The Ford Sohc Pinto & Sierra Cosworth Dohc Engines High-Performance Manual

Hailing originally from New Zealand, Des Hammill is a professional engineer with many years of practical experience of building race-winning engines and solving technical problems. The author of several books in the SpeedPro series, Des writes in an easy to understand manner and gives step-by-step guidance. Des also takes his own photographs and creates his own line drawings.

• Introduction Using this book Essential informationSierra Cosworth engineChapter 1. Problem areas Standard connecting rodsForged connecting rodsLater, cast connecting rodsCosworth rodsStandard connecting rodsCamshaft lobes and rockersCamshaft pillarsCamshaft bearingsPiston to valve contact Auxiliary shaft gear wearLoose sprocketsValve guidesChapter 2. Short block componentsPistons and connecting rodsPiston & connecting rod weightsPiston & connecting rodsCrankshaft and flywheelLarge capacity enginesClutchesChapter 3. Replacement partsPistonsForged pistonsPiston ring setsCrankshaft bearingsCamshaft bearingsCamshaft spray barCamshaft kitGasketsSpecial boltsAuxiliary shaft bearingSealsValvesCompetition valvesValve retainers and keepersValve stem sealsOil pump and oil pump driveSump (oil pan)Dry sumpTiming beltCamshaft and auxiliary shaft thrust plates Chapter 4. Short block rebuildPermissible bore oversizesRepaired blocksComponent inspectionBlock & main bearingsMain bearing capsCheck-fitting main bearing shellsChecking bearing crushConnecting rod checksConnecting rod crack testingConnecting rod straightnessConnecting rod lengthConnecting rod hardnessPiston pin to connecting rod fitChecking connecting rod big end tunnel sizeConnecting rod crankshaft bearing tunnel resizingRemoving connecting rod boltsRefacing connecting rod and cap jointFitting new connecting rod boltsConnecting rod bearing tunnel honingAftermarket connecting rodsConnecting rod boltsChecking connecting rod bolts for stretchConnecting rod bearing crushChecking connecting rod bearing internal diametersOptimum connecting rod bearing clearancesCrankshaftCrankshaft checkingCrack testingChecking straightnessCrankshaft detailingMeasuring journalsCrankshaft regrinding 'Check-fitting' connecting rods to crankshaftBuilding the short blockChapter 5. Cylinder head ValvesThe benefit of larger valvesGroup 1-type valves (1800/2000 engines)Group 2 inlet valves (2000 engines)Sierra IS head/valvesValve size summaryValve throat sizeInlet port size (std size valves)Exhaust port size (std size valves)Valve throat & port modifications (std size valves)Valve unmaskingInlet portsExhaust portsLarge valve modificationsEnlarging exhaust ports (large valves)Valve guidesChapter 6. Compression ratioHead planingThinner head gasketBlock planingRaised top pistons'O' ringing blocksCompression ratio summaryChapter 7. CamshaftsStandard camshaftHigh-performance camshaftsChoosing a camshaftCompetition enginesCamshaft data requirementsHolbay roller camshaftsCamshaft timingCamshaft summary Chapter 8. Valve springs Valve spring dimensionsStandard valve spring dataMeasuring valve spring poundageAdvertised valve liftCompetition enginesValve spring summary Chapter 9. Rockers & rocker geometryRocker geometry criteriaValve stem height Altered rocker geometryLash capsRocker sizes/designsRoller rockers Checking rocker geometryChapter 10. Exhaust systemsStandard cast iron exhaust manifold Exhaust system constructionFour into two into oneFour into onePrimary pipesPrimary pipe diametersPrimary pipe lengthsEqual length primary pipesChapter 11. Flywheel & clutchEngine balanceFlywheelEngine balanceChapter 12. Ignition systemDistributor spindleDrive gearEndfloat/endplayContact breaker pointsCondenserElectronic moduleDistributor capRotor armCoilLow voltage conventional (standard) coilUprated low voltage conventional coil Ballast resistor coilsElectronic coilsHigh tension wiresSparkplugsChecking spark qualityWiring & connectionsAlternatorIgnition switchHigh tension current (points type distributor)High tension current (electronic type distributor)Ignition timing marksChecking TDC markingsMarking crankshaft damper/pulley