The T3200E thread

[ash1293]

Picked up a useful bargain for the installation this weekend, £60 the pair

Nice bargain - are they going to be mounted in permenant view or tucked out of the way somewhere for diagnostic purposes?

[silverbullet]

I would like to be able to keep an eye on the mixture when on a run, dont want it going lean on a long motorway run.
Air/fuel ratio is as important as oil pressure and temperature so I will need a suitable central dash pod for the lot (another side project...)
Found the instructions, its a rebadged Lumenition AFR004.

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[silverbullet]

Potential snag avoided! I need to change one lower head stud (222mm) due to corrosion, but the Oettinger ones are a LOT thicker than the VW parts.
I found the same on the 2500E...all the lower studs were bigger diameter, 8.4mm vs 7.1mm
Turns out that Oettinger used to get special HD studs made, possibly to help equalize the tension in the longer ones against the shorter, thinner ones?
Anyway, I was having a small parts sort out and noticed that in a set of new studs (bought from someone who had abandoned a wbx rebuild) all of them apart from two had 8.0mm shanks
8.0 is closer to 8.4 than 7.1 so I'll take that.

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[silverbullet]

Needful Things...a beautiful new aluminium bronze cam wheel made by Gear Cutting Co, Heston.

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[DoubleOSeven]

Oh that’s nice, very nice.

[silverbullet]

If anyone is wondering, £6.50/tooth + vat...

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[937carrera]

That's less than a dentist charges

[silverbullet]

Time for a fresh checkist of things still to do:
Oil pump: apply Mansi porting mods, adjust drive & boss to suit new cam.
Crankshaft: clean, replace x-drilling plugs, build up with rods etc.
Camshaft: after receipt, machine and drill gear to suit.
Crankcase: Sort rear thrust arrangement. Probably mod to use suffix B thrust washers to get around 0.5mm thrust width problem (turn thrust flanges off the T4 bearing)
Flywheel: poss. mod to thrust face to eliminate shims using bronze insert.
Sump: extend oil pickup to centralize and make gated baffle for better oil control.
Heads: get hairlines laser welded, remove all exhaust guides and machine for new, oversize, top-hat guides. Lap valves etc.
Inlet elbow: cut and extend to suit syncro application, TIG weld inc. blank off lower/old IACV port (it has two!)
Throttle body: extend throttle cable spindle to suit above. Poss. support bearing required.
Assemble.
Test.
Fit to bus.
Get exhaust made.

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[silverbullet]

That was traumatic! Quite tricky to get the cut level, square and radial to the centreline of the bend but it has turned out well.
Might have to knock up a simple fixture for the welders though.
Throttle body raised by 43mm with a 55mm long insert (syncro engine bar is 45mm lower than 2wd)

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[4x4 Bus]

All very nice.

[silverbullet]

It's a lot of work. I am convinced that this one wasn't meant to fit a syncro (its a 2wd engine) maybe because it's only number 20 and they hadn't arrived at that point?
Anyway, I'll get there.
It's just a bit scary when cutting up such rare parts.

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[silverbullet]

And that one pitted head stud wound out cold with no drama
I didn't fancy heating up the sand-cast case without an oven, it is possible to crack such things.
Don't ask me how I know.

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[silverbullet]

The ongoing struggle to relocate the throttle body...coolant pipes needed a tweak, throttle cable bracket will need remaking too and the throttle arm on the TB extending downwards. Its tight on space and misses by about 40mm (vertically) and the cable angle is wrong...
All doable, need to get the inlet TIG'd first.

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[bigbadbob76]

I'll be interested to see how you get on with those AFR indicators.
Not wanting to teach my granny to suck eggs but I've never found them to be particularly useful as they use narrow band sensors so as soon as you go slightly rich or slightly lean they go off the scale.
Wideband sensors give you a much better indication of how rich or how lean you are but they're a bit on the pricey side.
Narrow band sensors are fine for controlling a closed loop injection system but not for diagnostics in my opinion. (other opinions are available )

[silverbullet]

I'm aware of the limitations of narrow-band lambda sensors, they will be more of a tell-tale for the mixture going out the window rather than an accurate readout of the engine's state of tune.
They were cheap enough, so worth a punt!

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