90 TSi Heart Transplant

[Usatuff]

Lets start with in the very beginning. What made me even get another vehicle was my truck. Since 14 I have had a Toyota Pickup and love it. The V6 motor is notorious for blowing head gaskets due to the poorly designed factory exhaust. So I finally saved enough money to have the motor bored, deck, hot tank and the same for the heads and plenum. So I have been borrowing my parents car, I am only 19. Well I finally got tired of a van, saved up enough money and bought my first DSM So with this newly found money burning a hole in my pocket pretty fast I set my sights on a 1ga Talon TSi. Not only because the are semi-rare, pretty damn sexy looking and a decently fast car but they are also good in snow, which I need here in NY. So I bought a 1990 Talon TSi. It is 5 speed, all wheel drive freshly rebuilt transmission and head, approximately 500 miles (have receipts) and basically stock. Since owning the car it has received a full 3" turbo back exhaust, with High flow cat and a Magnaflow muffler. Also it got a 3" GM MAF, MAFT, Wally 255 pump, SS fuel lines, Earls fuel filter, Boost, Volts, Temp, Oil psi gauge, ACT 2600 clutch, SS clutch line, EVO 8 Injectors, Super AFC old school 5 knob and probably a few other things but I cannot remember. Well here is what I started with:

Ran into a few problems.....

Few weeks ago I picked up some new wheels.. From a 69 GTX

Then tragedy struck.. As I left my house to go to school, Orange County Community College, my hood flew up and smashed my windshield.

 

[Usatuff]

So after waiting a few weeks I decided to get a new windshield. Called Safelite, they wanted $300 without trim install and tax. So I jumped on Craigslist and found a new shell. For $300 I got a 1990 Talon TSi. It too is all wheel drive and 5 speed. This car came with a full wiring harness, not too much cutting, an undented, unrusted body/frame, Blitz turbo timer, new radio, new tires, half way decent looking wheels, new glass and I am going back to buy his FMIC for another $100 (SCORE!)

First modification Hurst shifter!

So today I started to rip it apart. The battery was dead so it had to be jumped It also snowed the other night so I had to clean everything off. I got tired of wiping everything off so I unbolted the hood and took off down the road It felt so good being inside that car again. So here are some more pics:

There is so much room for fun activities

First thing to go under is the exhaust, since it's one big piece and the driveshaft

Well this has been the end of day one. Both cars are in the garage, the motor, transmission, transfercase, driveshaft, exhaust and any other little pieces I may need have been removed to get the car drivable. Tomorrow I have work at 3 so I plan on working in the morning and afternoon for a little. First thing I am going to put the motor, tranny and most of the other pieces on my trailer and bring it down to the car wash with some Power Purple! I want everything to be nice a clean before I put it away. Also I need to pick up some 8 awg wire to redo some ground wires (intake to firewall, tranny to frame and a few others and i need to get a battery box since the battery is in the trunk now. Future upgrades include but are not limited to:
BC 272/272 cams
Fidanza Adjustable cam gears
ECU socketed with DSMLink
FMIC
Some kind of turbo upgrade??? I have been going back and forth between Holset, 16g and a 20g and can't make up my mind Anyone suggestion or if I;m doing something wrong, help would be appreciated! Thanks everyone more pics will be up soon. Also before i removed the motor I took a quick video. It is making a weird almost grinding noise? YouTube - VIDEO0002

 

[BWeston]

I personally think Holsets are garbage, they are diesel turbos and they just aren't that good in my opinion. i would go with an Evo 3 16g, you would need some fuel mods to use the 20g to its full potential

 

[BWeston]

You should also go with the genuine hks 272/272s, they are better than Brian Crower cams, plus you wont have to install the adjustable cam gears, but with the 272's you are gonna need new springs/retainers, so you should spend your extra money on those instead. you'll want new springs/retainers with the 272/272s so you can rev them out a little higher, evo springs/retainers are stronger than oem dsm springs/retainers, i would go with them since they are cheaper. those are probably safe to 7500 which is plenty enough

 

[TGST90]

I don't know too much about Holset, but a EVO 16g will give u good enough power, that's what im going to get.

 

[Usatuff]

Can anyone tell me the benefits of have my SS fuel line? I wanted to put it in my new shell but this one still has the factory hard fuel line, filter and hose to mount it to the fuel rail. I have SS line from the pump to an Earl's fuel filter to SS line to the rail. Any benefits from SS and also which filter is better, stock or the Earl's? Thanks!

