR - REPLACE (one sige) SPECIAL SERVICE TOOLS REQUIRED: Piston Wind Back Tool .. 12-006 CAUTION: Rear brake system fs subjected to high pressure. 00 NOT apply footbrake once the caliper hes been removed from the anchor bracket. To Remove 1, Slacken wheet nuts, jack-up vehicle and fit chassis stands. Release handbral 2. Remove road wh 3, Detach handbrake cable from lower arn retaining clip. 4, Remove forward piston housing retaining bolt from anchor bracket. Swing piston housing ‘assenbly upwards away from brake disc. 5. Renove brake pads fron carrier bracket. 6. Using Spectal Service Too! 12-006, wind back piston inte piston housing. NOTE: Ensure slot in ptston face 1s positioned so that inner pad backing plate will engage in piston face. To Instat? 7. Locate brake pads in anchor bracket. 8. Swing piston housing over disc, positioning Slot in piston over peg of brake pad. Ensure brake pad anti-rattle springs are correctly positioned fn pfston housing. 9. Refit forward pfston housing to anchor Fetatniag bolt, torque bolt to specification. 10, Re-secure handbrake cable to lower arm assembly. 11. Apply footbrake to ensure correct brake pad disc auto-adjustment. 12. Refit road wheel, fit and tighten wheel nuts. 13. Loner vehicle and torque whee? nuts to spect fication. 990 FigeL. Remove front slide pin bolts. Fig.3. Wind back piston using Spectat Service Yoo! 12-006. Septenber 1990 FORD SIERRA RS COSWORTH: SECTION 126-14BRAKING SYSTER 12 743 0 CALIPER ASSEMBLY ~ FRONT — RENOVE AND. INSTALL SPECIAL SERVICE TOOLS REQUIRED: NONE WARNING: Switch ‘off* ignttion Position *0'. apply footbrake at least 20 applications or until the pedal effort increases and becones hard. To Renove 1. Jack up front. of vehicle, fit chassis stands, ‘open hood and fit fender'covers. Remove road wheel « 2. Renove clip retaining brake pipe flexible hose from suspension strut. 3. Disconnect brake pipe from caliper piston housing, fit blanking plugs. to prevent excessive fluid loss. or dirt entry into ‘caliper piston housing. 4, Renove bolts securing caliper to knuckle assenbly, and Hft off caliper assembly. To Insta 5. Locate cal fper assembly to knuckle and Elghten bolts to specification (see Technical Data), 6. Reconnect brake pipe to caliper piston housing, Tighten union to specification. 7. Re-secure flexible hose conection to suspension strut mounting bracket. Bleed front brake circuit. 9, Refit road wheel and lower vehicle, torque wheel nuts to specification. 10, Remove fender covers and close hood. Figel. Release retaining clip from suspension strut. Fig.2. Remove caliper to knuckle securing bolts. (Two-wheel drive iTustrated) Septenber 1990 FORD SIERRA RS COSNORTH: SECTION 120-15> BRAKING SYSTEM 32 267 4 PISTON ~ FRONT CALIPER - REMOVE AND INSTALL (Four-wheel drive varfants only) SPECIAL SERVICE TOOLS REQUIRED: ONE To Remove Ls Apply low tydraulic or low air pressure to caliper piston inlet port to eject from bore. Use a suitable spacer (wood) between Piston and caliper Fingers to prevent danage to piston face. NOTE: The pfston dust cover cannot be removed until the piston 1s renoved. 2. Wook out piston seal and dust cover. 3. Wash piston and cylinder bore in comercial alcohol or methylated spirits. Jo not use saineral-based flutds such as petrol or paraffin as brake failure may subsequently occur. 4, Check piston and cylinder bore for sign of damage, scuffing, scores or corrosion. IF the piston or cylinder bore 1s corroded, then ‘that component must be replaced. To Install 5. Lubricate cylinder bore with new brake fluid. 6. Locate new piston seat in cylinder bore groove. 7. Stretch dust cover over piston and assenble piston into cylinder bore. 8. Carefully push piston fully hoae into cylinder bore. “Refit brake pads and assemble caliper assembly to anchor bracket. 990 ERIIQ/252IN Fig.1. Piston housing assembly. A Dust cover C - Piston 8 - Piston seal sires Fig.2. Remove piston from piston housing using Tow air pressure. September 1990 FORD SIERRA RS COSWORTH: SECTION 120-16BRAKING SYSTEM 32 253 0 CALIPER ASSEWGLY ~ REAR — RENOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: KONE WARNING: Switch ‘off* 4gnition Position '0', apply footbrake at least 20 applications or until the pedal effort increases and becones hard. To Renove 1, Open hood and fit fender covers. 2. Stacken wheel nuts, jack-up vehicle and fit chassis stands. 3. Remove road wheels. 4. Release handbrake lever. 5, Disconnect flexible hose from brake pipe, fit blanking plugs to prevent excessive fluid loss or dirt entry, 6. Remove caliper anchor bracket retafning bolts. 