Saving my 2.2 (engine documentation thread)
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Thread: Saving my 2.2 (engine documentation thread)

  1. #1
    Über Genius My location First opel 1981's Avatar
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    Saving my 2.2 (engine documentation thread)

    I just found out that my 2.2 needs a rebuild.
    It will be done using existing parts, new parts and remanufactured parts.

    Feel free to comment on the rebuild.
    Opel GTs are not GM products
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    Humans are not an endangered species!
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  3. #2
    Über Genius My location First opel 1981's Avatar
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    First off, I would like to know what the stock rod journal diameter is. I found two journals at 51.50mm, one at 51.48, and one that's 51.46.
    Is the stock diameter 51.5 or 52mm?

    The engine shows signs that it was rebuilt at least once.
    Opel GTs are not GM products
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    Humans are not an endangered species!
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    2000 Post Club Site Supporter My location P.J. Romano's Avatar
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    I have attached page from Opel Service manual showing crankshaft journal sizes.
    Attached Files Attached Files
    Old racers never die. They just go bench racing.

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  6. #4
    7,000 Post Club My location wrench459's Avatar
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    The rod B/E bore 2.1653-2.1658

    Crank rod 2.0460-2.0467

    Si vis pacem, para bellum "If you want peace, prepare for war"

  7. #5
    Über Genius My location First opel 1981's Avatar
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    That's what I was afraid of.

    It looks like this crank has been ground down .020 (.50mm) already.
    It definitely needs another grind.
    Opel GTs are not GM products
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    Humans are not an endangered species!
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  8. #6
    Site Founder My location Gary's Avatar
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    Quote Originally Posted by First opel 1981 View Post
    That's what I was afraid of.

    It looks like this crank has been ground down .020 (.50mm) already.
    It definitely needs another grind.
    Are there any identifying numbers on the rod bearings that might show the undersize?
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  9. #7
    Über Genius My location First opel 1981's Avatar
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    Quote Originally Posted by Gary View Post
    Are there any identifying numbers on the rod bearings that might show the undersize?

    Just looked

    On one end,

    Clevite
    157

    The other end,

    CB1173AL
    0.50 K

    And that confirms my suspicion that the crank has been ground .020" (0.50mm)
    Gary likes this.
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    Humans are not an endangered species!
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  10. #8
    Über Genius My location First opel 1981's Avatar
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    OK, does anyone know the full dimensions of the 2.2 conrod?

    I found a few H-beam rods but the dimensions don't seem to jibe with what I have in my hand.

    These are the dimensions of the ones I found that are closest


    Center to center length:
    141.5mm

    Big end diameter:
    55mm

    Small end diameter:
    22mm

    Big end width:
    24.8mm

    Small end width:
    24.8mm
    Last edited by First opel 1981; 05-25-2014 at 07:16 PM.
    Opel GTs are not GM products
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  11. #9
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Quote Originally Posted by First opel 1981 View Post
    OK, does anyone know the full dimensions of the 2.2 conrod?

    I found a few H-beam rods but the dimensions don't seem to jibe with what I have in my hand.

    These are the dimensions of the ones I found that are closest


    Center to center length:
    141.5mm

    Big end diameter:
    55mm

    Small end diameter:
    22mm

    Big end width:
    24.8mm

    Small end width:
    24.8mm

    2.2 rods are identical dimensionally to 1.9 rods. In fact they are the same as late model cast steel 1.9 rods.

    They are 128 mm long center-to-center, pin ends are 23 mm.
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  12. #10
    Über Genius My location First opel 1981's Avatar
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    Quote Originally Posted by RallyBob View Post
    2.2 rods are identical dimensionally to 1.9 rods. In fact they are the same as late model cast steel 1.9 rods.

    They are 128 mm long center-to-center, pin ends are 23 mm.
    THis shows what a 2.2 noob I am.
    I saw the height of the piston/rod combo was different and assumed they just used 2.0 95mm pistons on shorter rods.
    I put the combo side by side with my 1.9 piston/rod specimen and see the pistons are the different component.

    This helps, and hurts less. I have a few extra 1.9 rods so that's no problem. Especially since the pistons are in great shape.

    So, the dimensions of a stock 1.9/2.0/2.2 rod are

    Big end - 55mm
    Small end - 23mm
    center to center - 128mm
    width - 24.95mm (garnered from measuring a rod from two different engines)

    Is this correct??
    Opel GTs are not GM products
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  13. #11
    7,000 Post Club My location wrench459's Avatar
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    A simple formula to keep in mind..

    Block height = 1/2 stroke + rod length + compression height

    Si vis pacem, para bellum "If you want peace, prepare for war"

  14. #12
    Über Genius My location First opel 1981's Avatar
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    Quote Originally Posted by wrench459 View Post
    A simple formula to keep in mind..

