95' TSi rebuild

[Ernie D]

I'm wanting to share my progress on my build up, I recently purchased my TSi about 2 months ago for $500 from a buddy of mine.

When I got the car I checked it out, it had no oil pressure and a low end knock, I pulled the whole sub-frame out and noticed quite a few bolts and a few bushings missing, so I figured perfect time to fix shit right.

The car already had a few upgrades done to it such as, a wally 255, yellow top 510cc injectors, a EVO II Big 16G, FMIC, a 6-bolt conversion, ARP head studs, fridanza flywheel with a ACT clutch, ECU chipped, Apexi SAFC and a AFX wideband

I pulled the engine apart and found my issue for no oil pressure, the balance shaft bearings had spun. ( please excuse the pics, my phone did a upgrade and I lost a few pics and others did this )

I started rebuilding my engine back up, I've done a BSE, added ARP rod studs and Mahle pistons with the stock 6-bolt rods, I'm using cometic gaskets, I built up a 2g head to use instead of the 1g head

My plans so far still is:

Trying to find a EVO III intake to use or use a 2g intake and porting it out to use a 1g throttle body

I have a set of racetronix 930cc fuel injectors to use instead of the yellow tops

I'm currently upgrading to fuel system more with AN-6 fittings and stainless line
also rewiring the pump

I plan on setting up DSMlink with speed density

The A/C was stripped out under the hood but I'm wanting to reinstall it, it gets hot here, gotta have a little creature comfort

I'm thinking about upgrading the clutch a little more with a stronger pressure plate and 6 puck disk

Any comments or suggestions are welcome

10/11/2012

Hey guys, I haven't forgot to post anything on here, just been working ALOT lately, (2 unit outtages where I work) I've gotten a few more things done.

I've got a set of HKS 272's from a buddy of mine that decided to sell his project, been cleaning and painting parts before installing on the engine

Still on the lookout for a EVO III intake, a 97-99 GSX complete A/C bracket

Thinking about sending my header,turbine housing, and O2 Housing to Darren at FFWD Connection to get Stage III CGB-1000 coatings done to them, any advice on that?

Gathering fittings and other parts to upgrade fuel system ( AFPR, and AN-6 fittings and fuel filter )

I will post some pics soon, later

10/20/12
A little update, progress is slowly going along, got a few things bolted up on my block, I found I now have a issue with my turbo, I didn't check it as close before than I have now, I have to rebuild it, it has a little too much play in it than what I think it should.

Also I was gonna use the header that I have BUT, also checked it out a little more, its a little warped on the flange to the head. I'm debating to buy a new header or between buying a EVO III manifold from RRE or buy a FP manifold, anybody to advise on this?

Here's a few pics of progress

 

[Ernie D]

Hey guys, its been a while since I posted any progress, here lately, progress has been going SLOOOOWWW, just been working alot and trying to build cash back up for car and for christmas, car has been put on the back burner a little bit because of that.

Here's a few pics of progress I did manage to get done, I redone my header exhaust flange because it was warped and didn't fit the head right, so I cut the old one off and tigged a new one on there, then cut the surface back flat, wrapped it back up with header wrap then coated it.

Then I decided to rebuild my turbo, because I didn't want to take a chance of installing a hurt turbo back on my car. For which I'm glad I did because the thrust bearing was broke in half when I tore it down, I got a legit MHI master kit from a local source

Slowly chipping away at the list of stuff to do

 

[Ernie D]

It's been a long time since I've posted anything on my project here, but thanks to many side jobs and ALOT of over time, things are fixing to get switched into hi gear , just placed my orders in and with in the week if all goes well, I'll have all my parts in to get me to the point of getting it tuned

Well, the last few days, new parts have been trickling in, fixin to start kicking things into high gear , I just rebuilt my throttle body, put all new seals, biss screw, and used mil-spec throttle shaft seals

I fabbed up my own spark plug wire cover out of thin gauge brass plate

Also just got my new replacment friction plate for my fidanza flywheel, along with these

Just got another box of goodies in today

Got a new lower cover but still had to trim it to fit my 6-bolt block, hated to have to cut on a new cover but it just would not fit around the water pump and the 90' OFH relief valve

