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FORD SOHC
4-CYLINDER PINTO 1 &
COSWORTH DOHC ENGINES
FOR ROAD & TRACK
Des Hammill
VELOCE PUBLISHING
THE PUBLISHER OF FINE AUTOMOTIVE BOOKS
HOW TO POWER TUNE
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Contents
Introduction
7
Piston ring sets
24
Piston pin to connecting rod fit
36
Using this book
8
Crankshaft bearings
24
Checking connecting rod big end
tunnel size
Essential information
8
Camshaft bearings
24
37
Sierra Cosworth engine
9
Camshaft spray bar
24
Connecting rod crankshaft bearing
tunnel resizing
Camshaft kit
24
38
Gaskets
25
Removing connecting rod bolts
38
Chapter 1. Problem areas
10
Special bolts
25
Refacing connecting rod and cap
joint
Standard connecting rods
10
Auxiliary shaft bearing
25
39
Forged connecting rods
10
Seals
25
Fitting new connecting rod bolts
39
Later, cast connecting rods
10
Valves
25
Connecting rod bearing tunnel
honing
Cosworth rods
11
Competition valves
26
40
Standard connecting rods -
summary
Valve retainers and keepers
27
Aftermarket connecting rods
40
12
Valve stem seals
27
Connecting rod bolts
40
Checking connecting rod bolts for
stretch
Camshaft lobes and rockers
12
Oil pump and oil pump drive
27
Camshaft pillars
13
Sump (oil pan)
28
40
Connecting rod bearing crush
41
Camshaft bearings
13
Dry sump
28
Piston to valve contact
13
Timing belt
28
Checking connecting rod bearing
internal diameters
42
Auxiliary shaft gear wear
13
Camshaft and auxiliary shaft thrust
plates
Loose sprockets
14
29
Optimum connecting rod bearing
clearances
Valve guides
14
42
Chapter 4. Short block rebuild ....30
Permissible bore oversizes
Crankshaft
42
Chapter 2. Short block
components
30
Crankshaft checking
43
15
Repaired blocks
31
Crack testing
43
Pistons and connecting rods
15
Component inspection
31
Checking straightness
43
Piston & connecting rod weights
19
Block & main bearings
31
Crankshaft detailing
44
Measuring journals
44
Piston & connecting rods -
summary
Main bearing caps
32
19
Check-fitting main bearing
shells
Crankshaft regrinding
45
'Check-fitting' connecting rods to
crankshaft
Crankshaft and flywheel
20
33
Large capacity engines
21
Checking bearing crush
35
45
Connecting rod checks
35
Building the short block
46
Clutches
21
Connecting rod crack testing
35
Chapter 3. Replacement parts
23
Connecting rod straightness
35
Chapter 5. Cylinder head
48
Pistons
23
Connecting rod length
36
Valves
49
Forged pistons
23
Connecting rod hardness
36
The benefit of larger valves
50
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Group 1-type valves (1800/2000
engines)
Primary pipes
91
Introduction
111
50
Summary of modifications
112
Primary pipe diameters
91
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)
Compression ratio (cr) - pinto &
Cosworth blocks
Primary pipe lengths
91
113
Equal length primary pipes
91
Cosworth head/pinto block
camshaft drive modifications
Chapter 11. Flywheel &
clutch
114
Cylinder head porting
114
93
Inlet ports
115
Engine balance
93
Exhaust ports
116
Flywheel
93
Camshafts
116
Engine balance
95
56
Valve lift limitations
116
Valve unmasking
57
Chapter 12. Ignition system
96
High-performance camshafts
(low lift)
117
Inlet ports
57
Distributor spindle
97
Exhaust ports
57
High performance camshafts
(high lift)
Drive gear
97
118
Large valve modifications
58
Endfloat / endplay
97
Enlarging exhaust ports (large
valves)
Valves
119
Contact breaker points
97
Standard valves
119
59
Condenser
98
Valve guides
60
Long stem, bigger diameter
valves
Electronic module
98
119
Distributor cap
98
Chapter 6. Compression ratio
61
Valve keeper grooves
120
Rotor arm
99
Head planing
61
Valve stem seals
120
Coil
99
Thinner head gasket
63
Valves - summary
120
Low voltage conventional
(standard) coil
Block planing
63
Valve springs
120
99
Raised top pistons
63
Standard valve springs
120
Uprated low voltage conventional
coil
0' ringing blocks
64
Valve springs for high lift
camshafts 121
Measuring valve spring pressure.... 123
Valve springs - summary
99
Compression ratio summary
64
Ballast resistor coils
99
Electronic coils
100
Chapter 7. Camshafts
66
124
High tension wires
100
Standard camshaft
66
Camshaft followers
124
Sparkplugs
100
Cylinder head rebuild
125
High-performance camshafts
66
Checking spark quality
100
Choosing a camshaft
67
Valve guides
125
Wiring & connections
100
Refacing valves
127
Competition engines
70
Alternator
100
Camshaft data requirements
70
Short block
128
Ignition switch
101
Piston clearance
128
Holbay roller camshafts
70