7. Unhook handbrake cable from lever and Vift caliper assembly. 8. Remove hydraul fc brake flexible hose from caliper piston housing. To Instat 9. Reconnect. hydraulic brake flexible hose to eal iper ptston housing. 10. Connect handbrake cable to caliper actuating Yever. LL. Mount. caliper onto support bracket and secure. Torque bolts to specification. 12. Bleed rear brake circutt as detailed in Operation No. 12 141 0. 13. Refit road wheel and secure, remove chassis stands and lower vehicle, U4. Fully tighten road wheel nuts. 990) pel2-Sr— SS a v Fig.l. Disconnect flexible hose from brake pipe. Fig.3. Rewove handbrake cable from caliper actuation Tever, September 1990 FORD SIERRA RS COSWORTH: SECTION 12c-17BRAKING SYSTEM 12 353 0 GRAKE PEDAL - REMOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: ORE To Remove 1. Open hood, fit fender covers and disconnect, battery. 2, Remove under dash tr{m panel from around brake pedal. 3. Using suitable hook, remove circlips securing cross shaft. Slide shaft out tovards clutch pedal sufficiently to release brake pedal. Note position of spacer tubes and washers. 4. Remove brake pedal from vehicle, renove shaft bushes and, if necessary, brake pedal rubber. Fig.27. A = Hook too} B- Cross shaft circlip € = Servo push rod clip To Install 5. Fit new pedal shaft bushes into brake pedal, refit brake pedal rubber. 6. Reposition brake pedal in vehicle, slide Gross shaft through until 'D' on shaft locates in pedal bracket housing. Ensure all spacers and washer are correctly fitted. Refit shaft securing circlips. 7. Reconnect hydraulic actuation assembly push rod to brake pedal retaining clip. 8. Adjust stop lamp switch. 9. Refit under dash panels. 10. Reconnect battery, remove fender cover and close hood. 990 Fig.3. « Remove circlip fron cross shaft and clip fron’ brake pedal push rod. |. Adjust stop lamp switch. Septenber 1990 FORD SIERRA RS COSNORTH: SECTION 12-18BRAKING SYSTEM 2 341 0 BRAKE FLUID RESERVOIR - REVOVE AND INSTALL, SPECIAL SERVICE TOOLS REQUIRED: HOWE WARNING: Switch off ignition (Position '0"). ‘Apply foot brake at least 20 tines or untit pedal becomes hard to ensure brake pressure is fully discharged. NOTE: If brake fluid fs sptlt on paintwork, the ‘affected area must be famediately washed down with cold water. To Remove 1, Open hood, Fit Fender covers and dtsconnect battery. Ensure braking system pressure is fully discharged. Disconnect brake flutd reservoir Filler cap muitiplugs. 4. Remove screw and cl{p securing reservoir to hydraulic unit. 5. Remove spring clip securing low pressure hose to electric hydraulic pump. Drain brake fluid into suitable container. 6. Carefully remove reservoir from hydraulic unit. 7, Remove reservoir seals from booster and master cylinder assemblies. 8, Renove Tow pressure hose from reservoir. DEH2-43) Fig.2. Renove spring clip releasing low pressure pipe. > Deri2-44 Fig.3. Lift off reservoir. September 1990 FORD SIERRA RS COSWORTH: SECTION 12-1912 uo Jo Install 9. Replace reservoir seals, Ensure that rear sea) 1s aligned correctly in booster and master cylinder. 10. Refit low pressure hose to reservoir. LL, Lubrfcate seals and reservoir connections with clean brake fluid. Fit reservoir to hydraulic unit. 12. Secure reservoir to hydrautic unit with screw and clip. NOTE: Ensure clip is fitted correctly to support clutch cable. (Right hand drive variants only). 13. Reconnect low pressure hose to hydrauite pump, refit locking clip. NOTE: Ensure that hose elbow connection is Firmly pushed into pump assenbly before fitting Vocking clip. 14, Top up reservoir with new brake Fluid. 15. Ensure ignition switch is ‘off’ (position 0}. Reconnect battery. 16. Bieed braking system as detatied in Operation No. 12 141.0, check for leaks, Reconnect fluid level multiplug connections. 17. Rentave Fender covers and close hood. 18. Check operation of braking system. BRAKING SYSTEM Fig.5. Secure reservoir to hydraulic unit. Septenber 1990 FORD SIERRA RS COSWORTH: SECTION 320-20wa a si87120-9 Fig.6. Hydraulic actuation unit assembly. A> Raservoir uid ~ Hal and #1 ~ Main vaive F - Electric motor and H - Booster assembly evel warning indicator 0 - Master cylinder hydraulte pressure pump J - Valve dlock 8 = Accunuiator E = Push rod assenbly 6 - Pressure switch 990 ing ‘September 1990, FORD SIERRA RS COSMORTH: SECTION 12¢-21> BRAKING SYSTEN 12 580 0 HYDRAULIC UNIT ~ REMOVE AND THSTALL, SPECIAL SERVICE TOOLS REQUIRED: NOWE WARMING: Switch off dgnition (postion ‘0"). Apply foot brake at least 20 tines or until ‘the brake pedal becones hard to ensure brake pressure 1s fully discharged. NOTE: If brake Flufd ts spf1t on paintwork, the affected area must inmediately be washed down with cold water. To Renove Open hood, fit fender covers and disconnect battery. WARNING: Ensure braking system pressure is fully discharged. 