Took awhile to find a car wash that would actually let us wash a motor.. Here are some new pics

Still needs to be cleaned....

Some left over junk

 

[Usatuff]

Well the motor is in now it is just tie to button it up. The last owner stripped the bolt holes on the transmission mount so I will be tapping them tomorrow. Also started making a coil mount plate. I'm gonna bolt it to the 3 bolt holes on the side of my intake manifold. The coil pack bracket it came with does not fit anywhere!!!!

Trying to figure out what plugs go to what and what is actually needed

Needed to weld the piece that holds the hood latch on

 

[Usatuff]

Some more pictures of stuff

What is this 1 prong sensor for? It is located on the backside of the T housing

 

[Dsm4lyfe12]

is that the coolant line that goes to the throttle body? or is it the large coolant line that goes to a hose you might have disconnected to the frame?

 

[Usatuff]

is that the coolant line that goes to the throttle body? or is it the large coolant line that goes to a hose you might have disconnected to the frame?

If you are talking about the last picture it goes to the throttle body. I'm trying to figure out what that 1 prong sensor or whatever it is goes to?

 

[2GEEZEY]

Im wondering the same thing, i broke mine

 

[Usatuff]

I never even noticed it before??? Anyone have a pic of there's and what it goes to?

 

[Usatuff]

Update from today. Car has been started. Need to finish greasing and installing front axles and tighten the 4 bolts on the rear for the driveshaft. Then bumper cover and done!=)

Here is the 14mmx2.0 Tap I snapped

JEGS!

 

[Usatuff]

Well here's how it sits as of tonight. 1 axle needs to be installed, bumper cover and lugs tightened I went to take a video of the first start up. Ended up being a complete failure but I'll still post the video haha. I ended up having a dead battery and needed to let it charge. Video of start up and idle tomorrow!

[url=http://www.youtube.com/watch?v=LX4WUE0jTAU]YouTube - VIDEO0003[/URL]

 

[Usatuff]

Well here it is today. New fender is on now though. Bumper and throttle cable tomorrow then interior!

 

[95weclipse]

well bud that one prong sensor is your coolant temp sensor ## doing all of this work and dont know what that simple sensor is?

and you broke that tap either because it was too tight and you forced it or you bottomed it out and forced it but the build is looking great rock on keep it up keep pushing check my blog out and my buddys blog we are rebuilding his 93 right now

 

[Usatuff]

Well the thing is I never once saw that sensor before... it was like hidden in the back right up against the head And the tap is just retarded! I broke a 16mmx2 tap yesterday. The first tap we put in the hole started to turn it and it caught then snapped... almost no pressure applied. The 16mm x 2, which is pretty big, I got all the way down the hole oiling every 1/4 turn then started to back it out and it snapped. Funny thing was that after it snapped I could justback it out by hand with little to no effort

 

[95weclipse]

yeah its sneaky,, cheap taps?
you know there is a chart that has all the drill sizes for the tap
you look at the tap size then look next to it and it tells you what size bit to use with that tap try checking that out

this build is lookin sick man keep it up

i updated mine check it out

 

[Usatuff]

Yea it was a 35/64 bit drilled it and still snapped but I managed to get it tapped. I got it started and its outside now. I'll try and get a video of it running and revving maybe a ride along will red check out your build when I get home. I'm at work nos so I'm kinda limited to what I can do

 

[95weclipse]

yeah well i just pulled my trans out and found that the tranny mount on the pass side that bolts to the trans was loose and was loose for a long long time because it wollerd out the hole really bad kinda like urs i am guessing so what i am gonna do is have some aluminum welded in there put the braket on where it needs to go and redrill and tap it and all of the trans mounts where broke except the front roll stop but both rear and side where broken sweet stuff

 

[Usatuff]

What happened with me was the last owner stripped it because it is aluminium. Both holes were stripped and retapped. I can't weld aluminium so I tapped it :/

 

[Usatuff]

New update! car started and I took it down the street Now its time for the interior

Newish fender

Crash bar!

 

[TGST90]

Looks great man! good job

 

[Usatuff]

Thanks but I'm still not done yet! Got a few minor things to do outside the car, have a idle surge and the interior

 

[Usatuff]

Finishing the o2 wiring! Lunchables FTW!!!!

A few goodies

Ignore the AFR gauge, will be replaced with Uego.

2 on the pillar

I was HAND tightening this, BY HAND