High tension current (points type
distributor)
Camshaft timing
71
Pistons
128
101
Piston rings
129
Camshaft summary
72
High tension current (electronic
type distributor)
101
Valve clearance
130
Chapter 8. Valve springs 73
Valve spring dimensions 74
Standard valve spring data 75
Measuring valve spring poundage ... 77
Advertised valve lift
Crankshaft
130
Ignition timing marks
102
Connecting rods
130
Checking TDC markings
103
Piston pin oiling modifications
131
Marking crankshaft damper/
pulley
103
Fitting cylinder head
132
Cylinder head gasket
132
79
Permanent advance degree
marking
Competition engines
80
103
Camshaft timing
134
Valve spring summary
80
Valve to piston clearance -
checking
Static advance
104
135
Total advance
105
Chapter 9. Rockers & rocker
geometry
Ignition system
136
Vacuum advance
105
High tension (HT) leads
136
81
Ignition timing setting and
checking
Ignition timing
137
Rocker geometry criteria
81
105
Exhaust system
137
Valve stem height
82
Rev-limiters
105
Altered rocker geometry
82
Carburettors
138
Ignition system summary
105
Lash caps
83
Road cars
139
Rocker sizes/designs
83
Chapter 13. Carburettors
107
Competition cars
139
Minimal conversions
140
Roller rockers
86
Throttle action
109
Checking rocker geometry
86
Carburettor summary
109
Chapter 15. Starting engines &
oiling requirements
Inlet manifolds
109
Chapter 10. Exhaust systems
89
Air filters
110
141
Standard cast iron exhaust
manifold
Ram pipes
110
Fuel supply
110
89
Index
143
Exhaust system construction
89
Chapter 14. Sierra Cosworth
engines & Cosworth-headed Pinto
engines
Four into two into one
90
Four into one
90
Ill
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Veloce SpeedPro books -
- more on the way!
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using this book
& essential
information
INTRODUCTION
requirements and any other aspects of
engine specification which will be
affected by your choice of equipment.
The Ford single overhead cam-
shaft (SOHC) 'Pinto' engine was
made in vast numbers to power a
great many different vehicles and,
although no longer in production for
passenger cars, it is still in wide use.
This all cast iron engine is quite large
and very heavy, but it's also readily
available, spares are reasonably
priced, there are plenty of tuning
components available and a very good
amount of extra power is attainable at
relatively low cost.
All three engines in the Pinto
series covered by this book share the
same crankshaft stroke (76.95mm/
3.029in). The bore sizes of the three
capacities are 81.32mm/3.201in
(1600cc), 86.20mm/3.394in (1800cc)
and 90.82mm/3.575in (2000cc).
There are other Pinto engines which
this book does not cover, namely the
1300cc engine (bore and stroke of
79.02mm by 66.0mm) the 1600cc E-
Max engine (bore and stroke of
87.67mm by 66.0mm) and the
American-built 2300cc Pinto engine
which, while similar in design to the
European units is, in fact, different in
almost every detail.
Pinto engines have several weak
points which place some limitation on
how far they can be taken in terms of
extra power. However, the engine's
evolution has resulted in improve-
ments which made the unit more
reliable than when first introduced.
Specialist high-performance manufac-
turers have also designed and devel-
oped components which have contrib-
uted to the removal of virtually all of
the problems associated with this unit,
meaning the engine can now be
modified for high-performance use
with real confidence.
These weak areas are the con-
necting rods, the camshaft lobes and
rockers, the centre and rear camshaft
pillars and the camshaft centre pillar
The aim of this book is to tell you how
to modify the single overhead
camshaft (SOHC) Ford 'Pinto'.
Cosworth-headed Pinto or Sierra
Cosworth 'Pinto engine and end up
with an engine that is reasonable
powerful and reliable. Whether you
want extra power for road or
competition use, you'll find the
information you need within this
book. Although this book specifically
deals with naturally aspirated
(carburettors, no compressor) engines,
because the broad aims of tuning for
high performance (minimum friction,
maximum gas flow, maximum
efficiency and reliability) are the same,
most of the information is also
applicable to turbocharged/
supercharged engines and fuel-
injected engines. If you are intending
to use forced induction, you'll need to
talk to the equipment supplier about
optimum compression ratios, rpm
Introduction,

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