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  1. dwb

    1G Engine bay wiring repair questions

    I was going to buy a couple rolls of SXL 18 AWG wire but I decided to see what wire scraps we had at work. I work for an OEM aircraft manufacture. I happened to walk in the wire shop right after the Laselec machine messed up a whole batch of 18 AWG. So I snagged that bundle of unshielded...
  2. dwb

    1G Machinist questions

    I'll be taking my head/block/crank to the shop tomorrow. HiPro Engines weren't taking any additional jobs for another month so I looked around and found another fairly local shop to Denver that seem to specialize in Japanese and American platforms. They specifically list the 4g63 DSM/EVO on...
  3. dwb

    Thieves

    If it were a more valuable bike, yes I believe it would. I want to say the deductible is $500 and the bike is only $700. Fortunately we're not talking about a pair of $6k bikes like @danl lost.
  4. dwb

    Thieves

    Oof. That's horrible. I couldn't imagine how scary that would be.My son is now using a 90's (maybe even 80's) beater. He needs an XL size, and this one is either XS or S. Queue the Benny Hill theme song. There are bike racks on the bus but he splits between public bus, light rail, and a school...
  5. dwb

    Thieves

    You mean pot? Pfffft...not really any different than before legalization except it's much safer and regulated now and the money isn't being funneled back to the crooks. Some people are phobs about it and that will never change. I do agree that hardcore drugs are a problem that heavily...
  6. dwb

    Thieves

    I just need to vent for a moment. TL;DR at the bottom. This has nothing to do with cars, but rather mountain bikes. For the record, I live in a fairly low crime area.My son has an excellent opportunity to attend a technical school to fulfil his last two years of high school and graduate with...
  7. dwb

    2G Strange boost issues

    Did you boost leak test your wastegate actuator? Also have you tried new spark plugs and wires?
  8. dwb

    1G replacing oil pump straight gears with helical

    My undercarriage is completely rust free! ROFL BTW, I like your old Dodge. I've got a '77 D150, but I kind of like the older body style like yours.
  9. dwb

    2G How to Remove Unorthodox Racing 1-Piece Water Pump Pulley?

    I wouldn't worry about it, it all has to be realigned anyway when you put the new belt on.
  10. dwb

    2G How to Remove Unorthodox Racing 1-Piece Water Pump Pulley?

    I'd be worried about denting or crushing the oil pan. I'm also guessing you still have all the driveline parts attached, which adds additional weight to the engine if you take that right mount off.Why not just take all the timing components off - tensioner/arm, pullies, belt etc. and then see...
  11. dwb

    1G replacing oil pump straight gears with helical

    Never had any oil pressure issues and I know this pump had at least 200k on it. Probably was more likely the factory pump, so 270k. I will not be reusing it. Not worth the risk.Makes sense that RTV would not be ideal inside the pump. I get it. Hence why I'm having this discussion now and not...
  12. dwb

    1G replacing oil pump straight gears with helical

    The amount of oil was negligible, but grimy like it had been leaking slightly. I wouldn't expect a metal-on-metal mating surface to be oil tight. Usually those spots call for RTV.
  13. dwb

    2G How to Remove Unorthodox Racing 1-Piece Water Pump Pulley?

    Since you're doing timing belt, I assume you will be doing the water pump too. Will the water pump + pulley come off/out together?
  14. dwb

    1G replacing oil pump straight gears with helical

    Castle nut was fine and not leaking. I did find a bit of old RTV in the sprocket and on the drive gear shaft when I disassembled it, possibly from the factory because I didn't do that last time I had it apart for BS delete. It really confused me when I started looking at that seal, because it...
  15. dwb

    1G replacing oil pump straight gears with helical

    I was inspecting my front case last night and realized it's the piece that takes most the wear, so replacing only the gears doesn't accomplish much. Those gears are so hard I can't see how an aluminum case is going to cause much, if any, wear on them. Maybe only a small bit of wear on the teeth...
  16. dwb

