95 TSi Build

Posted by wickedz, Jan 18, 2012
DSM Build Journals - Start a Journal to document your DSM build and document race events, dyno days, etc for the car.

  1. wickedz

    wickedz Proven Member

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    Madison, Wisconsin
    Just having issues running, so i drove her down to the garage and tore it apart. I know stupid right? Just glad I did with so much fail with everything

    Ok heres more information:
    I moved from Orlando Florida to Michigan. My car had been running fantastic and never really left me on the side of the road. Well moving to MI has destroyed my car. My tune just was not working well with the change. Well I made a good friend here who I met off dsmtuners to be honest. he did the best he could with a tune, but eveytime we tryed to richen it up, the car would pull more and more fuel. The minute you took even 1% fuel away from its running condition, the car would cut ALL fuel out completely. Well i drove the car with it running lean because this is my only transportation. Well on cold start ups i would have to sit there with my foot on the gas for about 2 minutes then it would idle. Well everyday the car would become worse and worse on running conditions.

    I'm running a COP setup that is home made. Well my oil cap looked to be leaking a little bit of oil, so it was running down into my valve cover Well the oil was running across the COP under side and getting into all the wiring. I thought this was causing the car to misfire, but yet i wasn't pulling any codes or CEL. I was having issues with the wideband UEGO, reading maxed out AFRs and my car was running like crap to where I had no throttle or anything. I would have to run the car like this until the AFR's started to richen up. Once the car began to richen up, it would throw you in the seat and clear up and run fantastic.

    Well with the bogging issue, the massive tuning issues, and everything else, I was getting frustrated. I was throwing $40 in gas in this thing every 3 days it seems and went no where. Well I desided to throw on another tune I had previously from florida where I was running well. Well that didn't seem to work too well. My car started smoking worse, you could see the RICH smoke marks in the snow, and smoking under my hood. Well the fricken head was pouring oil out of the head to where i had a broken exhaust manifold stud.

    I drove the car down to the barn to check further, thats when we made no progress on the issue, and said to tare it down. Well the head bolts were all tight, except the one in the corner of the head, where the oil was pouring out. This could have been ALL my issues, but we still said pull it apart. Needless to say, everything in this motor was RTV and no gaskets, and just fail on every end. Im not even joking when I said fail.

    The car I bought and had a trans shop install my transmission and install a new clutch kit. Well they only installed the trans with the front 2 bolts, which left the trans literally barely on. With the trans installed like this, it cause my starter plate to brake in half, you see the broken EAR on the trans from stress, the clutch was slipping bad and its new, and even the ear on my new slave was broken.


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    Head 6 bolt

    *New Viton valve Seals
    *Stock intake valves with 4 angle cut.
    *Evo sodium filled exhaust valves with 4 angle cut.
    *NGK brp6es Spark Plugs
    *cleaned up springs
    *cleaned up Cams
    *Black Top CAS
    *Cleaned up 1g intake

    Block 7 bolt
    *Permatorque Headgasket
    *New RIngs
    *New 2g Pistons
    *Cleaned up Rods
    *Balance Shaft delete
    *Polished Crank .005 endplay
    *New ACL Aluaglide bearings
    *All new OEM seals on oil pump

    Audio
    *(2) 12 inch Memphis 1000w Subs
    *(1) 1000w Memphis amp
    *Sony headunit
    *Stock front speakers
    *Pioneer 6x9's

    Other Stuff
    *Battary Trunk Relocate
    *Fuse box relocate
    *Engine Bay painted
    *ABS Deleted
    *AC Deleted
    *Power Steering deleted
    *Emissions Deleted
    *Coil On Plug (Chrysler 300 Coils)
    *Evo 560cc Injectors
    *V3 Full ECMlink
    *Greddy Style FMIC
    *HKS SSQV Bov
    *Injen intake with cone filter
    *Triple gauge Pod
    *Boost/oil pressure/AEM UEGO gauges
    *14b turbo upgrade from stock 2g
    *Oil SS line
    *4 Bar Omni Map
    *ECMlink Speed Density
    *Rear motor mount Red Poly mount
    *eBay Manual Boost Controller

    Exterior
    *Blitz body kit molded
    *Custom Red paint with metallic flake
    *Talon 2gb Front
    *Falken 17x7.5 Rims
    *215 45 17 tires Z rated
    *Smoked out Talon lights
    *2.5 inch full exhaust 4 in tip
     
    Last edited by a moderator: Jul 10, 2014
    #1
  2. mattasi

    mattasi Proven Member

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    Springfield, Oregon
    Yea, less wires is a nice look, my battery is in the location that you put the fuse box. But I didn't want to move the battery to the back. Good job man looks nice.
    I noticed you didn't take off parts from the firewall, the fenders or windshield cowl to paint the engine bay. Just trying to paint it quick?
     
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  3. wickedz

    wickedz Proven Member

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    Madison, Wisconsin
    Thanks man, it will be cleaner when I get trans in, then We can actually start the cleanup process

    Everything was removed from firewall to paint, and wiper crowl was taped off.
     
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  4. michael102691

    michael102691 Proven Member

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    Jefferson City, Missouri
    Looks clean, I like how you have your cop setup on there.
     
