Table of Contents

Introduction
Using this book
Essential information
Sierra Cosworth engine
Chapter 1. Problem areas
Standard connecting rodsForged connecting rods
Later, cast connecting rods
Cosworth rods
Standard connecting rods
Camshaft lobes and rockers
Camshaft pillars
Camshaft bearings
Piston to valve contact
Auxiliary shaft gear wear
Loose sprockets
Valve guides
Chapter 2. Short block componentsPistons and connecting rodsPiston & connecting rod weights
Piston & connecting rods
Crankshaft and flywheel
Large capacity engines
Clutches
Chapter 3. Replacement parts
Pistons
Forged pistons
Piston ring sets
Crankshaft bearings
Camshaft bearings
Camshaft spray bar
Camshaft kit
Gaskets
Special bolts
Auxiliary shaft bearing
Seals
Valves
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
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 Valves
The benefit of larger valves
Group 1-type valves (1800/2000 engines)
Group 2 inlet valves (2000 engines)
Sierra IS head/valvesValve size summaryValve 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
'O' ringing blocks
Compression ratio summary
Chapter 7. Camshafts
Standard camshaftHigh-performance camshafts
Choosing a camshaft
Competition enginesCamshaft 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 & clutchEngine balance
Flywheel
Engine balanceChapter 12. Ignition system
Distributor spindle
Drive gear
Endfloat/endplay
Contact breaker points
Condenser
Electronic module
Distributor cap
Rotor arm
Coil
Low voltage conventional (standard) coil
Uprated low voltage conventional coil
Ballast resistor coils
Electronic coils
High tension wires
Sparkplugs
Checking spark quality
Wiring & connections
AlternatorIgnition switch
High tension current (points type distributor)
High tension current (electronic type distributor)
Ignition timing marks
Checking TDC markings
Marking crankshaft damper/pulley

About the Author

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.