2. Disconnect electricat connections from hydrautic unit, (pressure switch, aain valve, valve block, reservoir fitier cap, electric hydraulic pump and earth connection) 3. Disconnect hydraulic pipes from hydraulic unit ‘or valve body, fit blanking caps to prevent dirt ingress or excessive fluid loss. 4. Remove under dash trim panel from around the brake pedal. 5. Remove brake pedal push rod clip. 6, Remove hydraulic unit mounting nuts. NOTE: The assistance of a second technictan should be used to support the hydraulic unit when removing mounting auts. 990 Fig.t. Disconnect. hnydraulic un Fig.2. Ofsconnect hydraulic pipes from hydraulic unit. > Fig.3. Remove hydraulic unit mounting nuts and Pedal push rod clip. September 1990 FORO SIERRA RS COSWORTH: SECTION 120-2232 580 0 7. Lift out hydraulic actuation unit from vehicle and drain reservoir, Renove spherical ball from push rod. NOTE: Do not Tift hydraulic actuation unit by hoses, reservoir or push rod. Do MOT ATTEMPT 10 ACTUATE HYDRAULIC UNIT By PUSHING PUSH ROD ONCE REMOVED FROM VEHICLE. 8. Remove sealing gasket from hydraulic unit. Figed. Refit under dash trim panel. To Install 9. Fit new sealing gasket to hydraulic untt. 10. Fit spherical ball to push rod. Carefully Install hydraulic unit tnto vehicte ensuring push rod enters brake pedal. fare should be ‘taken not to force push rod froa tts natural position. 11; Support hydraulic untt while second technician sigz-12c- Secures the hydraulic actuation unit with four Sigr-12C-40 « futs to the bulkhead. Torque to specif Cation. Fig.5. Flt spherteal bal] to pusn rod. 12, Reconnect brake pedal to hydraulic unit push clip. 13. Remove blanking caps from valve block and brake pipes, reconnect brake pipes to hydraulic unit. WARNING: ENSURE BRAKE PLPES ARE CONNECTED To CORRECT PORTS. Fig.6. Brake pfpe connection. 990 September 1990 FORD SIERRA RS COSHORTH: SECTION 126-23,<> BRAKING SYSTEM 12 880 0 14. Reconnect electrical multiplugs to valve block, main valve, pressure switch, electrical hydraulic pump and earth connection. 15. FAIL reservoir with new brake fluid, 16. Bleed front brake circuits as detailed in ‘Operation Ko. 12 161 0. 17, Reconnect battery. 18. Switch ‘on! Ignttion and check pune operatton. NOTE: Do not allow electrical hydraulic pum to ‘operate for more than 2 minutes. (IF pump does run for more, switch ‘off tgnition, Posittan '0", and'ailow motor to cool for 1¢ minutes. MOTE: IF difficulty is experienced with purging the hydraulic actuation unit, apply foot drake and retease witn ‘gnition ‘0k’, continue to apply foot brake unti? pimp motor running sound changes . 19, Bleed rear brake circuit as detailed in Gperation 12 141 0. Check systen for fluid Teaks. 20. Refit under dash trim panel. 21. Reconnect reservoir fluid filler cap ul tiplugs. 22. Remove fender covers and close hood. 23. Check operation of boost and anti-lock/brake function. 990 Fig.8. Top up reservoir to "Max" mark. a Septenber 1990 FORD SIERRA RS CoswoRT! SECTION 126-24> BRAKING SYSTEM 12 S81 0 VALVE BLOCK - REMOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: NONE WARNING: Pump brake pedal at least 20 times untiT ‘brake pedal becomes hard to discharge pressure from vraking systen. Right Hane Ori ve Variants To Renove ‘Open hood, fit fender covers and disconnect, battery. C08 -120-18 2. Ensure braking system pressure ts fully Figet. Wheel arch shield fasteners. discharged. 3. dack up vehicle and f{t chassis stands. Renove the passenger side front wie] . 4. Remove the six plastic fasteners securing the wheelarch shield {see Fig.43). 5. Separate the wheel arch shield Tower catch ang remove shield by pulling down and rotating in a clockwise direction. 6. Place drain tray beneath vehicle and disconnect hydraulic fluid pipes from valve block. Fit blanking caps to pipes and valve block ‘connections to prevent excessive fluid loss and dirt entry. sigrci2012 7. Disconnect valve block sul tiplug and earth cable. 8, Remave valve block mounting bracket retaining nuts from inner fender and 1ift out valve block. To Instali 5. Locate valve block and bracket onto tnner fender and secure. 