Engine and gearbox finally finished

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I have finally finished the main installation of my AFN and Long geared 5 speed box.

Mario and Daz at MV engineering did the main engine work.  We started with a Sharon AFN engine which we stripped and assessed the condition - the bottom end was fine but the top end was rebuilt, we took this opportunity to fit larger nozzles on the rebuilt injectors, and new turbo was also fitted.

Cruise control was also fitted using a brand new stalk from VW Classic which was very well priced against the second hand ones when available - brickwerks ordered this for me - thank you.

They did a good job on the whole and I am very pleased with their work.

I drove the van like this for the summer holiday - it was quite quick to 60mph on the std 3H gearing, but I didn't go faster than this due to engine speed and "mechanical sympathy" for the engine.

The box was then booked in with Aidan.  The box was rebuilt with a 4.14 diff, 0.73 5th gear and SA oil plates.  Aidan informed me that this is the longest 2wd box he has built!

The results of this are very impressive - 1st is now usable and it still pulls well in 5th gear.

With the std 205/XX/14 tyres (std multivan alloy size) it now cruises at 70mph (on the gps speedo) at 2900rpm or 80mph at 3300rpm.  at these speeds it will stall accelerate up the hills on the motorway as well.

I am really pleased and would recommend both Aidan and MV engineering - thank you both

I have a couple of things to sort out now - NVH - there is some vibration coming from the engine installation - this I think is due to the intercooler I have used and the very short run from intercooler out to inlet manifold, and to have a look at the accelerator pedal - over long journeys my ankle starts to ache.

This isn't an advert for either company I am just over the moon with the final product and wanted to give praise where praise is due.

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jc_geddes Members Profile Send Private Message Find Members Posts Add to Buddy List Yardie Joined: 26 Jun 06 Location: United Kingdom Status: Offline Points: 452	Post Options Post Reply Quote jc_geddes Report Post Thanks(0) Quote Reply Topic: Engine and gearbox finally finished Posted: 16 Oct 12 at 19:31
	I have finally finished the main installation of my AFN and Long geared 5 speed box. Mario and Daz at MV engineering did the main engine work. We started with a Sharon AFN engine which we stripped and assessed the condition - the bottom end was fine but the top end was rebuilt, we took this opportunity to fit larger nozzles on the rebuilt injectors, and new turbo was also fitted. Cruise control was also fitted using a brand new stalk from VW Classic which was very well priced against the second hand ones when available - brickwerks ordered this for me - thank you. They did a good job on the whole and I am very pleased with their work. I drove the van like this for the summer holiday - it was quite quick to 60mph on the std 3H gearing, but I didn't go faster than this due to engine speed and "mechanical sympathy" for the engine. The box was then booked in with Aidan. The box was rebuilt with a 4.14 diff, 0.73 5th gear and SA oil plates. Aidan informed me that this is the longest 2wd box he has built! The results of this are very impressive - 1st is now usable and it still pulls well in 5th gear. With the std 205/XX/14 tyres (std multivan alloy size) it now cruises at 70mph (on the gps speedo) at 2900rpm or 80mph at 3300rpm. at these speeds it will stall accelerate up the hills on the motorway as well. I am really pleased and would recommend both Aidan and MV engineering - thank you both I have a couple of things to sort out now - NVH - there is some vibration coming from the engine installation - this I think is due to the intercooler I have used and the very short run from intercooler out to inlet manifold, and to have a look at the accelerator pedal - over long journeys my ankle starts to ache. This isn't an advert for either company I am just over the moon with the final product and wanted to give praise where praise is due.

jason k Members Profile Send Private Message Find Members Posts Add to Buddy List Admin Group twinklerims Joined: 14 Jan 05 Location: Wales Status: Offline Points: 15934	Post Options Post Reply Quote jason k Report Post Thanks(0) Quote Reply Posted: 16 Oct 12 at 19:34
	Nice to hear of someone producing the goods on a conversion! Can't get a better recommendation than a happy customer!!
	Bcs shallowest surf award winner 2006 camperjam 2011 chug and tug team member aberdare. south wales newest member of karmann korner no longer the only moderator to manage to ban himself