Got the rest of my parts to build up my fuel system, I'm running AN-6 from the pump to the engine and back to tank
this is the FPR I decided to run

Its ready to go back in the car, installed the TB coolant lines, new turbo coolant hose, all silicone hoses, installed my wideband in my O2 housing, AN-6 adapters to my fuel rail, just all the little tie-in jobs that add up

Brought the subframe around and degreased it, fixed the rear tranny mount ( was only held in with 2 half screwed down bolts ) chased tap in the threads, installed the correct amount of bolts, installed a newly aquired speedo sensor to replace my broken one

Just put my car back on the lift to get all my stuff done on it before I put the sub back in, whats left on the list: run AN-6 fuel line, reroute wideband harness, flush out A/C condenser and evap core, mount FPR on firewall, fix all the halfass wiring that was done,degrease and steam clean the engine bay, rewire my fuel pump, and the list goes on...., but I can start seeing the light at the end of the tunnel

 

[Ernie D]

Well, its been slow and steady progress, the big slow up has been the huge amount of electrical gremlins I've been chasing, whoever installed the SAFC originally did a half ass hack job ( skinned ecm wires with a pocket knife as twisted the wires around it wrapped up in electric tape) on it plus the fuse block under the hood was hacked up in one way or another :shock: , but I got 95% of my wiring done,I did my pump rewire, I'm needing a adapter harness for my greddy turbo timer. I also installed my megan short throw shifter and I machined a one off shift knob out of 316SS Stainless ( about 8 hrs of work ) but I believe it came out decent

I relocated my wideband to the top of my column

I didn't manage to get a before pic but this is my ecm harness after I got done

Needs to get back together

Spring time has not done the paint job any good, pollen over everything

To my surprise when I was getting ready to install new shifter, the airbag ecu was just sitting on the stud mountings with no bolts holding it down, needless to say with the way my luck woulda been, I might have had a surprise while driving :shock:

While I was installing new shifter

New shifter in place

Newly machined shift knob to top things off

 

[Ernie D]

I made quite a bit of progress the last few days managed to get engine in the car today
just snapped a few pics of the progress

My way of getting the sub back in the car ( whatever works )

Lifted in to the Car

A days worth of work paying off

 

[Ernie D]

It's been a while since I posted anything, I figured I'd share some progress
It's back on all 4 tires

Still chippin away at it, got all my electrical back straight, finished cleaning and flushing out the A/C so its ready to charge when its time. I ordered all new intercooler piping because the old transitioned from 2.25 to 3 inch in several places before it reached the IC or the throttle body, I ordered a 2.5 inch pipe kit.

Got this in , just waiting on my piping to get here

I fabbed up a mounting to install my turbo timer

 

[Ernie D]

I started prepping to install my intercooler by first replacing my power steering cooling hoop with a small oil cooler
First, removed some sheet metal next to condenser to reroute the hoses

Started getting my IC into place,(excuse the dent in the bottom of my IC, that was a spare I had, took it down from my shelf and it slipped from my hands :x )

Got all my IC piping ran

 

[Ernie D]

Here's a little bit more of a update
Got the hood back on and bumper fitted
( before)

Decided to clean it up a little, while waiting on parts to come in
After

Got tired of looking at black rims, and rebuilt the brake calipers because the car has been sitting up for a total of two and a half years

 

[952g63t]

Nice color choice on the rims. Sucks about the intercooler dent, I flip **** when I ding parts

 

[Ernie D]

Nice color choice on the rims. Sucks about the intercooler dent, I flip **** when I ding parts

Thanks I appreciate it, in the pics it looks worse than it actually is, it just bent the outside bar, the tubing is unhurt, I could straighten it if I was really worried about it

 

[Jesse2012]

Nice work, what are your suspension plans? It's in severe need of a drop

 

[Ernie D]

Nice work, what are your suspension plans? It's in severe need of a drop

I'm planning on gettin some tien coilovers to install on it, I'm plannin on setting it up for autocross but I havent decided if Im staying with the factory 16" wheels or bumpin it up to 17"