10. Renove blanking plugs from pipes and valve block and reconnect brake pipes. Ensure Pipes are connected in their correct positions. Fig.3. Remove valve block bracket securing nuts. 990 September 1990 FORD SIERRA RS COSHORTH: SECTION 12¢-2542 581 0 LL. Reconnect valve block mul tiplugs and earth connections. 12. Refit wheel arch shield and engage lover catch. 13. Align wheel arch shield and refit plastic clips. 14. Refit road wheel and lower vehicle to ground. Fully tighten wheel nuts. 15. Reconnect battery. 16, Bleed braking system as detailed in Operation No. 12 141 0. 17. Check operation of valve block assenbly by Carrying out Diagnostic Procedure shown in Section 12C, Condftion 10, step d) of the Vehicle System Test. 18. Road test vehicle and check operation of braking systen. sie 120-18 w Fig.4. A - Bracket to valve block mounting bolts: 0 = Mul tiplug connections B= Adaptor plate E = Earth cable connections C= Valve block 990 September 1990 FORD SIERRA RS COSWORTH: SECTION 120-26BRAKING SYSTER 12 582 0 ACCUMULATOR - REMOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: NONE WARNING: Switch off ignttion (position '0") Apply foot brake at least 20 times or until the brake pedal becomes hard, to ensure brake pressure is fully discharged. MOTE: {Ff brake fluid is spilt on paintwork, the ‘affected area mist innediately be washed down with cold water. To Remove 1. Open hood, fit fender covers and disconnect battery. 2. Ensure braking system pressure is fully atscharged. 3. Carefully remove accumulator from hydraulic unit, using @ suftable hexagon key. Cover base’ of accumulator with clean cloth to Prevent any dirt ingress. To Install 4. Ensure "0" ring is fitted and in good ‘cond’ tion. 5, Fit accumulator to hydraulic unit and torque ‘to specification. 6. Reconnect battery. 7. Switch Yon* ignttion and check accumulator charge time, (should be less than 60 seconds). jleed braking systen as detailed in Operation No. 12 1410. Check for leaks. 9. Romave Fender covers and close hood. 10. heck operation of boost and anti-lock function. 990 Fig.1. Stacken accumulator, cover base of cor with clean cloth. DEI2-48 Fig.2. Fit new ring seal to accumulator. Septenber 1990 FORD SIERRA RS COSWORTH: SECTION 120-27BRAKING SYSTEM 12 $86 0 HYDRAULIC PUMP AND ROTOR ASSEMBLY REMOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: Pressure Switch Wrench .. 12 008 WARNING: Switch off ignition (position '0") Apply foot brake at least 20 tines or until the brake pedal becones hard to ensure brake pressure 's fully discharged, NOTE: If brake flufd 4s spilt on paintwork, the ‘affected area mist Immediately be washed down with cold water, To Renove 1. Open hood, fit fender covers and disconnect battery. 2. Ensure braking system pressure is fully discharged. 3. Remove nigh pressure pipe from pump body. 4, Using hexagon key adaptor, renove accumulator from punp body. 5. Disconnect multiplug connection from pressure switch. 6. Disconnect hydraulic pump electric motor nultiplug. 990 sip7-120-37 Fig.2. Remove spring clip releasing low pressure pipe fran hydraulfe pump. au September 1990 FORO SIERRA RS COSWORTH: SECTION 120-28BRAKING SYSTEN 12 586 0 7. Remove pump housing to tydraul fc actuation assembly mounting Bol t. 8, Remove punp housing asseably from hydraulic unit. 9. Remove spring cl{p retaining low pressure hose to hydraul tc pump. Clamp Tow pressure hose using suitable clamp to prevent excessive flutd loss. 10. Remove pressure switch from pump housing. Ll. Prise out punp mounting insulators and tubes from punp body. To Install 22. Fit mounting tubes and insulators to pump housing. Refit pressure switch into pump housing, ensure sealing '0' ring 1s in good condition. 14. Comect low pressure hose and secure with spring clip.’ Locate punp onto hydraulic unit. Fit mounting bolt through bushes and torque to specification. 1s Reconnect high pressure pipe, torque pipe unton to specification. 16. Fit new ‘0’ ring to accumulator and fit to unp housing tighten accumulator. 990 St7-120-70 Fige4. Disconnect punp notor multiplug. Det-12-69 q DEI 12-49 7 Fig.6. Fit new accumilator ‘0* ring. September 1990 FORD SIERRA RS COSWORTH: SECTION 12¢-29BRAKING SYSTEM 12 586 0 17. Reconnect mul tiplugs to pump motor and pressure switch, 18. Top up reservoir with new brake fluid. 19, Reconnect battery. 20. Switch ‘on’ ignition, check for hydraulic fluid leaks, allow pinp to run untit switeh ol Bo not allow hydraulic pump to operate for more than 2 minutes (1? pump does run for. Tonger, switch ‘off’ ignition position '0" and alfow pump motor to cool for 10 nutes) 21, Bleed brake system as detailed in Operation No. 12 141 0. 