Tee3 Members Profile Send Private Message Find Members Posts Add to Buddy List Admin Group Coprophagous Cretin Joined: 06 Jun 04 Location: Huddersfield Status: Offline Points: 9763	Post Options Post Reply Quote Tee3 Report Post Thanks(0) Quote Reply Posted: 16 Oct 12 at 19:39
	Awesome. Im leaning towards a TDI for mine... ive outgrown the AAZ and i have the longer final drive already.
	YOU CANT EDUCATE GAMMON http://www.tee3.co.uk/

lloydy Members Profile Send Private Message Find Members Posts Add to Buddy List Yardie Joined: 14 Jun 10 Location: surrey Status: Offline Points: 998	Post Options Post Reply Quote lloydy Report Post Thanks(0) Quote Reply Posted: 16 Oct 12 at 19:44
	Good news! On the peddle problem, i really do reccomend the peddle i used, it's great. Basically feels like its in the same position as the standard peddle
	16" syncro multivan

jc_geddes Members Profile Send Private Message Find Members Posts Add to Buddy List Yardie Joined: 26 Jun 06 Location: United Kingdom Status: Offline Points: 452	Post Options Post Reply Quote jc_geddes Report Post Thanks(0) Quote Reply Posted: 16 Oct 12 at 19:45
	What still puts a smile on my face is cruising down the motorway at 80 in the outside lane flying past all the T2s and T3s in the slow lane.

VW Nerd Members Profile Send Private Message Find Members Posts Add to Buddy List Yardie Joined: 20 Jan 08 Location: Bristol Status: Offline Points: 831	Post Options Post Reply Quote VW Nerd Report Post Thanks(0) Quote Reply Posted: 16 Oct 12 at 20:17
	Great news, another member to the AFN bus club. This really is a great engine to use in the bus. Loads of power and good fuel economy as well. What throttle set up are you using. I have found that the spring in the std throttle pot is to strong for the bus set up and needs to be adjusted with less pre load. Enjoy.
	Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts. Tim Shettle www.ultimate-engineering.co.uk Bristol Tel/txt 07810 320 464 AFN TDI Panel Van

jc_geddes Members Profile Send Private Message Find Members Posts Add to Buddy List Yardie Joined: 26 Jun 06 Location: United Kingdom Status: Offline Points: 452	Post Options Post Reply Quote jc_geddes Report Post Thanks(0) Quote Reply Posted: 16 Oct 12 at 20:24
	i have the std sharon pedal up front .

timmythedog Members Profile Send Private Message Find Members Posts Add to Buddy List Vanorak westy fetishist Joined: 29 May 08 Location: Nr Grenoble Status: Offline Points: 3415	Post Options Post Reply Quote timmythedog Report Post Thanks(0) Quote Reply Posted: 16 Oct 12 at 23:05
	You've used the whole sharan pedal assembly? Hhhmm. I butchered mine. So it's not pedal stiffness that's the issue then, more pedal angle? After the many hurdles in installing my afn(big learning curve) I really like it now.
	Syncro doka td T4 Multivan Generation, 151 89 Caravelle Exclusive 2.1 Caravelle GL AFN tdi 53 plate T4 Panel.888 special x factor. 88 DG Panel(uncut) calypso Atlantic pop.

mrhutch Members Profile Send Private Message Find Members Posts Add to Buddy List Moderator Group the ginger princess Joined: 21 Aug 07 Location: Herefordshire Status: Offline Points: 5147	Post Options Post Reply Quote mrhutch Report Post Thanks(0) Quote Reply Posted: 16 Oct 12 at 23:14
	I want to use the e-pedal on the 20V.. pics please!
	T3 1981 Westy Vanagon - thinks lubricant is a fuel

lloydy Members Profile Send Private Message Find Members Posts Add to Buddy List Yardie Joined: 14 Jun 10 Location: surrey Status: Offline Points: 998	Post Options Post Reply Quote lloydy Report Post Thanks(0) Quote Reply Posted: 17 Oct 12 at 07:15
	pedal from lhd sharan And part number i started off with a peddle from a rhd passat, it really hurt your ankle due to the angle
	16" syncro multivan

timmythedog Members Profile Send Private Message Find Members Posts Add to Buddy List Vanorak westy fetishist Joined: 29 May 08 Location: Nr Grenoble Status: Offline Points: 3415	Post Options Post Reply Quote timmythedog Report Post Thanks(0) Quote Reply Posted: 17 Oct 12 at 08:45
	My Sharan had the earlier style throttle pot, like the 1Z jobs. They action is too stiff when used with the T3 pedal. Tim Shettle has sussed out how to "detune" them for better foot control. lloydy, that's a later style job and looks by far the better option for a neat install. . I wonder if I might be able to use that style on mine? It's a 97 Sharan donor. That looks to be later. The pot had six wires out, but I don't think they're all required (unless you have auto or cruise perhaps)
	Syncro doka td T4 Multivan Generation, 151 89 Caravelle Exclusive 2.1 Caravelle GL AFN tdi 53 plate T4 Panel.888 special x factor. 88 DG Panel(uncut) calypso Atlantic pop.

