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Street Build 96 tsi overhaul

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96talonchick

Proven Member
202
10
Feb 3, 2016
Chippewa Falls, Wisconsin
I had set my sites on an affordable dream car and ended up wanting a 2g talon. My first talon was my baby for 9 years, by all means she is slow but purdy. Took far too long for my dream to be achieved mostly because my husband has an even bigger love for cars and his car took the forefront. I had originally set out this winter to do preventative maintenance on my n/t but quickly snagged up a 2g fwd tsi on Craigslist. Now I have THE dream car as I had always wanted a tsi talon but doing that to my n/t would have been a waste of time and money.

I picked up a 96 fwd tsi that was a non runner but a decently clean body. The night we picked it up I had noticed an 'minor' title issue and had been told that the car had just had the head rebuilt but wouldn't start. It took me almost 2 months to sort out the title issue thanks to the schmuck who had signed his name as the purchaser but no other information. Thank god for Facebook and my willingness to stalk the previous owners to track down the culprit. Once I made contact it was a speedy process, he drove 2 hours to meet me at the dmv and he had registered it and then signed it over immediately. Then my husband and I started to figure out why the car wouldn't start, didn't take us long to realize that we needed to do a tear down and see what the damage was.
 
A few weeks back I got all of my parts and my engine back from the machine shop. So far it's been going as smoothly as expected. Taking a bit longer than I had hoped to get it all back together but my 4 year old insists on trying to help.

So far most of the block has been assembled. By tomorrow I am hoping to be able to drop the engine and transmission back in.
 

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Located a 14b turbo which has some cracks in the housing and wastegate. I do know it came off a running, driving car but my husband has decided to try to epoxy the cracks in hopes of not running into issues.
 

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The engine looks freaking amazing! Love the Kiggley Brace and ARP's. Nice build! Looking at the pictures of the 14b though, You're going to need a new hot side housing at the very least. If you epoxy it, the expansion and contraction rates of the epoxy won't match the cast iron and it won't be long before you're leaking again. I would find a used crack free housing on this forum, e-bizzle or craigslist and just replace it. You won't be able to properly tune the car (even in stock trim) and you will never see full boost from it. I'm wondering if the vehicle this came off of had an anti-lag setup. If it did, then the fuel was actually combusting inside the turbo as well as the cylinders. Not good for turbo life and if that's the case, I would be cautious about the rest of the turbo. If it's a question mark, I would just find another complete 14b or 16G. Even a stock T25 would be better than trying to epoxy that one. Up to you, but if you use this one, just keep these issues in the back of your mind if you need to trouble shoot boost leak or driveability issues. Glad to see you finally got the dream whip though. Congrats!
 
Finally got the engine dropped back in. Hoping next weekend we will be able to connect everything and finally fire it up :)
 

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My husband finally had time to get back into the garage this weekend. All in all he spent between 10-12 hours this weekend trying to figure out my car. Yesterday it was the issue of the ecm not reading in my car which it turns out was the result of a sensor being plugged into where it didn't belong. With that fixed we then ran into the annoying issue of the clutch not bleeding after we replaced it with an SS line. Which we fixed this afternoon-that was a highly annoying cluster f#%$ of fun. After that he plugged in the remaining sensors, got the fuel pump to read, ran all the vacuum lines and installed the radiator. First few attempts at a start failed but again it was because of something that was oh so silly... apparently the 95 eprom ecm needs to have the plug wires flopped.

So once we got all of those annoyances taken care of, it fired right up. Now mind you, it's a fresh motor and doesn't run like a champ yet but it is finally alive after 6mo of sitting in my garage.

Upper radiator hose is close to bursting so that is a must to replace and we also have the issue of coolant spraying out of the thermostat housing around the gasket (3k rpm or higher) also have an issue with lifter noise which I'm not happy about (I had a shop rebuild the head) oil pressure holds steady, Temps doesn't but we also do not have fans installed just yet. And I can finally say I have had a car make boost! Hit 2psi in my garage, haha! Yeah, I know... weak sauce for all you dsm'ers but absolutely epic for my as I have never had a turbo car. My baby is nearly complete. When it's drivable and doesn't leave me stranded it will be one of my happiest days.