22. Rewove fender covers and close hood. 23. Check operation of anti-lock system. 990 Fig.7. Top up reservotr to ‘Max’ mark. September 1990 FORD SIERRA RS COSWORTH: SECTION 12043012 589 0 PRESSURE SWITCH - REMDVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: Pressure switch wrench —.. 12-008 WARNING: Switch off tgnftton (position '0") Apply foot brake at Teast 20 times or until the brake peda? becomes hard to ensure pressure fs fully discharged. NOTE: If brake fluid is sptit on paintwork, the ‘affected area must immediately be washed down with cold water. To Renove 1. Open hood, fit fender covers and disconnect battery, 2. Ensure braking system pressure 1s fully discharged. 3. Disconnect pressure warning switch multfplug. 4. Using Spectal Service Tool 12-008, remove Pressure warning switch. To tnstatt Fig.2. Renove pressure warning switch using 5. Fit new /0" ring seal to pressure warning Spectal Service Tool 12-008. switch. 6 Screw tn_aw'teh and tighten using Spectal Service Tool 12-008. 9 Spee 7. Reconnect pressure warning switch mul tiplug- 8. Reconnect battery, switch ‘on’ ignition and check switch and pump operation. 9, Bleed brake system as detailed in Operation No. 12 161 0. 10, Remove fender covers and close hood. 990 September 1990 FORD SIERRA RS COSWORTH: SECTION 126-31> BRAKING SYSTEM 12 S91 0 LOW PRESSURE WOSE ~ REMOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: MONE WARNING: Switch off fgnition (position 0") Apply foot brake at least 20 times or until the brake pedal becomes hard to ensure pressure 4s fully discharged. NOTE: If brake fluid is spilt on paintwork, the ‘affected area ust immediately be washed down with cold water. To Remove A. Open hood, Fit fender covers and disconnect, battery. 2, Ensure braking system pressure 1s fully discharged. 3. Remove hydraulic actuation protective heat, shield. 4. Remove spring clip retaining low pressure pipe to electric hydraulic pump. Allow hydraulic flufd to drain into suftable container. 5. Pull off hose from reservoir filter connection. 990 ‘$1877120 -34 Fig.1. Remove spring chip releasing low pressure hhose from pump body. Fig.2. Rewove low pressure hose from reservoir. Septenber 1990 FORD SIERRA RS COSHORTH: SECTION 12¢-32xt BRAKING SYSTEN 12 5910 Ton 6. Connect Tow pressure hose to reservoir filter connection. Push on fully. 7. Connect hose to hydraulic punp,, secure with spring clip. Once fitted, check security of hose in pump. NOTE: Ensure tow pressure hose fs correctly routed around Tower pump insulator. 8. Top up reservoir with new brake flufd. for fluid leaks. Check 9. Refit heat shield. 10, Reconnect battery. 11. Bleed braking system as detatled tn Operation Nos 12 181 0 and check for hydrauite flutd jeaks, 12. Remove fender cover and close hood 990 Fig.3. Route low pressure hose below Tower insulator. September 1990 FORD SIERRA RS COSWORTH: SECTION 12¢-33> BRAKING SYSTEM 12 755 0 BRAKE PRESSURE CONTROL VALVE — REMOVE AND, INSTALL SPECIAL SERVICE ‘TOOLS REQUIRED: NONE To Renave 1, Open hood, Fit fender covers and atsconnect battery. 2, Pump brake pedal at least 20 tines unti1 pedal becones hard to ensure pressure Is fully discharged. 3. dack-up rear of vehicle and fit chassis Figel. Disconnect brake pressure control valve stands. fron brake pipes. 4, Disconnect rear brake pipes fron brake pressure control valve. Fit blanking plugs 0 prevent excessive fiuid loss or dirt ingress. NOTE: DO NOT attenpt to disw ttle valve assembly. To Instat 5. Renove blanking plugs and reconnect brake 26 pipes to pressure control vaive. Si87-120 -32 ° Fig.2. Brake pressure contro! valve. 6. Reconnect battery. 7, Bleed rear brake circuit as detailed in Operation Wo. 12 181 0, check for fluid jeaks. 8. Resiove fender covers and close hood. 990 September 1990 FORD SIERRA RS COSNORTH: SECTION 126-34p> BRAKING SYSTEM 12 760 0 MODULE ANTI-LOCK BRAKING SYSTEM ~ REMOVE AND. INSTALL SPECIAL SERVICE TOOLS REQUIRED: NONE To Remove 1, Open hood, fit fender covers and disconnect, battery. 2, Renove passenger side crash pad trim panel. 3. Carefully remove anti-lock module fron bracket. © Push module nvards releasing securing catch. © Purl out module and disconnect multi plug. To Instat 4. Reconnect mitttplug to modul plug 1s fully engaged. + ensure mul tt 5. Refit module into bracket and secure. 6. Refit trim panel to passenger side crash pad. 7. Reconnect battery, renove fender covers and close hood. 8, Check operation of anti-lock warning tight functions. 