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Blog Title: Calan

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'92 TSI Complete Rebuild From Firewall Forward - Part 23

Posted 05-11-2010 at 09:02 AM by Calan
Updated 05-11-2010 at 10:16 AM by Calan

Ok...where was I?

When I started working on the rear of the car, it was pretty apparent that the fasteners were in even worse shape than the ones on the front of the car. After some close inspection, it turned out that most of it was just surface rust and years of road grime. So rather than spend lots of $$ on new suspension bolts, I decided to media blast them all and started thinking...
Attached Images
File Type: jpg SB_heim_3.jpg (16.9 KB, 1915 views)
File Type: jpg SB_links_1.jpg (21.1 KB, 1898 views)
File Type: jpg SB_links_2.jpg (20.1 KB, 1883 views)
File Type: jpg SB_links_installed.jpg (25.9 KB, 1893 views)
File Type: jpg shock_and_caliper.jpg (22.4 KB, 1893 views)
File Type: jpg nasty_bolts.jpg (25.1 KB, 1894 views)
File Type: jpg bolts_blasted.jpg (21.0 KB, 1888 views)
File Type: jpg bolts_coated.jpg (26.2 KB, 1891 views)
File Type: jpg bolts_block.jpg (21.2 KB, 1884 views)
File Type: jpg elliptical_bolts.jpg (21.1 KB, 1889 views)
File Type: jpg washers.jpg (24.0 KB, 1885 views)
File Type: jpg rear_sus_done.jpg (17.5 KB, 1864 views)
Views 2548 Comments 17 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 22

Posted 04-11-2010 at 10:25 PM by Calan
Updated 04-12-2010 at 02:18 PM by Calan

I got a lot accomplished with the car this weekend but before we get to that, there was one more thing I forgot to mention in the last entry.

Since I live out in the country, I decided I could use some driving lights. The stockers are long gone, and wouldn't work anyway since I'm using the factory locations for a CAI and oil cooler. What I ended up getting was a pair of mini halogens...
Attached Images
File Type: jpg driving_lamp.jpg (17.0 KB, 1496 views)
File Type: jpg driving_lights_3.jpg (22.8 KB, 1486 views)
File Type: jpg fuel_filler_2.jpg (31.8 KB, 1475 views)
File Type: jpg lamp_switch.jpg (20.6 KB, 1472 views)
File Type: jpg lines_dropped.jpg (24.0 KB, 1483 views)
File Type: jpg rear_diff_3.jpg (22.8 KB, 1477 views)
File Type: jpg rear_diff_4.jpg (24.8 KB, 1479 views)
File Type: jpg rear_diff_cover.jpg (18.6 KB, 1473 views)
File Type: jpg rear_diff_done.jpg (18.7 KB, 1474 views)
File Type: jpg rear_subframe_done.jpg (23.8 KB, 1471 views)
File Type: jpg sub_frame_welds_1.jpg (19.8 KB, 1475 views)
File Type: jpg sub-frame_parts_1.jpg (22.8 KB, 1470 views)
File Type: jpg tank_painted_1.jpg (25.2 KB, 1465 views)
File Type: jpg tank_painted_2.jpg (23.6 KB, 1461 views)
File Type: jpg underbody_painted_4.jpg (20.8 KB, 1467 views)
File Type: jpg underside_stripped.jpg (21.5 KB, 1477 views)
File Type: jpg underbody_painted_1.jpg (21.8 KB, 1348 views)
File Type: jpg underbody_painted_2.jpg (28.4 KB, 1385 views)
File Type: jpg underbody_painted_3.jpg (22.4 KB, 1373 views)
Views 1625 Comments 7 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 21

Posted 04-09-2010 at 01:36 AM by Calan
Updated 04-09-2010 at 07:29 PM by Calan

Well it's been about 6 months, so I thought I better post an update on what's been going on with the never-ending project (but that's why we love 'em ).

