Date:         Thu, 9 Oct 2003 11:26:15 -0700
Reply-To:     Larry Chase <roadguy@ROADHAUS.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Larry Chase <roadguy@ROADHAUS.COM>
Subject:      Roadhaus - Eurocars Engine Update
Comments: To: "wetwesties@yahoogroups." <wetwesties@yahoogroups.com>,
          vanagon@yahoogroups.com, Syncro@yahoogroups.com
Content-Type: text/plain; charset="us-ascii"

Volks,

A brief update on my latest Eurocars 2.2L Revision "E" Engine breakdown.

I'll do a more detailed write up in a few days.

Quick Summary.

Number one piston exploded at 18,000 miles (approx 3 weeks ago)

You might remember some photos I sent around.

Dan Larson of Completion Egr in PHX has done the work to get me back on
the road.

Dan has lots of VW Engine building experience ..... race cars, sand
rails etc.

His diagnosis as to why the piston failed.

Detonation problem because of a too lean condition.

The fix,

Replace two pistons on the side that failed with the last version (I'll
call them version three) Eurocars 2.2L revision E pistons.

Since the pistons were the same weight as the originals he recommended
we leave the good side alone.

Added a "Manual Fuel Pressure Regulator"  and slightly colder spark
plugs.

I've put 500 test miles on the newly, partially rebuilt engine and all
seems well for now.

So I'm off to see if I can squeeze a bit more life out of this engine.

Do I have confidence that another catastrophic failure won't occur ....
NO.

Based on Dan Larson's recommendations ... I've decided to give it a
shot.

Do I know for sure that Dan was right about the "too lean" condition ...
NO.

But I trust his judgment and believe he is making an honest, sincere,
very qualified recommendation.

I pushed Dan hard to remove the Eurocars pistons and install German 94mm
OE pistons.

But he felt .... the original pistons were fine and that the problem has
been addressed by adding a bit more fuel.

Time will tell.

On the shelf in reserve I have a set of new German OE 94mm pistons.

Just in case.



all roads lead to adventure,


Larry Chase
Email: RoadGuy@RoadHaus.com
Web:  <http://www.roadhaus.com/> www.RoadHaus.com
Cell: 480 620 8966
What: North American Road Trip
How: RoadHaus - 1990 White VW Westfalia Syncro
Today: Arizona