990 : “SS SeRE-09 1 Fige1. Renove crash pad to gain access to the anti-lock module Fig.2. Disconnect anti-lock module. September 1999 FORD SIERRA RS COSWORTH: SECTION 12-3512 785 0 WHEEL SENSOR - REMOVE AND TNSTALL — REAR SPECIAL SERVICE TOOLS REQUIRED: NORE To Renove 1, dack up vehfcle and fit chassis stands. 2. Open hood, and fit fender covers. 3. Unclip anti-lock oom from chassis side rati. Disconnect wheel sensor multiptug. FigeL. Front wheel sensor loom muTtiptug. 4, Remove bolt securing wheel sensor to spindle carrier. Carefully pull out sensor. 5. Unclip sensor loom from cable supports. To Insta Gefore refitting, ensure hee! sensor spindle “ier bore and’ sensor mounting face is clean and free from rust, or rough edges. Check condition of toothed rotor. 6, Liberally coat sensor spindle carrier bore and chanfer with wheel bearing grease. 7. Fit new "0" ring to whee? sensor. : 8. Coat sensor with grease and push sensor firmly into spindle carrier bore until flush. Secure’ with bolt and washer. 9. Refit sensor loom into cable supports. 10, Reconnect sensor loon to main lace and secure to side rafl clip. Ensure connector ‘0’ ring is correctly seated. AL. Renove fender covers, and close nood. 12. Lower vehicle and check anti-lock operation. DEF6-22 Fig.2. Remove wheel sensor. 990 Septenber 1990 FORD SIERRA RS COSMORTH: SECTION 12¢~36> BRAKING SYSTEM 12 785 0 WHEEL SENSOR - REMOVE AND INSTALL — REAR SPECIAL SERVICE TOOLS REQUIRED: NONE CAUTION: Rear brake systen ts subjected to high hydraul{c pressure. 00 NOT apply foot brake once caliper has been removed from anchor bracket. To Renave 1. dack up vehicle and fit chassts stands. 2. Remove road wheels. 4. Release handbrake cable lever. 4, Ratse rear seat cushion. 4. Remove side ktek panel and fold carpet forvard to gain access to wheel sensor plug connection. 6. Remove wheel sensor plug from clip and disconnect fron mata Toon, 7. Prise out gromet and pass sensor cable ‘through floor panel. 8, Remove handbrake cable from lower arm securing clip. 9. Remove forward bolt of caliper slide pin, swing calfper up and retain in posttion. 10. Renove bolt securing whee! sensor to mounting bracket, carefully remove wheel sensor. Fig.l. Remove side kick panel and fold carpet forward. Fig.3. Remove forward bolt of caliper slide pin. Septenber 1990 FORD SIERRA RS COSWORTH: SECTION 120-37BRAKING SYSTEM 12 785 0 To Instant Before refitting wheel sensor, check bare area around sensor mounting for damage, rust or ough edges. Rotate road wheel and check toothed rotor for damage. 11, FA11 wheel sensor mounting bracket bore with wheel bearing grease. 12. Fit new '0' ring to wheel sensor. 13, Coat wheel sensor with grease and push sensor firmly into mounting bracket bore unti1 flush, secure with bolt and washer. NOTE: Sensor mounting bolt and washer are unique (bolt 28 mm long and washer i,5 am thick). 14, Refit caliper mounting bolt and torque to spect ication. 15, Relocate handbrake cable Into lower arw bracket. 16. Route wheel sensor cable along suspension Tower arm and clip in position. Push sensor Toom through floor panel and refit gromet. 17, Reconnect wheel sensor loom to matn loom, ané Secure into retaining clip. Ensure ‘0' ring in connector 1s correctly located and pushed fully hone. 18. Replace carpet and refit side kick panel and secure. 19. Return seat cushion to tts correct position. 20. Apply handbrake, refit road wheels. 21. Lower vehicle and check operation of anti- Tock, 999 DEI-t2. Fig.d. Renove wheel sensor and check toothed wheel for damage. Fig.6. Ensure correct gromet fitment. September 1990 FORD SIERRA RS COSWORTH: SECTION 120-38Escort RS Cosworth XN POWER ASSISTED STEERING (Cam Gears) 1A Index Page Technical Data se Special Service Tool Recognition .. -. +. 3 Service and Repair Operations Contained in Page Operation 13-116 9 Steering Gear Assenbly - Remove and Install . Be 13 116 8 Steering Gear Assembly - Overhaul we eee 13 134.0 Bellows - Steering Rack - Replace (one) «swe ee ee LY 13 416 1 Power Steering system - Bleed 6. ee eee a 13 4240 Belt - Poner Steering Punp Orive ~ Replace te 1 13 434 0 Pump Assembly - Power Steering - Renove and Install =) we 6 13.4348 Pump Assembly - Power Steering - Overhaul -. es weve eee 13 42.0 Fluid Hoses - Power Steering - Replace (211) . wae 0 135230 Steering Wheel = Centralise 6. ken at 13 543.0 Steering Colum - Replace “ . - 2 13,566 0 Flexible Coupling - Steering Cotuan - Renove and Install Be ongz April 1992 