The car was running really well after firing it up, and still is. After break-in and a bit of tuning, ECMLink HP and 70-90 estimates put it right around 400 awhp on the e316g, which feels about right. (I plan on getting to a dyno...
Attached Images
File Type: jpg nasty_tank_parts.jpg (20.9 KB, 1613 views)
File Type: jpg rear_well_herc_2.jpg (31.8 KB, 1605 views)
File Type: jpg trailing_arm_3.jpg (24.8 KB, 1602 views)
File Type: jpg bat_fusebox_1.jpg (27.1 KB, 1594 views)
File Type: jpg front_brakes.jpg (23.3 KB, 1594 views)
File Type: jpg front_caliper_orig.jpg (20.0 KB, 1589 views)
File Type: jpg fusebox_decal_1.jpg (66.9 KB, 1599 views)
File Type: jpg fusebox_decal_2.jpg (27.1 KB, 1599 views)
File Type: jpg nasty_lines_1.jpg (29.1 KB, 1592 views)
File Type: jpg nasty_tank_1.jpg (24.5 KB, 1586 views)
File Type: jpg new_rear_parts.jpg (26.0 KB, 1587 views)
File Type: jpg rear_caliper_assy.jpg (24.9 KB, 1580 views)
File Type: jpg rear_caliper_disassembled.jpg (26.3 KB, 1580 views)
File Type: jpg rear_caliper_orig.jpg (21.8 KB, 1575 views)
File Type: jpg rear_diff_2.jpg (21.0 KB, 1580 views)
File Type: jpg rear_subframe_out.jpg (25.1 KB, 1573 views)
File Type: jpg rear_well_herc.jpg (29.1 KB, 1576 views)
File Type: jpg rear_wheel_well_before.jpg (28.3 KB, 1580 views)
File Type: jpg sub_frame_and_diff.jpg (25.6 KB, 1566 views)
File Type: jpg turbo_oil_feed.jpg (29.2 KB, 1583 views)
File Type: jpg blasted_inner_hub.jpg (16.2 KB, 1464 views)
File Type: jpg clean_hub.jpg (18.5 KB, 1463 views)
Views 1755 Comments 13 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 20

Posted 09-30-2009 at 12:07 PM by Calan
Updated 02-02-2010 at 06:44 PM by Calan

It's ALIVE!

It started right up, and other than a couple of very minor issues it has been running pretty well. The only real "problem" I've had so far is a weeping turbo oil feed line that just doesn't want to go away. It's not enough to even smoke or drip, but still...I'll probably end up going to a stainless line with AN fittings in the next week or so.

In the interest...
Attached Images
File Type: jpg fans.JPG (33.9 KB, 2633 views)
File Type: jpg hood_stuts.JPG (21.5 KB, 2642 views)
File Type: jpg j-pipe.JPG (24.6 KB, 2635 views)
File Type: jpg LICP.JPG (22.5 KB, 2622 views)
File Type: jpg maiden_voyage.JPG (29.1 KB, 4553 views)
File Type: jpg MBC_1.jpg (21.2 KB, 2650 views)
File Type: jpg modified_prothane_1.jpg.jpg (27.8 KB, 3049 views)
File Type: jpg modified_prothane_3.jpg (19.0 KB, 3047 views)
File Type: jpg modified_prothane_4.jpg (22.7 KB, 3046 views)
File Type: jpg oil_cooler_12.jpg (21.8 KB, 2628 views)
File Type: jpg front_screen.JPG (19.4 KB, 2628 views)
File Type: jpg hood_struts_2.JPG (29.8 KB, 2615 views)
File Type: jpg fuse_labels.jpg (42.5 KB, 2584 views)
File Type: jpg MBC_3.jpg (28.9 KB, 2345 views)
File Type: jpg dash_1.jpg (18.2 KB, 2349 views)
Views 2998 Comments 24 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 19

Posted 09-14-2009 at 08:20 AM by Calan
Updated 02-02-2010 at 06:45 PM by Calan

We're getting closer!

I've finally gotten the suspension back together and the brake work done, but as usual... it ended up being more of a project than originally planned. While getting ready to put everything back together, I inspected the calipers and found quite a bit of corrosion, so I decided to rebuild them. (I wrote a tech article on it that can be found here).

...
Attached Images
File Type: jpg brake_hard_lines.JPG (25.4 KB, 1485 views)
File Type: jpg brake_lines_new.JPG (22.5 KB, 1486 views)
File Type: jpg brake_lines_old.JPG (22.8 KB, 1486 views)
File Type: jpg caliper_rebuild_7.jpg (22.2 KB, 1675 views)
File Type: jpg caliper_rebuild_8.jpg (25.2 KB, 1673 views)
File Type: jpg pass_hub.JPG (21.2 KB, 1481 views)
File Type: jpg rotor_done.jpg (22.7 KB, 1478 views)
File Type: jpg speed_bleeder_1.jpg (19.2 KB, 1481 views)
File Type: jpg speed_bleeder_2.jpg (17.7 KB, 1471 views)
File Type: jpg strut_spacer_and_studs.JPG (19.0 KB, 1481 views)
File Type: jpg strut_spacer_and_studs_2.jpg (20.0 KB, 1197 views)
Views 1529 Comments 7 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 18

Posted 09-08-2009 at 12:41 PM by Calan
Updated 02-02-2010 at 06:46 PM by Calan

As I get closer and closer to "finishing" this build, I find myself having a hard time remembering what things were like before it all started. So much has changed, but the last year has been a blur.