    1G replacing oil pump straight gears with helical

    I should have done this before posting. Here's a little data to back up the front case vs. oil pump gear changes. Definitely the '90 and early '91 case/gears were different than later 6 bolts. Although the front case changed between 6 and 7 bolt, the helical gears did not.Front Case:Large...
  17. dwb

    1G replacing oil pump straight gears with helical

    I can't say I've even noticed the whine. Actually, now that I think about it, that probably wasn't my alternator.That's what I'm working with, but an early 91. I feel bad I'm going to have to machine it.So it seems I either need to source straight gears or buy a full front case if I want to...
  18. dwb

    1G replacing oil pump straight gears with helical

    I thought it would be prudent to replace the oil pump after 270k. Nothing is "wrong" with my old setup, though. I read maybe there was a design change on the front case between the early and later 6 bolts.However I do want to check clearances to see if the old straight gears are still in spec...
  19. dwb

    1G replacing oil pump straight gears with helical

    I have an early 6bolt with original straight cut oil pump gears. Since those gears are discontinued, can I swap directly to the helical gears or do I have to replace the front case along with the gears?
  20. dwb

    How many "Old-Timer" DSM Guys on here?

    I haven't been here long, but in the DSM game for longer than this site has been around. I bought my '91 TSi in '99 when I was 20. Daily driven for 23 years. Now all it's guts are strewn across the garage for it's first engine rebuild ever. I miss the days of parts being readily available, in...
  21. dwb

    1G 6 bolt piston options

    Thinking, yes, but not without due diligence. If we're talking budget solution for a ~stock setup, what would be today's choice for piston/rod combo? Something like this? https://www.ebay.com/itm/161974975522?hash=item25b675fc22:g:SaoAAOxyni9TCZ4h
  22. dwb

    1G 6 bolt piston options

    This is great information. Thank you everyone for your valuable input. I seem to have some possible mis-information about 2g pistons, so I'm going to be digging into that some more. Furthermore, I will be getting the block/crank to a machine shop so I know what I'm working with and what parts I...
  23. dwb

    1G 6 bolt piston options

    Sure I have, but I'll be the first one to tell you I have no idea what I'm doing ROFL:DJust for fun, here's what 270k miles looks like (yes, #2 has a broken ring)
  24. dwb

    1G 6 bolt piston options

    Good to know! I guess I didn't look hard enough. ROFLRight? I'm on the fence about this one. It's getting a rebuild anyway...
  25. dwb

    1G 6 bolt piston options

    Nope, timing belt broke:
  26. dwb

    1G 6 bolt piston options

    I'm looking for some replacement piston options for my 6 bolt 4g63 turbo engine. Not looking for forged (unless the price is right) or anything with higher compression. Basically I'm going with a stock-ish rebuild. My current stock pistons have valve marks on them and I've considered fixing them...
  27. dwb

    1G Machinist questions

    Yep, was running before and I'm reusing as much as I safely can. I have no reason to believe anything is out of whack. Thanks!Now more questions: Do I buy the main/rod bearings and pistons/rings before or after machining? Also looking for information on head, main, and rod bolts or studs. Are...
  28. dwb

    1G Machinist questions

    Would this be something I can do myself or is this a task for the machinist?
  29. dwb

    1G Machinist questions

    I am a bit concerned about the crankshaft dead end throws after reading up on it. Seems that debris sometimes comes loose during break-in. I don't think I have a chance of pulling the balls so I'm going to do my best with a solvent. Is brake cleaner the preferred solvent here? I sprayed some...
  30. dwb

    1G Machinist questions

    All good stuff. Thank you.You are correct, I do have a head with bent valves. Not going to try to salvage those. This is a different head with higher mileage I'm working with.On that note, are there any parts that should not be swapped from one head to another, assuming identical heads? Mr...
  31. dwb

    1G Machinist questions

    Maybe I should be posting this in the noob forum because I'm definitely a noob when it comes to engine rebuild. But hopefully there will be some good info here anyway. Maybe this stuff has already been discussed but it's hard to search this site.I'm prepping my 6bolt turbo head, block, and...
  32. dwb