FORD ESCORT RS COSWORTH: SECTION 134-1> Power ASSISTED STEERING TECHNICAL DATA Type Turns Vock to lock «2 ewe Rack slipper adjustment Power steering lubricant .. Power steering fluids. ve Loctite 270 2. Tightening Torques Steering coupling clamp bolts. Steering coupling pinch bol ts/nuts Lower pinion securing mut o Tie rod end lock nuts Tie rod end to steering arm Te rod inner ball joint Pressure hose to puitp Bolt = PAS pump pulley Steering column clasp and brace Bolt - PLAS. pump bracket to block Bett ~ PAS pump we Adjustable steering through bolt. Steering wheel retaining bolt. Valve body clanp plate bolt < s Steering rack to crossmembar bolts ase Escort RS Cosworth Power assisted variable rack and pinion 2,88 Screw-in plug Calipsol Grease type SF3-131 ESPH-2C~ 66H 5003600 xo dott 20,0 to 28,0 18 to 21 24,0 to 26,0 18 to 19 37,0 to 47,0 27 to 34 57,0 to 68,0 42 to 50 25,0 to 30,0 18 to 22 72,0 to 8,0 53 to 65 26,0 to 31,0 19 to 22 10,0 to 12,0 Tto 8 1710 to 24,013 to 47 52,0 to 64,0 38 to 47, 21,0 to 26,0 18 to 21 6,0 to 8.0 4 to 6 45,0 to 55,0 33 to 40 22,0 to 24,0 16 to 17 35,0 to 45,0 26 to 33 Apri 1992 FORD ESCORT AS COSMORTH: SECTION 138-2PONER ASSISTED STEERING SPECIAL SERVICE TOOL RECOGNITION Escort RS Cosworth Tool Too! Wane Steering pinion socket i Ball joint separator va ee sea 04g April 1992 FORD ESCORT RS COSWORTH: SECTION 13A-3Escort RS Cosworth 13 116-0 STEERING GEAR ASSEMBLY - RENOVE AND INSTALL SPECIAL SERVICE TOOLS REQUIRED: Ball Joint separator... 13-008 To Remove 1, Open hood, Fit fender covers and disconnect battery. 2, Align steering in the strat ght ahead position. 3. Ratse vehicle on ramp and remove sump shield. Steering tle rod end. Remove lower pinch bolt securing Flexible A~ Castellated nut” ¢ - Steering arm coupling to steering gear pinton shaft. B = Split pin 0 Ball Joint 4, Disconnect tie rods from spindle body steering arms using Special Service Tool 13-006, Fig.1. Remove clamp plate bolt securing high and tow Pressure pipes from steering gear valve body. Renove screw securing pressure hose clamp to Steering getr housing. Pull pfpes clear of steering gear and alfow flutd to drain into suftable container. 6. Blank off all pipe connections and valve body to prevent dirt entry. 7. Renove two bolts securing steering gear to engine front crossnember, Fig.2. Renove steering assembly from crossmenber as detailed in Fig.3: Fig.3. A= Slide steering gear towards driver's side of ventcle = Swing non=pinion end of steering rack out fron crossnenber C= Rotate steering gear clockwise disengaging lower pinion bearing cap from crossnenber Lift cut steering gear To Instal1 8. Position steering gear assenbly onto engine front crosananber, fit mounting bolts and tighten to specification (see Technical Data). Fig.3. Remove steering gear in correct sequence. o4se april 1992 FORD ESCORT RS COSWORTH: SECTION 132-4POWER ASSISTED STEERING wu a 10, ue 1a. Be 16 0 Remove hose and valve body blanking plugs. Replace ‘0' rings on pressure and return hoses. Refit clamp plate and fit securing bolt, Fig.4, tighten retaining bolt to specification, (see Technical Data). Reconnect tie reds to spindle carrier steering arms, tighten casteliated nut and Fit new split pins. Align block splines of steering gear and Flexole coupling, reconnect coupling to pinion shaft and fit pinch bolt, Fig-5. Tighten pinch bolt to spect fication (see Technical Data). Refit sump si lower vehicle. Reconnect battery. Ref111 power steering reservoir and bleed as described below: © Using clean, non-aerated Fluid, top up reservoir to the ‘max’ ark. © Disconnect negative lead fron coil. Crank engine (short two second bursts) and slowly turn steering wheel from Tock to Tock three or four tines. NOTE: Ensure fluid in reservoir does not fall “a 1. ong ‘below ‘mfataua’ mark and afr bubbles no Tanger appear. @ Reconnect negative tead to coll, start engine, turn steering from lock’ to Tock. Switch’ ‘off! ignition, © Reccheck fluid tevel, replace cap and check Steering gear for fluid leaks. Check and adjust front wheel toe alignment. Refer to.Section 14 fn this microfiche. Remove fender covers and close hood. Escort RS Cosworth Fig.4. Power steering pipe seals and clamp plate. Fig.8. Pinion block spline and flexible coupling. Aprt 1 1992 FORD ESCORT RS COSHORTH: SECTION 13A-5POWER ASSISTED STEERING 13-116 8 STEERING GEAR ASSEMBLY ~ OVERHAUL SPECIAL SERVICE TOOLS REQUIRED: Pinion oi! seai/bush installer .. 13-010 Steering pinion socket... 