In an effort to remind myself of what I've gone through and to help keep me motivated, I started going through some of the pictures that I've shot over the last three years since owning...
Attached Images
File Type: jpg 1a.JPG (42.1 KB, 1252 views)
File Type: jpg 1b.jpg (46.4 KB, 1251 views)
File Type: jpg 2a.jpg (31.7 KB, 1244 views)
File Type: jpg 2b.jpg (39.6 KB, 1239 views)
File Type: jpg 4a.jpg (57.3 KB, 1244 views)
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File Type: jpg 5a.JPG (41.5 KB, 1239 views)
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File Type: jpg 6a.jpg (52.8 KB, 1246 views)
File Type: jpg 6b.jpg (62.1 KB, 1240 views)
File Type: jpg 7a.jpg (44.0 KB, 1229 views)
File Type: jpg 7b.JPG (47.1 KB, 1229 views)
File Type: jpg 8a.JPG (38.6 KB, 1234 views)
File Type: jpg 8b.JPG (62.3 KB, 1236 views)
Views 1073 Comments 6 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 17

Posted 09-08-2009 at 10:07 AM by Calan
Updated 02-02-2010 at 06:47 PM by Calan

Things are moving along fairly quickly now, but I still have some minor hurdles to get past. The biggest issue is that I still need to find a proper J-pipe and get my LICP welded up, and then get the fans/radiator in place and wired. But more on that in a later part...

The last few weeks have mostly been spent dealing with the bolt-on stuff. (SS lines, oil cooler, VC, etc). I also wrapped...
Attached Images
File Type: jpg 90_CAS_3.JPG (18.7 KB, 3254 views)
File Type: jpg BOV_done.jpg (25.5 KB, 1375 views)
File Type: jpg cc1_piping_1.jpg (28.3 KB, 1367 views)
File Type: jpg new_tps_1.JPG (25.0 KB, 3252 views)
File Type: jpg oil_cooler_1.JPG (21.8 KB, 1373 views)
File Type: jpg oil_cooler_2.JPG (23.8 KB, 1371 views)
File Type: jpg oil_cooler_4.jpg (22.1 KB, 1368 views)
File Type: jpg oil_cooler_5.jpg (21.0 KB, 1366 views)
File Type: jpg oil_cooler_10.jpg (24.2 KB, 1365 views)
File Type: jpg oil_cooler_11.jpg (20.2 KB, 1366 views)
File Type: jpg vc_AN_breather_1.JPG (16.9 KB, 1379 views)
File Type: jpg vc_AN_breather_2.JPG (20.3 KB, 1380 views)
File Type: jpg vc_AN_breather_3.JPG (18.1 KB, 1380 views)
File Type: jpg oil_cooler_9.jpg (23.6 KB, 1371 views)
File Type: jpg vc_breather_out.jpg (23.7 KB, 1374 views)
Views 1364 Comments 0 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 16

Posted 08-29-2009 at 08:32 AM by Calan
Updated 02-02-2010 at 06:48 PM by Calan

Once I figured out what I wanted to do with the catch cans, everything else around the intake manifold started falling into place.

First up was modification of the PCV valve outlet on the VC. I've never liked the way it comes straight out and into the TPS, so I decided to modify it for a better angle towards the catch can. I also wanted to keep the snorkel to help eliminate as much...
Attached Images
File Type: jpg booster_hose.JPG (21.4 KB, 2151 views)
File Type: jpg IM_plugs_1.JPG (18.1 KB, 2151 views)
File Type: jpg IM_plugs_2.JPG (25.1 KB, 2155 views)
File Type: jpg injectors_2.JPG (30.8 KB, 2149 views)
File Type: jpg new_manifold_port_1.JPG (20.2 KB, 2151 views)
File Type: jpg new_manifold_port_2.JPG (25.5 KB, 2136 views)
File Type: jpg PCV_elbow_2.JPG (18.9 KB, 2155 views)
File Type: jpg PCV_routing_1.JPG (31.5 KB, 2151 views)
File Type: jpg vac_mani_1.JPG (18.0 KB, 2150 views)
File Type: jpg vac_mani_4.JPG (24.6 KB, 2153 views)
File Type: jpg vac_mani_8.JPG (27.1 KB, 2155 views)
File Type: jpg vac_mani_9.JPG (27.0 KB, 2154 views)
File Type: jpg PCV_elbow_1.JPG (17.0 KB, 2159 views)
File Type: jpg PCV_elbow_3.JPG (17.4 KB, 2153 views)
Views 2356 Comments 7 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 15

Posted 08-18-2009 at 12:29 PM by Calan
Updated 02-02-2010 at 06:50 PM by Calan

This one is a bit long...