Thanks for all the forum help, you guys have been life savers!
 
Well I have been driving the car the past 2 weeks and have had a few issues, which thanks to great people on this forum I have been able to fix or understand why it was doing what it was.

However, as of tonight I'm fearful I may have popped my engine. I had a chance to have a little fun with my coworkers 2016 5.0 mustang. Yes, I knew I was going to be beat... and horribly.. but I wanted to have my first street race of the season. We had agreed on a 2nd gear roll. I down shifted to 2nd and gave it half throttle and it face planted hard. Checked gauges and realized I had no oil pressure. Shut it off and coasted to a stop and got out. Yup, oil pouring out from the drivers side of the car. Got it towed home and now here it sits and here I sit wondering if I just leaked all my oil out and yes I mean all.. or if some how dropping it into 2nd at 2.5k rpm some how caused serious damage. Now my luck isn't great, so ya know why I'm leaning towards breaking something that had less than 300 miles on the engine. This weekend I shall know if it was an oops or an aww f*&@...
 
Well I woke up to a text from my husband. Guess he had to look at it last night when he got home at 3am. And yes, oil filter spun off. So that is great news compared to what it could have been.

Husband tried to fix it this morning but it's still leaking oil. So now the question is, why did it spin off? And why won't it go back on w/o leaking. That shall be looked at tomorrow since we both have off. Now I'm just hoping that my filter housing isn't stripped out because I'm sure that is no fun to try to replace while the engine is in the car.
 
Ofh wouldn't be too bad to do. But idk if that's it. Oil filters spin off from vibration or improper/not enough tightening usually. You'll still want to check things out thoroughly, identify where the leak is actually coming from. It's possible there is some damage from low oil levels, but until you get things looked at and test it all, it will be hard to tell.

Bummer to hear, but GL, hope its nothing major.
 
Well from the time the car face planted to when I shut it off wad less than a minute. So I'm feeling optimistic about no damage. It wasn't until my husband mentioned blown motor that it hit that "OMG, could I have?"

Husband tighten filter and replaced oil but he says it was still leaking. So, that's the plan now. Find leak and fix it.
 
Car is absolutely fine. No damage! And we found the leak, silly hose clamp wasn't tight enough. Turns out we also blew the seal off the oil filter... so I did learn the hard way that Fram filters suck. Will never use a Fram again!
 
Well my drive home tonight was a nightmare. Had an issue with my afr sticking at 8.7 for awhile but the car ran fine and after a shut off it reset to 14.9. Then I encounter I being stuck at 20.9 and had the oh so fun issue of it getting a random misfire and running like ass while trying to get on the hwy. Cruised at 70 as best as I could and had to take a back road home because of constant misfire running like cap issue. Oh and the most fun of the evening was while on the hwy while I pushed in the clutch to get rid of the random misfire, I had total power loss! As in car shut off, rpm was at zero and no power steering... gotta love doing 70 and having a power cut although it was a very easy restart... just let out the clutch....

Found a minor boost leak and fixed that and just changed out my wastegate actuator because the old one wasn't working well. Really hoping my car just got a "6 bolt in a 2g" bug up its ass and this won't turn into a constant issue that requires time to fix it :-(
 
Well we finally had friend look at my car and instantly he knew what was wrong. Crank timing was off! So we timed it again and the car is a brand new car. The idle is better, boost is now at 3k rpm,hauls some serious hinney now! Well that is until last night :-( while driving the car decided it was going to hate me. Random misfire every 30 second's and almost got me ass ended getting up to speed. Thinking I have a boost leak somewhere and the hubs will get that fixed today. Definitely need to purchase dsmlink sooner than later because my car is too fun to not be a daily driver and a dd shouldn't have misfire issues this severe.
 
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