Subject: Re: 2.2 - 2.6 conversion

[mlp]

-----Original Message-----
From: Michael Pederson [mailto:mlped at concentric.net]
Sent: Friday, November 30, 2001 8:45 AM

The engine is done.  It sits ignored and forlornly in the car,
in front of its new (to it) 6 speed tranny, and waits for other things
to happen.

- Block (I'm using the original AAN 2.2 liter bored out to 82mm),
crankshaft, rods, bearings, camshafts, pistons, head & every thing
else in there, along with the brake rotors cryo'd (supposedly) by 300
Below;

- Carrillo "turbo" or "specialized" connecting rods (these are very,
very light.  It's been suggested maybe too light?  Carrillo OTOH, says
"No worries mate.";

- JE Pistons, the pin has been move "up" in the piston @ 4 - 5 mm &
the piston rather deeply dished (at least by comparison to a stock
AAN) to keep the CR below 9:1;  The pistons have been (a) thermally
coated (the tops with Swains "Gold Coat"); and (b) side "slippery"
coated.

-  Someone's, I'm not sure if Carrillo supplied them, or JE or ?the
international man of mystery, special wrist pins - also very light by
comparison to the stock pin.

- Camshafts were also "slippery coated"

- Valve faces have been "thermally coated" (this is a whitish finish)
nd the stems slippery treated to Swain's "slippery" coating.  The
slippery stem treatment, at Swains "recommendation" according to the
machine shop screws up the valve guide clearance enough (this is
denied by Swain) so that all, or at least every visible portion of the
coating had to be buffed off.

-  The head combustion chambers and intake/exhaust runners have also
been treated to Swains thermal barrier process.

- A special tubular exhaust manifold.  Swain Tech coated to keep the
heat of combustion in the exhaust, & out of the engine compartment;

- Stock extruded honed intake manifold, Swain Coated (thermally
"buffered to keep heat out);

- Head to Block ARP "studs" vs. the OEM bolts;

- Something larger than stock - don't want to say how large for sure
or I'll have a mad Hawaiian, or Texan on my hands, "semi" ball bearing
turbocharger, that's been variously accused of, or described as "The
spawn of a drunk date between a Cummings Turbo diesel and slyphish
German Lufthansa stewardess..... or was that steward?"  Pooh-poohed as
"Oh yeah, you can get one of those at any West Virginia (or Alabama or
Ozark) truck stop."

The only part we elected to use out of the Eurovan block was the
crankshaft, but you can do it the other way, or so I am told.  The
major stumbling blocks that I know of by "word of mouth," i.e. no BTDT
experience, in going the other way (see German Steward vs. Diesel
Cummings turbo, above) are:

- You need to machine & fit piston oil squirters (that is if your
application is going to be one of the turbocharged heads) to the
Eurovan block.  I'm told it can, and in fact has been done by
ScottBoy, but his machinist apparently had to buy some specialized
tooling to do it, so it may not be something every shop  either can,
or would be willing to try.

- I believe you also have to do something to the back of the block to
add a hot water fitting for ?? the Audi heater or heater return line.
This I think is supposed to be relatively simple.

-  I don't know about a 20v head direct bolt up to the Eurovan.  We
looked at it, and I was told it "looked" very doable, but the only
Eurovan Block / Audi head mating I know of I am pretty sure uses an
Audi 10V head.

- You'll have to solve the timing belt problem - i.e. the Eurovan
block is @ 8 to 10mm at least "taller" than the Audi AAN & its ilk, so
your timing belt has to cover that additional 1" or so of travel that
is going to occur between the cam drive gear in the head, and the
crankshaft pulley.

- On the plus side, you MAY not have to muck about with doing special
pistons with the pin relocation.

Let me know how you come along with your project.  What chassis were
you going to put your engine in again?

mlp
>
> > -----Original Message-----
> > From: Marc Thomas
> > Sent: Thursday, November 29, 2001 11:55 PM
> > To: mpederson at bigfoot.com
> > Subject: Re: 2.2 - 2.6 conversion
> >
> >
> > Mike,
> > Have you finished this engine yet?  I just bought a 2.5
> > eurovan long block
> > and plan to use it....what have you done?
> >
> > Marc
> > 84 non running urq