I finally got around to finishing the design of my catch cans and getting them built. But first, a little history...

Some of you (with no life) may have read through the Stupid PCV question thread and remember that several of us were trying all sorts of different things a couple years ago to find a catch can setup that worked. Long story short,...
Attached Images
File Type: jpg cc1_3.JPG (19.5 KB, 2565 views)
File Type: jpg cc1_on_IM.JPG (30.8 KB, 2562 views)
File Type: jpg cc2_1.jpg (21.1 KB, 2561 views)
File Type: jpg cc2_2.jpg (19.5 KB, 2567 views)
File Type: jpg cc2_4.jpg (30.3 KB, 2603 views)
File Type: jpg clean_axles.JPG (21.8 KB, 2564 views)
File Type: jpg clean_PS_parts_2.JPG (26.5 KB, 2553 views)
File Type: jpg clean_struts.JPG (26.1 KB, 2556 views)
File Type: jpg herculiner_1.JPG (36.5 KB, 2559 views)
File Type: jpg herculiner_2.JPG (31.1 KB, 2554 views)
File Type: jpg polished_TB_elbow.JPG (19.6 KB, 2553 views)
File Type: jpg ps_pump_done_1.JPG (22.9 KB, 2565 views)
File Type: jpg SS_AFPR_Line.JPG (30.6 KB, 2563 views)
File Type: jpg clean_intake_2_sm.jpg (19.5 KB, 2156 views)
File Type: jpg oil_1_sm.jpg (23.3 KB, 2089 views)
Views 2954 Comments 13 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 14

Posted 08-04-2009 at 10:16 AM by Calan
Updated 02-02-2010 at 06:51 PM by Calan

Since dropping the motor in, I've been working mostly on re-assembling the little stuff and finishing off some sensor wiring, along with some more minor fabrication projects.

While working on the new injector wiring, it quickly became obvious that the ignition coils had to be moved. Besides being in the way of injector #1, I've never been crazy about the way the coils sit in the manifold....
Attached Images
File Type: jpg coil_bracket_1.JPG (19.6 KB, 1455 views)
File Type: jpg coil_bracket_3.JPG (12.2 KB, 1446 views)
File Type: jpg coil_bracket_fab_1.JPG (21.8 KB, 1451 views)
File Type: jpg coil_bracket_fab_2.JPG (20.8 KB, 1446 views)
File Type: jpg coil_bracket_fab_3.JPG (19.7 KB, 1448 views)
File Type: jpg coil_bracket_fab_4.JPG (19.2 KB, 1449 views)
File Type: jpg coil_mount_1.JPG (19.2 KB, 1446 views)
File Type: jpg coil_mount_2.JPG (25.1 KB, 1440 views)
File Type: jpg coil_mounted_1.JPG (25.6 KB, 1439 views)
File Type: jpg coil_mounted_2.JPG (24.4 KB, 1441 views)
File Type: jpg coil_wiring_1.JPG (21.4 KB, 1446 views)
File Type: jpg coil_wiring_2.JPG (18.6 KB, 1440 views)
File Type: jpg plug_wires_1.JPG (22.8 KB, 1443 views)
File Type: jpg plug_wires_3.JPG (26.2 KB, 1439 views)
File Type: jpg plug_wires_4.JPG (33.3 KB, 1441 views)
Views 1385 Comments 8 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 13

Posted 08-03-2009 at 02:44 PM by Calan
Updated 02-10-2010 at 12:54 PM by Calan

I've got the motor in, so now it's just a matter of lots of tedious work; a bit more wiring, some minor fabrication, and hooking everything back up.

I wasn't really looking forward to torquing the flywheel bolts, stabbing the tranny, and dropping the motor in by myself, but it was actually really easy. (Most of this entry will be spent describing the method I used).

For...
Attached Images
File Type: jpg lift_bracket_1.JPG (25.2 KB, 1503 views)
File Type: jpg lift_bracket_2.JPG (24.5 KB, 1499 views)
File Type: jpg engine_flywheel.JPG (23.0 KB, 1486 views)
File Type: jpg engine_flywheel_2.JPG (25.0 KB, 1494 views)
File Type: jpg engine_going_in_1.JPG (29.3 KB, 1479 views)
File Type: jpg engine_going_in_2.JPG (26.2 KB, 1485 views)
File Type: jpg engine_going_in_4.JPG (28.7 KB, 1483 views)
File Type: jpg engine_going_in_5.JPG (27.1 KB, 1480 views)
File Type: jpg engine_on_hoist.JPG (29.4 KB, 1510 views)
File Type: jpg engine_pressure_plate.JPG (24.0 KB, 1484 views)
File Type: jpg engine_trans_1.JPG (30.4 KB, 1479 views)
File Type: jpg holding_crank_1.JPG (25.5 KB, 1490 views)
File Type: jpg holding_crank_2.JPG (28.8 KB, 1482 views)
File Type: jpg engine_in_1.JPG (32.9 KB, 1479 views)
Views 1875 Comments 13 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 12

Posted 07-30-2009 at 07:49 AM by Calan
Updated 02-02-2010 at 06:54 PM by Calan

The last couple weeks were spent wrapping up the motor, and finishing up some little projects that needed to be done before the new stroker gets dropped back in to it's new home.