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  5. hazmat6135

    hazmat6135 Proven Member

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    canton, Ohio
    the most undescriptive and short build thread ever! your leaving alot out Paul! :p
     
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  6. wickedz

    wickedz Proven Member

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    I know man I hear ya, I was in a hurry. Updating to the top now
     
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  7. dented_coffee

    dented_coffee Proven Member

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    West Branch, Michigan
    All the bearings were getting ready to fail pretty much.
    2 of the rod bearings tangs where starting to go flat, thrust bearing was out of spec and nearing CW probably.
    2 cam journals were only riding on half the bearing surface (no clue what was going on there).
    It was pushing crap tons of oil on #4 cyl (enough to make a mess all over everything arround the exhaust leak he had).
    1 head bolt was near backed out.
    Turbo journal bearing was coaked up and frozen on the turbines shaft.
    Manny seals were bad, and someone told him to cut the rear seals sealing spring because it was near wrapped arround the crank.
    The flywheel was so badly slipping it was a perfect mirror reflection.
    One trans Dowel pin was missing. One trans mounting ear is busted off.
    Oil pickup tube was near plugged from a dented in oil pan.

    That's the most of it really. Iv been helping as much as I can and throwing spare parts, time, tools and new seals in to get this finished because of a tight budget. She's fitted with my old ARP's now, new aluaglide acl bearings, new oem seals, my custom home made felpro gaskets, permatorque Headgasket, my old but basically brand new 6-bolt head I bought from mitsubishi, my home made BSE kit (modded oil pump support shaft nub), new 2g turbo pistons and rings, polished crank, soon the be CAS converted, abs delete, mild wire tuck, and batt relocation.

    This project will be finished the next time I go to his garage and finish some wiring, and trans install, and finish up a few loose ends. It would of been finished already if it were warm out LOL. To cold when it reaches -1*F outside and the fuel oil runs out in the heater.
     
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  8. wickedz

    wickedz Proven Member

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    Madison, Wisconsin
    More pictures during rebuild

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  9. wickedz

    wickedz Proven Member

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    Madison, Wisconsin
    Just a UPDATE

    Not much more has been done really. I got pretty much everything installed under the hood and all my piping and front mount. I'm still waiting for my friend to show up, because we need to do a few things before installing the tranny. Such a clean car, then I install my UPIC and its ugly long route. I can't wait for a job, so I can redo all my piping and FMIC
     
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  10. wickedz

    wickedz Proven Member

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    Madison, Wisconsin
    Update.

    Well I must say im so ####ing frustrated right now. Now my FMIC piping isnt fitting, and I have a few oher issues with doing the 7 bolt head swap to a 6 bolt head. Now I must walk away and take a deep breath

    Ah #### it, here is how she sits for the night. Im done for the day
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    Got the Fuel hooked up, the throttle is hooked up, some plugs are done now, got the rest of my piping installed, few other odds and ends are done for now.

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    And got some nice injector clips that wont break.
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  11. wickedz

    wickedz Proven Member

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    Madison, Wisconsin
    Update,

    Well today, she got her bumper on her. Also Im trying to figure out the wiring on the COP, so that will be done. Slowly getting there
     
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  12. sypherzero

    sypherzero Proven Member

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    Marion, North_Carolina
    Awesome progress! Its looking really good, can't wait until mine gets to that stage.
     
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  13. wickedz

    wickedz Proven Member

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    Madison, Wisconsin
    Thanks buddy, yeah I started all this just after christmas. So yeah between my friends and I, we have completely done to this in a months time, what others accomplish in a years time or more of project down time.
     
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  14. wickedz

    wickedz Proven Member

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    Madison, Wisconsin
    Some more updates

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  15. wickedz

    wickedz Proven Member

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    Madison, Wisconsin
    car is running fantastic. will try to get video after few new parts arrive
     
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  16. 95TSIBoostin

    95TSIBoostin Probationary Member

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    Santa Barbara, California
    great re-build!!! im about to start mine in april. got a 95 tsi awd! love it! i was going to give my opinion why it was running so bad, thought it may have been the power transistor or coil pack. any way awesome build! any advise you can give??
     
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  17. 2slow4utsi

    2slow4utsi Proven Member

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    Eastpointe, Michigan
    Nice man. Where at in Michigan?
     
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  18. wickedz

    wickedz Proven Member

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    Doing alot of major upgrade changes :). Here is some today just clean up detial work

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    To THIS
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  19. sypherzero

    sypherzero Proven Member

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    Marion, North_Carolina
    Still looking great man, the COP setup looks sweet! On the picture of the rear of the talon with the high rise spoiler, on the left side of the hatch there is a decal that says BUILT [ ]. Where did you get that?
     
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  20. wickedz

    wickedz Proven Member

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    Madison, Wisconsin
    It says built 4g63 :). I got it from a friend of our car group in Orlando
     
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  21. wickedz

    wickedz Proven Member

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    Madison, Wisconsin
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  22. wickedz

    wickedz Proven Member

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    Here is some more update on the talon

    Sitting in her spot, getting all done up with new upgades
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    New Manifold came in today
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    Will install it this weekend. I'm expecting my 4 layer copper gasket Saturday, and my new studs and nuts came today also.

    That is all for now. Waiting for more parts to arrive like always :)


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  23. wickedz

    wickedz Proven Member

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    Madison, Wisconsin
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  24. zcoh2gdsm

    zcoh2gdsm Proven Member

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    i was waiting for you to put up a pic of some shiny new IM. build looks great, sub'd.
     
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  25. wickedz

    wickedz Proven Member

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    Madison, Wisconsin
    That's how I roll. I'm rice with some go go ;-)
     
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