    Compliments

    ditto here. I've had several people leave notes wanting to buy it. Even with clearcoat cancer I still get people oogling over it. My 14y son's friend couldn't get enough of it and just had to see under the hood. It's all stock and he couldn't stop drooling. Of course my kids don't give a rats...
  33. dwb

    Resolved FWD transmission on AWD setup

    All normally aspirated (non-turbo) DSMs are FWD.
  34. dwb

    Resolved FWD transmission on AWD setup

    :idontknow: That would just be a FWD DSM, maybe with a rear diff that isn't hooked up to the driveline. I'm pretty sure there's plenty of info about that FWD trans out there with a little google-fu. The engine is no different FWD vs AWD as long as you're talking 4g63t, but the engine is...
  35. dwb

    1G Valve contact - are these pistons salvageable?

    Gotch, no worries at all. @biglady112 already recommended HiPro, so that's my plan for now.
  36. dwb

    1G Valve contact - are these pistons salvageable?

    Is there a way to tell how much has already been milled? I'm pretty sure the one I plan to use has never been milled, but not so sure about the other one.Speaking about machinists, Steve, since you're in Boulder do you know of anyone you can trust? I'm just down the turnpike from you. I'm...
  37. dwb

    1G Valve contact - are these pistons salvageable?

    Good point! I'm really just looking at my options for now. There's probably a lot more things I need than I realize.
  38. dwb

    1G Valve contact - are these pistons salvageable?

    Maybe 3k rpm with no load. I'll be going through the bottom end anyway, 270k and it was using a lot of oil.
  39. dwb

    1G Valve contact - are these pistons salvageable?

    Probably not. I'm putting a different head on.
  40. dwb

    1G Valve contact - are these pistons salvageable?

    Timing belt broke and I finally got the head off. All the pistons look about the same with valve marks. Are these pistons salvageable?
  41. dwb

    1G Yoke recall question

    Here's a pic of a yoke that leaked, if that helps: https://www.dsmtuners.com/threads/transfer-case-choices.515507/post-153816980I was also able to fill the splined side with oil (I used ATF because it's red/easy to see) and let it sit upright overnight. Could see it leaking the next morning.
  42. dwb

    1G Engine bay wiring repair questions

    Thanks danl. This is exactly the type of info I'm looking for. Economical is one thing but doing it right is another. I'm more a fan of the later at this stage in life, as long as I'm not getting bent over financially.I've already purchased some of those Sheridan connectors and realized I'm...
  43. dwb

    1991 TSi AWD

    Currently working a full engine rebuild. Timing belt broke so no better time to refresh the whole thing. 270k miles on the virgin bottom end, so it is definitely due. I'll try to keep things updated here!
  44. dwb

    1G Engine bay wiring repair questions

    I'm redoing several electrical connectors in the engine bay on my 1g, like the injectors, knock sensor, coolant temp sensor, oil pressure sending unit, etc. I have to replace a few inches of the wire due to cracking insulation and sometimes broken copper. In the past I just used whatever wire I...
  45. dwb

    1991 TSi AWD

    This is the Build Thread for 1991 TSi AWD. Reply below.
  46. 1991 TSi AWD

    1991 TSi AWD

  47. dwb

    The Funny Truth

    My DSM was my daily since '99. Until recently the Gates timing belt decided valves weren't important.Of course with a DSM as my daily I need at least three other vehicles for spares - 06 Toyota Highlander (wife's / family), 97 Toyota Corolla (current daily and great on gas mileage but sucks...
  48. dwb

    1G So much I don’t know where to start with this 1G NT

    Do you know why the previous owner replaced the TPS, MAF, and ECU? Did he/she leave you with the originals? I have to question if the replacement ECU and/or MAF were known good. Might be worth a look at the ECU for leaking capacitors and correct part number for your application. Does your wiring...
  49. dwb

    1G So much I don’t know where to start with this 1G NT

    Sorry, didn't realize until now this is NA. Probably still a good idea to replace those vacuum lines though.Pull the throttle body, then you can have good access to both sides of the BISS and won't have to worry about that crud pushing through. Gives you a chance to clean/inspect it too while...
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