While waiting on parts, I finished up the wiring harness down by the battery, and got the cables wrapped and tucked out of the way. I also got the coolant overflow painted and mounted next to the CAI, and...
Attached Images
File Type: jpg CAI_8.jpg (23.5 KB, 1705 views)
File Type: jpg degree_wheel_3.jpg (26.4 KB, 1696 views)
File Type: jpg degree_wheel_mounting.JPG (22.1 KB, 1691 views)
File Type: jpg indicator_plate.jpg (20.5 KB, 1690 views)
File Type: jpg modified_t-stat_housing_1.jpg (16.0 KB, 1696 views)
File Type: jpg lifter_mod_1.jpg (20.6 KB, 1695 views)
File Type: jpg lifter_mod_3.jpg (21.3 KB, 1686 views)
File Type: jpg lifter_mod_4.jpg (19.9 KB, 1686 views)
File Type: jpg exhaust_cam_degreeing.JPG (28.9 KB, 1690 views)
File Type: jpg cam_lift.jpg (23.2 KB, 1682 views)
File Type: jpg exhaust_ACG.jpg (22.3 KB, 1688 views)
File Type: jpg titanium.JPG (29.0 KB, 1694 views)
File Type: jpg modified_PS_bracket.jpg (20.7 KB, 1696 views)
File Type: jpg new_engine_27.jpg (26.6 KB, 1681 views)
File Type: jpg new_engine_25.jpg (25.0 KB, 1681 views)
Views 1936 Comments 10 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 11

Posted 07-14-2009 at 03:29 PM by Calan
Updated 02-02-2010 at 06:55 PM by Calan

The last few weeks have been all about more blasting, polishing, detailing, and some odds and ends that don't require much cash.

I took my E316G apart and cleaned up the porting a bit more and re-polished it. While I was at it, I blasted the compressor cover, hotside, O2 housing, and exhaust manifold. I also ported the manifold, and took it (along with the O2 housing and hotside)...
Attached Images
File Type: jpg compressor_housing_2.jpg (21.4 KB, 1583 views)
File Type: jpg hotside_3.jpg (19.1 KB, 1586 views)
File Type: jpg hotside_1.jpg (24.1 KB, 1574 views)
File Type: jpg hotside_2.jpg (20.9 KB, 1578 views)
File Type: jpg ported_2G_EM_1.jpg (24.2 KB, 1579 views)
File Type: jpg water_pipe_2.jpg (15.5 KB, 1575 views)
File Type: jpg water_pipe_4.jpg (16.6 KB, 1577 views)
File Type: jpg water_pipe_5.jpg (20.0 KB, 1567 views)
File Type: jpg OFH_1.jpg (22.5 KB, 1578 views)
File Type: jpg OFH_2.jpg (21.9 KB, 1575 views)
File Type: jpg coolant_tank_3.jpg (21.0 KB, 1588 views)
File Type: jpg coolant_tank_4.jpg (25.4 KB, 1579 views)
File Type: jpg coolant_tank_5.jpg (23.7 KB, 1580 views)
File Type: jpg polished_fuel_rail.jpg (38.2 KB, 1567 views)
File Type: jpg CAI_5.jpg (26.7 KB, 1569 views)
Views 1541 Comments 1 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 10

Posted 06-17-2009 at 08:17 PM by Calan
Updated 02-02-2010 at 06:55 PM by Calan

Well it seems like I'm FINALLY seeing a little light at the end of the tunnel, but there is still a lottttttt of tunnel left

