►►INCREASE POWER BHP FORD SOHC PINTO DOHC ENGINE WORKSHOP REPAIR MANUAL Taunus Escort Mk1 Mk2

►►► 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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