mrhutch Members Profile Send Private Message Find Members Posts Add to Buddy List Moderator Group the ginger princess Joined: 21 Aug 07 Location: Herefordshire Status: Offline Points: 5147	Post Options Post Reply Quote mrhutch Report Post Thanks(0) Quote Reply Posted: 17 Oct 12 at 08:46
	top job. cheers lloydy
	T3 1981 Westy Vanagon - thinks lubricant is a fuel

lloydy Members Profile Send Private Message Find Members Posts Add to Buddy List Yardie Joined: 14 Jun 10 Location: surrey Status: Offline Points: 998	Post Options Post Reply Quote lloydy Report Post Thanks(0) Quote Reply Posted: 17 Oct 12 at 09:08
	No worries, Tim, my donor car had the earlier pedal set up and got swapped over to this style. I think it's just a matter of changing the wires over to the new peddle connector. Syncroandy could maybe give the drawing for it. Also, Elvis fitted it so he would be able to tell you what wire goes where. If you go for it and get stuck, I should be able to check what colour wire goes where for you
	16" syncro multivan

timmythedog Members Profile Send Private Message Find Members Posts Add to Buddy List Vanorak westy fetishist Joined: 29 May 08 Location: Nr Grenoble Status: Offline Points: 3415	Post Options Post Reply Quote timmythedog Report Post Thanks(0) Quote Reply Posted: 17 Oct 12 at 14:23
	Cool. Thank you. I will get one off ebay and see what's what. It might even have the same wire colour scheme. Just good to know that it's not going to be rejected by the ecu.
	Syncro doka td T4 Multivan Generation, 151 89 Caravelle Exclusive 2.1 Caravelle GL AFN tdi 53 plate T4 Panel.888 special x factor. 88 DG Panel(uncut) calypso Atlantic pop.

jc_geddes Members Profile Send Private Message Find Members Posts Add to Buddy List Yardie Joined: 26 Jun 06 Location: United Kingdom Status: Offline Points: 452	Post Options Post Reply Quote jc_geddes Report Post Thanks(0) Quote Reply Posted: 18 Oct 12 at 19:33
	My pedal looks similar to that - but the last two lettres of the PN are different. Does the kink in the bar bend down or sideways? Mine goes sideways you looks like down but it might just be the pictures. It looks like I could angle the pedal down a little as its not touching the carpet when at full throttle - I might try this at the weekend. I also have a chipped ecu to have a play with - 300Nm

VW Nerd Members Profile Send Private Message Find Members Posts Add to Buddy List Yardie Joined: 20 Jan 08 Location: Bristol Status: Offline Points: 831	Post Options Post Reply Quote VW Nerd Report Post Thanks(0) Quote Reply Posted: 18 Oct 12 at 20:58
	How many Nm is your VW transmission good for? Good be a costly play time.
	Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts. Tim Shettle www.ultimate-engineering.co.uk Bristol Tel/txt 07810 320 464 AFN TDI Panel Van

jc_geddes Members Profile Send Private Message Find Members Posts Add to Buddy List Yardie Joined: 26 Jun 06 Location: United Kingdom Status: Offline Points: 452	Post Options Post Reply Quote jc_geddes Report Post Thanks(0) Quote Reply Posted: 18 Oct 12 at 21:14
	Aidan said 300Nm

lloydy Members Profile Send Private Message Find Members Posts Add to Buddy List Yardie Joined: 14 Jun 10 Location: surrey Status: Offline Points: 998	Post Options Post Reply Quote lloydy Report Post Thanks(0) Quote Reply Posted: 18 Oct 12 at 21:20
	What's the bhp/torque curve like on that ecu? Still pretty flat?
	16" syncro multivan

niko Members Profile Send Private Message Find Members Posts Add to Buddy List Vanorak Nice fella. Joined: 01 Jul 07 Location: Stroke On Tent Status: Offline Points: 2639	Post Options Post Reply Quote niko Report Post Thanks(0) Quote Reply Posted: 18 Oct 12 at 22:03
	I have a MV engine conversion and Aidan box.......and I love mine too....
	1989 westy Joker now with TDi