A couple weeks ago I finally bit the bullet and picked up a blasting cabinet and a bucket of 80 grit glass media from Harbor Freight. I've wanted one for about 20 years now, and with all the DSM parts that needed some TLC for my rebuild, I said what the hell...
Attached Images
File Type: jpg blaster.jpg (24.2 KB, 1858 views)
File Type: jpg intake_manifold.jpg (29.5 KB, 1654 views)
File Type: jpg intake_manifold_2.jpg (23.1 KB, 1643 views)
File Type: jpg cam_gear_tape.jpg (20.5 KB, 1643 views)
File Type: jpg cam_gears.jpg (24.8 KB, 1647 views)
File Type: jpg new_engine_2.jpg (23.3 KB, 1641 views)
File Type: jpg new_engine_8.jpg (23.4 KB, 1632 views)
File Type: jpg new_engine_9.jpg (27.4 KB, 1639 views)
File Type: jpg new_engine_13.jpg (31.9 KB, 1636 views)
File Type: jpg new_ps_lines_6.jpg (26.2 KB, 1633 views)
File Type: jpg new_PS_lines_7.jpg (20.8 KB, 1645 views)
File Type: jpg ps_line_clamps_1.jpg (17.4 KB, 1639 views)
File Type: jpg ps_line_clamps_3.jpg (18.2 KB, 1652 views)
File Type: jpg as_it_sits.jpg (28.6 KB, 1638 views)
File Type: jpg getting_closer.jpg (25.4 KB, 1640 views)
Views 1800 Comments 6 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 9

Posted 05-27-2009 at 08:19 AM by Calan
Updated 02-02-2010 at 06:58 PM by Calan

YEAH BABY! I got the 2.3L stroker short block back from the machine shop, so now the real fun can begin.

Name:  engine_on_stand.jpg
Views: 2778
Size:  29.7 KB

Before I start building the motor, I wanted to set it in the car temporarily so I could do some final mock-up on a few remaining parts. After attaching the front and rear mounts, I dropped it in and bolted up the driver's side mount. I then...
Attached Images
File Type: jpg engine_in_bay_1.jpg (30.8 KB, 1652 views)
File Type: jpg engine_in_bay_2.jpg (28.6 KB, 1642 views)
File Type: jpg engine_in_bay_3.jpg (24.5 KB, 1636 views)
File Type: jpg engine_in_bay_4.jpg (33.1 KB, 1645 views)
File Type: jpg injectors.jpg (25.8 KB, 1642 views)
File Type: jpg intake.jpg (29.9 KB, 1633 views)
File Type: jpg modified_fuel_rail.jpg (38.9 KB, 1638 views)
File Type: jpg new_ps_line_1.jpg (25.4 KB, 1637 views)
File Type: jpg new_ps_line_2.jpg (20.7 KB, 1633 views)
File Type: jpg side_posts.jpg (27.5 KB, 1632 views)
File Type: jpg mock-up.jpg (28.0 KB, 1630 views)
File Type: jpg brake_PV.jpg (17.3 KB, 1628 views)
File Type: jpg pan_bung_1.jpg (26.2 KB, 1646 views)
File Type: jpg pan_bung_2.jpg (22.2 KB, 1634 views)
Views 1807 Comments 7 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 8

Posted 05-05-2009 at 07:55 PM by Calan
Updated 02-02-2010 at 06:57 PM by Calan

Well after a lot of thought, I decided not to relocate my battery. My excuses include too much stuff already coming through the firewall, potential NHRA tech problems, cost, screwing with my interior, etc. etc. But while looking into it, I started getting some ideas for power distribution and that crazy mess of wiring connected to the battery.

While sourcing parts I came across a 3-in/4-out...
Attached Images
File Type: jpg DB_1.jpg (22.7 KB, 1360 views)
File Type: jpg DB_2.jpg (24.5 KB, 1361 views)
File Type: jpg DB_3.jpg (28.1 KB, 1359 views)
File Type: jpg DB_bracket_3.jpg (22.7 KB, 1362 views)
File Type: jpg DB_finished.jpg (27.0 KB, 1357 views)
File Type: jpg DB_mockup_1.jpg (23.3 KB, 1352 views)
File Type: jpg DB_mockup_2.jpg (19.1 KB, 1363 views)
File Type: jpg DB_mockup_3.jpg (22.9 KB, 1356 views)
File Type: jpg DB_wires_1.jpg (22.7 KB, 1355 views)
File Type: jpg DB_wires_2.jpg (26.9 KB, 1354 views)
File Type: jpg DB_Bracket_raw.jpg (16.5 KB, 1361 views)
File Type: jpg DB_Bracket_4.jpg (27.7 KB, 1339 views)
File Type: jpg DB_4.jpg (29.2 KB, 1330 views)
File Type: jpg DB_5.jpg (28.7 KB, 1340 views)
File Type: jpg battery_1.jpg (23.8 KB, 1339 views)
Views 1408 Comments 3 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 7

Posted 05-05-2009 at 08:20 AM by Calan
Updated 02-02-2010 at 07:01 PM by Calan

Not a whole lot to talk about with this one, but thought I better stay up-to-date. I spent the majority of last weekend cleaning my garage and workbench; it had gotten WAY out of hand and I couldn't find anything anymore.