13-004 Pre-load gauge 15-081 To Remove 1, Mount steering gear in vice using soft Jaw protectors, support steering gear at pinion housing. Slowly traverse steering rack from Tock to lock draining fluid from valve body. 2 Remove track rod ends and lock nuts noting the nunber of turns required to remove each track rod end. Remove and ¢fscard gaiter retaining clips, slide off gafter. 3. Traverse steering rack so that rack teeth are visable, reposition steering gear so that rack teeth are held in vice, Fig.l. Use vice Jaw protectors to ensure no’ damage ta steering rack teeth occurs. 4. Using suitable wrench, unscrew inner bal1 Joints. NOTE: The steering rack mist be held securely when the tie rods are removed, otherwise danage to the pinion may occur. 5. Remove yoke pinion cover using suitabie hexagonal bar (26mm), Fig.2. Remove yoke spring. 6. Reposition steering gear in vice, holding pinion housing. Centralise steering gear (nid-position of total turns Tock to lock}. Nark pinion to valve body position, measure steering rack projection from end of steering rack tube. 7. Renove core plug from pinfon valve housing, Feaove pinion locknut, Fig.3. 8. Renove pinton input shaft dust cover, remove cirel{p and carefully pull pinion vaive shaft assenbly out of valve body, Fig.4. (A ‘twisting action will afd removal). 1: Care should be taken during this operation, to prevent dirt entering the valve body or sleeve assensly. 0492 Escort 85 Cosworth share Figrl. Secure steering rack teeth to prevent danage to pinion. sia7-1a8-4 Fig.2. Remove pinton yoke cover. A~ Hexagonal bar + DE1-138-10 Fig.3. Renove pinion locknut, mark central position of pinion to’ steering rack. Apri} 1992 FORD ESCORT RS COSWORTH: SECTION 13A-613 116 8 Escort RS Cosworth 9. $1fde seat and bearing off pinion shaft. Do ‘not dismantle valve assembly. 10. Renove steering rack support bearing and seal. @ Rotate the support bearing locking collar anti-clockwise until the end of the Vocking wire 4s visible in the rack tube slot. 0E1-198-158 1 Prise end of locking wire out of slot, Fig. Renove pinton assenbly- continue to rotate locking collar until the wire is removed from the annular groove. 11, Carefully withdraw rack from rack tube. NOTE: At this stage the remaining steering gear Fluid will be released. 12. Slide rack support bearing and seal off steering rack shaft, Fig.5. DEI-13-12 « Fig.S. Remove rack support bearing, rotate Tocking coltar anti-clockwise. 13, Remove pinion support bearing and seal from pinton housing using suitable punch. 14. Remove rack inner seal and support ring Using suitable drift (26 mm diameter} in direction of rack tube, Fig.6. Fige6. Remove rack tnner seat and support ring. osg2 April 1992 FORD ESCORT RS COSNORTH: SECTION 13A-713:16 8 Escort RS Cosworth DEI-138-90 Fig.7. Stee a ce De moly E+ Loner pinfon bearing 492 Aprt 1992 FORD ESCORT RS COSNORTH: SECTION 13A-813 6 8 To Reass: Before reassenbly, al1 parts must be inspected for damage and thoroughiy cleaned: a} check al), contact faces of radial ip seals ‘on valve body and steering shaft. b) Check pinion teeth, support bearing and valve body roller bearing for wear. c) Check rack teeth and inner ball joint threads for wear or danage. 4) Check yoke contact area on rack and yoke for wear. fe} Ensure a11 rack feed pipes are free from any ‘obstruction or damage. f) Check Tower pinton bearing and pinion contact. face for damage or wear. ) Check al1 P.T.F.E. contact faces for damage. h) Ensure that rack air bypass tube is free fron ‘any obstruction and grease. 5) If any damage to pinion or valve sleeve is evident, a new valve assenbly must be fitted. NOTE: If new °.1-F-£. seals are to be fitted, following Arocedure should be adopted: Subwerge seals in botling water before Fitting to valve assembly. After fitting to valve assembly @ short perfod s/is8/18 of tine should be allowed for the seals to recover their natural shape. Escort RS Cosworth Fig.8. Assemble P.T.F.£. seats (A) onto sleeve valve using boiling water to afd k) AIL radial Tip seats should be packed with Caltpsol grease (see Technical Data). If there 1s any danage to pinfon or valye sleeve, a new valve assenbly mst be fitted. AS. Fit new pinfon seal. Using Special Service Too! 13-010, F1g.9, press in until seal 4s ‘seated on pinton housing seat. Using same tool, press in plain pinion bush until groove in Spectal Service Tool 1s level with top of pinfon housing. BEV9B-18 recovery time of P.T.F.E. seals. Fig.9. Fit new pinton seal using Spectal Service Tool 13-010. ‘onsz Aprit 1992 FORD ESCORT RS COSMORTH: SECTION 134-9