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  • 144 Pages
  • 200 Photos & Illustrations
  • Paperback
  • Black and White
  • Published in 2002
  • 2nd Edition
  • Part of the SpeedPro Series
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The Ford SOHC 'Pinto' & Sierra Cosworth DOHC Engines High Performance Manual
By Des Hammill

  • Features

    - Revised, updated and enlarged edition of a best-seller from the SpeedPro series.
    - Ford's adaptable and tough SOHC engine is still a hugely popular for high performance applications, here is the tuning Bible.
    - The author is an engineer with much professional experience of building race engines: all the information is based on practical experience.
    - Suitable for the enthusiast as well as the more experienced mechanic.

    Description

    Build a reliable, high-performance 1600/1800/2000 ‘Pinto’ engine for road/track, using many stock parts. Covers Cosworth versions of Pinto engines, too, and fitting Cosworth cylinder heads to Pinto blocks.

    Synopsis

    Expert practical advice from an experienced race engine builder on how to build a high-performance version of Ford's naturally aspirated 4-cylinder 1600, 1800 & 2000cc Pinto engine which has been used in Ford's most popular cars (Escort, Capri, Cortina & Sierra - Ford/Mercury Capri, Pinto, Bobcat in USA) over many years. Whether the reader wants a fast road car or to go racing, Des explains, without using technical jargon, just how to build a reliable high-power engine using as many stock parts as possible and without wasting money on parts and modifications that don't work.

    Also covers Cosworth versions of Pinto engines and fitting Cosworth heads to Pinto blocks. Does not cover 1300, E-Max 1600 or American-built 2300.
Table of Contents
Introduction 7

Using this book 8

Essential information 8

Sierra Cosworth engine 9



Chapter 1. Problem areas 10

Standard connecting rods 10

Forged connecting rods 10

Later, cast connecting rods 10

Cosworth rods 11

Standard connecting rods -

summary 12

Camshaft lobes and rockers 12

Camshaft pillars 13

Camshaft bearings 13

Piston to valve contact 13

Auxiliary shaft gear wear 13

Loose sprockets 14

Valve guides 14


Chapter 2. Short block

components 15

Pistons and connecting rods 15

Piston & connecting rod weights 19

Piston & connecting rods -

summary 19

Crankshaft and flywheel 20

Large capacity engines 21

Clutches 21


Chapter 3. Replacement parts 23

Pistons 23

Forged pistons 23

Piston ring sets 24

Crankshaft bearings 24

Camshaft bearings 24

Camshaft spray bar 24

Camshaft kit 24

Gaskets 25

Special bolts 25

Auxiliary shaft bearing 25

Seals 25

Valves 25

Competition valves 26

Valve retainers and keepers 27

Valve stem seals 27

Oil pump and oil pump drive 27

Sump (oil pan) 28

Dry sump 28



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Timing belt 28

Camshaft and auxiliary shaft thrust

plates 29


Chapter 4. Short block rebuild 30

Permissible bore oversizes 30

Repaired blocks 31

Component inspection 31

Block & main bearings 31

Main bearing caps 32

Check-fitting main bearing

shells 33

Checking bearing crush 35

Connecting rod checks 35

Connecting rod crack testing 35

Connecting rod straightness 35

Connecting rod length 36

Connecting rod hardness 36

Piston pin to connecting rod fit 36

Checking connecting rod big end

tunnel size 37

Connecting rod crankshaft bearing

tunnel resizing 38

Removing connecting rod bolts 38

Refacing connecting rod and cap

joint 39

Fitting new connecting rod bolts 39

Connecting rod bearing tunnel

honing 40

Aftermarket connecting rods 40

Connecting rod bolts 40

Checking connecting rod bolts for

stretch 40

Connecting rod bearing crush 41

Checking connecting rod bearing

internal diameters 42

Optimum connecting rod bearing

clearances 42

Crankshaft 42

Crankshaft checking 43

Crack testing 43

Checking straightness 43

Crankshaft detailing 44

Measuring journals 44

Crankshaft regrinding 45

'Check-fitting' connecting rods to

crankshaft 45

Building the short block 46


Chapter 5. Cylinder head 48



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Valves 49

The benefit of larger valves 50

Group 1-type valves (1800/2000

engines) 50

Group 2 inlet valves (2000

engines) 51

Sierra IS head/valves 52

Valve size summary 53

Valve throat size 54

Inlet port size (std size valves) 54

Exhaust port size (std size valves) 55

Valve throat & port modifications

(std size valves) 56

Valve unmasking 57

Inlet ports 57

Exhaust ports 57

Large valve modifications 58

Enlarging exhaust ports (large

valves) 59

Valve guides 60


Chapter 6. Compression ratio 61

Head planing 61

Thinner head gasket 63

Block planing 63

Raised top pistons 63

'O' ringing blocks 64

Compression ratio summary 64


Chapter 7. Camshafts 66

Standard camshaft 66

High-performance camshafts 66

Choosing a camshaft 67

Competition engines 70

Camshaft data requirements 70

Holbay roller camshafts 70

Camshaft timing 71

Camshaft summary 72


Chapter 8. Valve springs 73

Valve spring dimensions 74

Standard valve spring data 75

Measuring valve spring poundage 77

Advertised valve lift 79

Competition engines 80

Valve spring summary 80


Chapter 9. Rockers & rocker

geometry 81

Rocker geometry criteria 81



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Valve stem height 82

Altered rocker geometry 82

Lash caps 83

Rocker sizes/designs 83

Roller rockers 86

Checking rocker geometry 86


Chapter 10. Exhaust systems 89

Standard cast iron exhaust

manifold 89

Exhaust system construction 89

Four into two into one 90

Four into one 90

Primary pipes 91

Primary pipe diameters 91

Primary pipe lengths 91

Equal length primary pipes 91


Chapter 11. Flywheel &

clutch 93

Engine balance 93

Flywheel 93

Engine balance 95


Chapter 12. Ignition system 96

Distributor spindle 97

Drive gear 97

Endfloat/endplay 97

Contact breaker points 97

Condenser 98

Electronic module 98

Distributor cap 98

Rotor arm 99

Coil 99

Low voltage conventional

(standard) coil 99

Uprated low voltage conventional

coil 99

Ballast resistor coils 99

Electronic coils 100

High tension wires 100

Sparkplugs 100

Checking spark quality 100

Wiring & connections 100

Alternator 100

Ignition switch 101

High tension current (points type

distributor) 101

High tension current (electronic

type distributor) 101

Ignition timing marks 102

Checking TDC markings 103

Marking crankshaft damper/

pulley 103