But I did get a few things done on the car as well. For starters, that used up yellow tubing for the windshield washers had to go. I bought some Excelon RNT clear PVC tubing from U.S. Plastics,...
Attached Images
File Type: jpg washer_hose_1.jpg (20.0 KB, 1147 views)
File Type: jpg washer_hose_2.jpg (27.4 KB, 1150 views)
File Type: jpg ps-reservoir.jpg (25.4 KB, 1155 views)
File Type: jpg motor_mounts.jpg (18.6 KB, 1152 views)
File Type: jpg new_PS_lines_1.jpg (25.2 KB, 1158 views)
File Type: jpg new_PS_lines_2.jpg (27.9 KB, 1152 views)
File Type: jpg new_PS_lines_5.jpg (24.8 KB, 1147 views)
File Type: jpg car_1.jpg (28.1 KB, 1151 views)
File Type: jpg car_2.jpg (29.5 KB, 1148 views)
File Type: jpg oil_pump_parts.jpg (30.1 KB, 1072 views)
Views 1091 Comments 1 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 6

Posted 04-29-2009 at 10:15 PM by Calan
Updated 02-02-2010 at 07:02 PM by Calan

I spent the last few evenings working on mounting the radiator, modifying my bumper, mounting the intercooler, and various small projects.

I bought this CX Racing radiator off ebay last fall, and never installed it. So now that the time has come, I found that it didn't fit as nicely as I wanted. The main problem is the top mounting posts; they are uneven and not located in the same...
Attached Images
File Type: jpg rad_mount_1.jpg (20.1 KB, 1524 views)
File Type: jpg rad_mount_2.jpg (20.1 KB, 1516 views)
File Type: jpg rad_mount_3.jpg (24.5 KB, 1524 views)
File Type: jpg rad_mount_5.jpg (22.5 KB, 1521 views)
File Type: jpg rad_mount_6a.jpg (68.2 KB, 1532 views)
File Type: jpg bumper_cut.jpg (27.4 KB, 1524 views)
File Type: jpg fmic_1.jpg (26.6 KB, 1520 views)
File Type: jpg fmic_2.jpg (21.2 KB, 1504 views)
File Type: jpg air_dam_1.jpg (26.9 KB, 1514 views)
File Type: jpg air_dam_2.jpg (23.7 KB, 1515 views)
File Type: jpg coolant_CAI.jpg (21.3 KB, 1514 views)
File Type: jpg rad_inside.jpg (24.3 KB, 1518 views)
File Type: jpg CAI_4.jpg (21.3 KB, 1480 views)
File Type: jpg rad_OF_tank.jpg (58.1 KB, 1495 views)
File Type: jpg CAI_1.jpg (18.2 KB, 1488 views)
Views 1616 Comments 2 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 5

Posted 04-27-2009 at 07:40 AM by Calan
Updated 02-02-2010 at 07:03 PM by Calan

It's been a few months, so I guess I need to get this thing updated. Now...Where was I?

I didn't get much accomplished over the holidays, other than finishing up the engine bay cleaning and getting the first coat of paint on. After taking a break for a couple of months, I caught a few warm days in early March and finished painting the bay. I used Duplicolor Low Gloss Black, with Gloss...
Attached Images
File Type: jpg car_front.jpg (63.2 KB, 1442 views)
File Type: jpg battery_area.jpg (24.5 KB, 1438 views)
File Type: jpg lower_pass_harness.jpg (29.9 KB, 1439 views)
File Type: jpg brake_area.jpg (27.3 KB, 1437 views)
File Type: jpg wai_line_2.jpg (69.3 KB, 1430 views)
File Type: jpg wai_line_3.jpg (69.4 KB, 1433 views)
File Type: jpg front_harness.jpg (58.2 KB, 1429 views)
File Type: jpg wiring_pass_front_1.jpg (26.1 KB, 1425 views)
File Type: jpg fuse_block.jpg (67.6 KB, 1442 views)
File Type: jpg wiring_pass_front_2.jpg (18.2 KB, 1431 views)
File Type: jpg wai_line_1.jpg (30.8 KB, 1436 views)
File Type: jpg pre-paint_1.jpg (23.9 KB, 1188 views)
File Type: jpg pre-paint_2.jpg (27.7 KB, 1184 views)
Views 1587 Comments 3 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 4

Posted 12-02-2008 at 05:42 PM by Calan
Updated 02-02-2010 at 07:04 PM by Calan

I spent the last week or so finishing up the basic cleaning, building new brackets, and mocking up the new firewall layout. Extensive work was done on the wiring harness; several wires were shortened and others that were not needed were removed.

