Description

►►► POWER TUNE FORD SOHC 4-CYLINDER PINTO & COSWORTH DOHC ENGINES ◄◄◄
SPECIALIST PDF MANUAL SHOWING YOU HOW TO TUNE THESE GREAT PINTO ENGINES
The Pinto engine is used in the following vehicles:
Taunus Escort Mk1 RS2000 Escort Mk2 RS2000, Mexico Cortina Capri Sierra Granada Scorpio Transit van TVR Tasmin 200

If you want more power out of your SOHC or DOHC engine then this is the manual, goes into great detail of what and how things need to be done, all bookmarked so you can get to the section you want quickly.



Introduction 7
Using this ebook 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
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
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
0 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
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
Permanent advance degree
marking 103
Static advance 104
Total advance 105
Vacuum advance 105
Ignition timing setting and
checking 105
Rev-limiters 105
Ignition system summary 105
Chapter 13. Carburettors 107
Throttle action 109
Carburettor summary 109
Inlet manifolds 109
Air filters 110
Ram pipes 110
Fuel supply 110
Chapter 14. Sierra Cosworth
engines & Cosworth-headed Pinto
engines Ill
Introduction 111
Summary of modifications 112
Compression ratio (cr) - pinto &
Cosworth blocks 113
Cosworth head/pinto block
camshaft drive modifications 114
Cylinder head porting 114
Inlet ports 115
Exhaust ports 116
Camshafts 116
Valve lift limitations 116
High-performance camshafts
(low lift) 117
High performance camshafts
(high lift) 118
Valves 119
Standard valves 119
Long stem, bigger diameter
valves 119
Valve keeper grooves 120
Valve stem seals 120
Valves - summary 120
Valve springs 120
Standard valve springs 120
Valve springs for high lift
camshafts 121
Measuring valve spring pressure.... 123
Valve springs - summary 124
Camshaft followers 124
Cylinder head rebuild 125
Valve guides 125
Refacing valves 127
Short block 128
Piston clearance 128
Pistons 128
Piston rings 129
Valve clearance 130
Crankshaft 130
Connecting rods 130
Piston pin oiling modifications 131
Fitting cylinder head 132
Cylinder head gasket 132
Camshaft timing 134
Valve to piston clearance -
checking 135
Ignition system 136
High tension (HT) leads 136
Ignition timing 137
Exhaust system 137
Carburettors
Road cars
Competition cars
Minimal conversions
Chapter 15. Starting engines &
oiling requirements
Index


Information below from Wiki:
In Europe, the Pinto OHC was introduced in 1970 to replace the Essex V4 in the Mk3 Ford Cortina and Taunus V4 for the German Fords range (mainly the new Taunus TC). It was the first Ford engine to feature a belt-driven overhead camshaft (thus the name).

Applications:

Ford Taunus
Ford Escort Mk1 RS2000
Ford Escort Mk2 RS2000, Mexico
Ford Cortina
Ford Capri
Ford Sierra
Ford Granada
Ford Scorpio
Ford Transit van
TVR Tasmin 200

The Pinto engine was available in five displacements: 1.3 L (1,294 cc), earlier 1.6 L (1,593 cc), later 1.6 L (1,598 cc), 1.8 L (1,796 cc) and the 2.0 L (1,993 cc). Due to emission requirements it was phased out towards the end of the 1980s to be replaced by the CVH engine and DOHC engine, the latter being (contrary to popular belief) a completely new design and not a twin-cam development of the Pinto unit. The 16-valve version of the Ford DOHC unit is still used on the Ford Transit. The only DOHC direct derivative of Pinto engine is the Cosworth YB 16-valve engine, powering Ford Sierra and Ford Escort RS Cosworth variants.

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