Description
Factory Ford Sierra RS Cosworth Workshop Manual (1986-1992)
This is the factory-level repair manual used by Ford-authorized workshops to service and rebuild the legendary Sierra RS Cosworth in all its forms – covering every production variant from the original homologation hatchback through the Sapphire saloon and the all-wheel-drive 4×4 model.
Powertrain & Drive Coverage
| Component | Variants Covered |
|---|---|
| Petrol | 2.0L turbocharged Cosworth (YBB, YBD) – engine codes N5A, N5C, N5F |
| Diesel | N/A |
| Transmissions | 5-speed manual Borg Warner T5 (RWD); 5-speed manual MT-75 (4×4) |
| Drive | RWD; AWD (Ferguson viscous coupling on 4×4 models) |
| Model Years | 1986, 1987, 1988, 1989, 1990, 1991, 1992 |
| Badge Twins | Ford Sierra Sapphire RS Cosworth (4-door saloon); Sierra RS Cosworth 4×4 |
Common Sierra RS Cosworth Repairs Covered
| System | Procedures |
|---|---|
| Garrett T3 Turbocharger | Boost control inspection, wastegate actuator adjustment, turbo oil feed line replacement |
| Weber-Marelli Fuel Injection | Injector testing and replacement, throttle body cleaning, ECU fault diagnosis |
| Cylinder Head & Gasket (YBD) | Head gasket replacement, torque sequences, coolant passage inspection – a known failure point on high-mileage engines |
| Ferguson 4×4 Transfer & Diff | Viscous coupling service, propshaft removal, front and rear differential overhaul procedures |
Format & Delivery
PDF. Instant download; lifetime re-downloads.
Frequently Asked Questions
Does this manual cover both the three-door hatchback and the Sapphire four-door saloon?
Yes. All Sierra RS Cosworth body styles are included – the original three-door hatchback (1986-1990), the Sapphire four-door saloon RS Cosworth (1988-1992), and the Sierra RS Cosworth 4×4 AWD variant. Procedures address model-specific differences where applicable.
Which engine codes and specifications are documented?
The manual covers the 2.0-litre Cosworth turbocharged units identified under engine codes N5A, N5C, and N5F (YBB and YBD designations). Full rebuild data includes Garrett T3 turbocharger specs, Weber-Marelli injection system calibration, and complete torque figures for all fasteners.
Are wiring diagrams and electrical schematics included?
Comprehensive wiring diagrams are included for the engine management system, turbo boost control circuits, fuel injection wiring, ignition, instrument cluster, charging system, lighting, central locking, and electric windows. All schematics use factory color-coded wire identification with connector and ground-point locations.
What format is the manual?
This manual is a PDF file, available for immediate download following purchase. It is fully searchable, compatible with Windows, Mac, Linux, iOS, and Android devices, and individual pages or entire sections can be printed for workshop use.
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