    Block height = 1/2 stroke + rod length + compression height
    Does not compute.

    Does not factor the distance from the center of the wrist pin to the top of the piston.
    Unless that's an industry standard somewhere.
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  15. #13
    7,000 Post Club My location wrench459's Avatar
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    Yepper

    Si vis pacem, para bellum "If you want peace, prepare for war"

  16. #14
    Über Genius My location First opel 1981's Avatar
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    Quote Originally Posted by wrench459 View Post


    Yepper
    AH. I see now
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  17. #15
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    IIRC, a 1.9 and 2.0 have a compression height of about 1.771", while a 2.2 has a compression height of about 1.619".
    My Flickr photos.
    C.R.L. 9/22/69 - 12/8/99, J.M.L. 3/3/43 - 6/15/04, D.M.L. 9/19/50 - 6/23/10
    E.G. Sauer 2/26/66 - 2/18/10. Rest in peace big guy...

    '70 GT 'Bonnie', '71 Ascona 4-dr turbo - winter beater, '71 Ascona 4-dr 'Turd' - rallycar, '72 Manta Rallye - hillclimb car, '72 Ascona wagon - 'Red', '72 Manta - caged street car, '73 Manta Luxus, '73 Ascona 2-dr, '74 Ascona 2-dr - Project X, '74 Manta Luxus - factory sunroof, '74 Manta ITB racecar, '75 Manta, '75 Sportwagon, '75 Manta - racecar

  18. #16
    7,000 Post Club My location wrench459's Avatar
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    1.1 pin vs stock 1.9L

    Si vis pacem, para bellum "If you want peace, prepare for war"

  19. #17
    Über Genius My location First opel 1981's Avatar
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    Quote Originally Posted by RallyBob View Post
    IIRC, a 1.9 and 2.0 have a compression height of about 1.771", while a 2.2 has a compression height of about 1.619".
    I will accept those numbers as they correspond, VERY closely, with my measurements. I'm not using the most sophisticated measuring devices so I have to have the +/- that fits within your stated measurements.

    OK, so I'm good on the pistons and rods, still.
    I just need to cross my fingers that I can have the crank machined in one pass.

    The main journals, so far, seem fine.



    P.S. I started rebuilding the head a week ago. Although it was never run with this engine, it was in about the same state of having been rebuilt before.
    I found really nice intake valves, good exhaust valves and a set of lifters that looked relatively new. One lifter was collapsed though, having been stored in a compressed position for a while. And, soft rubber on the valve seals.
    The one slightly worn lifter convinced me to pull it all apart, clean and inspect the guides, examine the seats, and lap the valves.
    I'll put in a new set of lifters and a combo cam because I have them on hand.

    I inspected the timing and found newer chain guides. The timing chain was one tooth off. This isn't a huge issue but will be resolved when I reassemble everything.

    I'm also going to check the gap on the rings. As long as I'm putting all this time into this thing I might as well check all my bases.
    Viny Charb likes this.
    Opel GTs are not GM products
    ̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶— ̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶ ̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶ ̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—
    Humans are not an endangered species!
    ̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶— ̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶ ̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶ ̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—

  20. #18
    Über Genius My location First opel 1981's Avatar
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    1.9 vs 2.2 pistons

    Attached Images Attached Images
    Opel GTs are not GM products
    ̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶— ̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶ ̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶ ̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—
    Humans are not an endangered species!
    ̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶— ̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶ ̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶ ̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—

  21. #19
    7,000 Post Club My location wrench459's Avatar
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    With used hyd. lifters we all ways collapsed them during a simple rebuild.
    Sometimes even took them apart and did some internal cleaning.....just sayin

    With a fresh valve job... well the lifters will need to readjust things a bit.

    Cool pic


    How much does that non-tapper pin weigh?
    Last edited by wrench459; 05-25-2014 at 10:30 PM.

    Si vis pacem, para bellum "If you want peace, prepare for war"

  22. #20
    Über Genius My location First opel 1981's Avatar
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    Quote Originally Posted by wrench459 View Post
    With used hyd. lifters we all ways collapsed them during a simple rebuild.
    Sometimes even took them apart and did some internal cleaning.....just sayin

    With a fresh valve job... well the lifters will need to readjust things a bit.

    Cool pic


    How much does that non-tapper pin weigh?
    Have no idea what things weigh at this point.
    The 1.9 is a low comp that's going to be tossed.
    The 2.2 is from the engine I'm doing in this thread.

    When I assemble things I will weigh them and do my best to match weight within 1 gram. I might even go a little tighter than that.
    Opel GTs are not GM products
    ̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶— ̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶ ̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶ ̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—
    Humans are not an endangered species!
    ̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶— ̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶ ̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶ ̶̶̶—̶̶̶̶̶̶̶—̶̶̶̶̶̶̶—

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