How to Power Tune Ford SOHC 4-Cylinder Pinto & Cosworth DOHC Engines PDF

How to Power Tune Ford SOHC 4-Cylinder Pinto & Cosworth DOHC Engines

This text gives practical advice on how to power tune a high-performance version of Ford’s 4-cylinder 1600, 1800 and 200 cc Pinto engine which has been used in Ford’s most popular cars (Escort, Capri, Cortina, Sierra) over many years. Whether the reader wants a fast road car or to go racing, Des Hammill explains, without using technical jargon, 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. The text also covers Cosworth versions of Pinto engines and fitting Cosworth heads to normal blocks. It does not cover 1300, E-Max 1600 or American built 2300.


Using this book
Essential information
Sierra Cosworth engine
Chapter 1. Problem areas
Standard connecting rods
Forged connecting rods
Later, cast connecting rods
Cosworth rods
Standard connecting rods summary
Camshaft lobes and rockers
Camshaft pillars
Camshaft bearings
Piston to valve contact
Auxiliary shaft gear wear
Loose sprockets
Valve guides

Chapter 2.

Short block components
Pistons and connecting rods
Piston & connecting rod weights
Piston & connecting rods – summary
Crankshaft and flywheel
Large capacity engines

Chapter 3.

Replacement parts
Forged pistons
Piston ring sets
Crankshaft bearings
Camshaft bearings
Camshaft spray bar
Camshaft kit
Special bolts
Auxiliary shaft bearing
Competition valves
Valve retainers and keepers
Valve stem seals
Oil pump and oil pump drive
Sump (oil pan)
Dry sump
Timing belt
Camshaft and auxiliary shaft thrust plates

Chapter 4.

Short block rebuild
Permissible bore oversizes
Repaired blocks
Component inspection
Block & main bearings
Main bearing caps
Check-fitting main bearing shells
Checking bearing crush
Connecting rod checks
Connecting rod crack testing
Connecting rod straightness
Connecting rod length
Connecting rod hardness
Piston pin to connecting rod fit
Checking connecting rod big end tunnel size
Connecting rod crankshaft bearing tunnel resizing
Removing connecting rod bolts
Refacing connecting rod and cap joint
Fitting new connecting rod bolts
Connecting rod bearing tunnel honing
Aftermarket connecting rods
Connecting rod bolts
Checking connecting rod bolts for stretch
Connecting rod bearing crush
Checking connecting rod bearing internal diameters
Optimum connecting rod bearing clearances
Crankshaft checking
Crack testing
Checking straightness
Crankshaft detailing
Measuring journals
Crankshaft regrinding
‘Check-fitting’ connecting rods to crankshaft
Building the short block

Chapter 5.

Cylinder head
The benefit of larger valves
Group 1-type valves (1800/2000 engines)
Group 2 inlet valves (2000 engines)
Sierra IS head/valves
Valve size summary
Valve throat size
Inlet port size (std size valves)
Exhaust port size (std size valves)
Valve throat & port modifications (std size valves)
Valve unmasking
Inlet ports
Exhaust ports
Large valve modifications
Enlarging exhaust ports (large valves)
Valve guides

Chapter 6.

Compression ratio
Head planing
Thinner head gasket
Block planing
Raised top pistons 0′ ringing blocks
Compression ratio summary

Chapter 7.

Standard camshaft
High-performance camshafts
Choosing a camshaft
Competition engines
Camshaft data requirements
Holbay roller camshafts
Camshaft timing
Camshaft summary

Chapter 8.

Valve springs
Valve spring dimensions
Standard valve spring data
Measuring valve spring poundage
Advertised valve lift
Competition engines
Valve spring summary

Chapter 9.

Rockers & rocker geometry
Rocker geometry criteria
Valve stem height
Altered rocker geometry
Lash caps
Rocker sizes/designs
Roller rockers
Checking rocker geometry

Chapter 10.

Exhaust systems
Standard cast iron exhaust manifold
Exhaust system construction
Four into two into one
Four into one
Primary pipes
Primary pipe diameters
Primary pipe lengths
Equal length primary pipes

Chapter 11.

Flywheel & clutch
Engine balance
Engine balance

Chapter 12.

Ignition system
Distributor spindle
Drive gear
Endfloat / endplay
Contact breaker points
Electronic module
Distributor cap
Rotor arm
Low voltage conventional (standard) coil
Uprated low voltage conventional coil
Ballast resistor coils
Electronic coils
High tension wires
Checking spark quality
Wiring & connections
Ignition switch
High tension current (points type distributor)
High tension current (electronic type distributor)
Ignition timing marks
Checking TDC markings
Marking crankshaft damper/ pulley
Permanent advance degree marking
Static advance
Total advance
Vacuum advance
Ignition timing setting and checking
Ignition system summary

Chapter 13.

Throttle action
Carburettor summary
Inlet manifolds
Air filters
Ram pipes
Fuel supply

Chapter 14.

Sierra Cosworth
engines & Cosworth-headed Pinto engines Ill
Summary of modifications
Compression ratio (cr) – pinto & Cosworth blocks
Cosworth head/pinto block camshaft drive modifications
Cylinder head porting
Inlet ports
Exhaust ports
Valve lift limitations
High-performance camshafts (low lift)
High performance camshafts (high lift)
Standard valves
Long stem, bigger diameter valves
Valve keeper grooves
Valve stem seals
Valves – summary
Valve springs
Standard valve springs
Valve springs for high lift camshafts
Measuring valve spring pressure
Valve springs – summary
Camshaft followers
Cylinder head rebuild
Valve guides
Refacing valves
Short block
Piston clearance
Piston rings
Valve clearance
Connecting rods
Piston pin oiling modifications
Fitting cylinder head
Cylinder head gasket
Camshaft timing
Valve to piston clearance checking
Ignition system
High tension (HT) leads
Ignition timing
Exhaust system
Road cars
Competition cars
Minimal conversions

Chapter 15.

Starting engines & oiling requirements

Language: English
Format: PDF
Size: 33.6 Mb
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