I also started testing various paints for the engine bay. The first paints I tested were standard rattle cans of Krylon and Rustoleum. Interestingly,...
Attached Images
File Type: jpg Krylon.jpg (19.4 KB, 1008 views)
File Type: jpg fuel_filter_bracket.jpg (18.8 KB, 1002 views)
File Type: jpg resistor pack.jpg (17.7 KB, 1010 views)
File Type: jpg firewall_components.jpg (26.0 KB, 999 views)
File Type: jpg AFPR.jpg (20.4 KB, 993 views)
File Type: jpg AC_cover.jpg (16.1 KB, 1002 views)
File Type: jpg res_location.jpg (22.6 KB, 1004 views)
File Type: jpg WAI_Sensor.jpg (19.7 KB, 996 views)
File Type: jpg sensor_wiring.jpg (20.4 KB, 994 views)
File Type: jpg fuse_mount.jpg (24.2 KB, 998 views)
Views 1576 Comments 2 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 3

Posted 11-20-2008 at 10:09 PM by Calan
Updated 02-02-2010 at 07:05 PM by Calan

Well I finally got the motor torn all the way down and off to the machine shop for measurements and a thorough inspection. Over the next few weeks, it will be tanked, magnafluxed, and blueprinted. In the mean time, I'll be trying to decide exactly which direction I want to go with it and trying to come up with the funds to actually do it .

As of right now, I'm leaning towards a 2.3l...
Attached Images
File Type: jpg main_caps_1.jpg (25.0 KB, 900 views)
File Type: jpg main_caps_3.jpg (19.1 KB, 897 views)
File Type: jpg crank.jpg (18.2 KB, 892 views)
File Type: jpg suspension_gone.jpg (17.0 KB, 895 views)
File Type: jpg hub_and_knuckle.jpg (20.0 KB, 893 views)
File Type: jpg wheel_well_liner.jpg (23.5 KB, 896 views)
File Type: jpg liner_test.jpg (16.7 KB, 899 views)
File Type: jpg clean_bay_4.jpg (21.7 KB, 895 views)
File Type: jpg clean_bay_5.jpg (34.1 KB, 893 views)
Views 1519 Comments 4 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 2

Posted 11-18-2008 at 09:14 PM by Calan
Updated 02-02-2010 at 07:06 PM by Calan

The last several days have been all about removing more crap and cleaning, cleaning, and doing some more cleaning. It's unbelievable how much grime and gunk can accumulate in every nook and cranny over the course of 17 years.

First things first, I had to remove most everything from the bay and get the firewall pad off. It wasn't too bad, but getting it out from behind the brake booster...
Attached Images
File Type: jpg insulation_removed.jpg (31.6 KB, 1187 views)
File Type: jpg brake_mess.jpg (26.1 KB, 1186 views)
File Type: jpg WAI_mounting.jpg (16.5 KB, 1185 views)
File Type: jpg clean_bay_1.jpg (27.1 KB, 1189 views)
File Type: jpg clean_bay_2.jpg (26.2 KB, 1186 views)
File Type: jpg fender_well_1.jpg (30.8 KB, 1183 views)
File Type: jpg fender_well_2.jpg (24.5 KB, 1180 views)
File Type: jpg fender_well_3.jpg (25.6 KB, 1173 views)
File Type: jpg almost_there.jpg (36.3 KB, 1186 views)
File Type: jpg wheel_hub_1.jpg (23.6 KB, 1186 views)
Views 1668 Comments 0 Calan is online now
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'92 TSI Complete Rebuild From Firewall Forward - Part 1

Posted 11-18-2008 at 08:53 AM by Calan
Updated 02-02-2010 at 07:07 PM by Calan

A few weeks ago I decided to replace my radiator...which led to needing a new fan and wiring. After staring at the wiring for a minute, and knowing that a recent compression and leakdown test had shown cylinder #1 to be low, I decided to put the car on stands, maybe pull the head and do a "few" other things to it over a couple of weeks.

Well as it usually goes, one thing led to another...
Attached Images
File Type: jpg firewall-1.jpg (23.0 KB, 947 views)
File Type: jpg firewall-2.jpg (25.4 KB, 942 views)
File Type: jpg wiring-1.jpg (25.3 KB, 938 views)
File Type: jpg wiring-2.jpg (21.3 KB, 937 views)
File Type: jpg engine-1.jpg (31.8 KB, 943 views)
File Type: jpg engine-2.jpg (22.9 KB, 940 views)
File Type: jpg engine-3.jpg (28.0 KB, 936 views)
File Type: jpg engine-4.jpg (25.7 KB, 941 views)
File Type: jpg ouch_1.jpg (27.9 KB, 952 views)
File Type: jpg ouch_2.jpg (20.2 KB, 946 views)
Views 1300 Comments 2 Calan is online now
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