Street Build 92 Tsi AWD

[onefast2gdsm]

Sorry for the long read, I should have started this log awhile ago

I bought this 92 Talon along with a 92 Laser for 1k back in November. The Talon was pretty much complete but the Laser is just a shell, no engine trans or tcase.

My intentions with the Talon is to make it a decently quick daily driver for me and my girlfriend. When I bought it, it had no turbo, ecu, fuel pump and sending unit, and missing a sunroof glass. I did some tuning for a buddy of mine and received a blackbox ecu, tactrix cable and 20g turbo. I sourced the plugs to make a jumper harness from another friend of mine, and began making the harness.

In between working on the harness I was also working on other things with the car. I received a sending unit from the same guy who gave me the plugs for the harness, installed it with my DW300 fuel pump I had left over from my 2g partout, and found out the feed line was leaking on the sending unit. I also found out the 20g I had gotten was also trash, and needed rebuilt, as it had too much shaft play. I bought and installed another sending unit, installed my holset hx35 with bep housing I also had left over from my part out, and finished and installed the ecu harness along with the ecu. I found out the return line on the gas tank was leaking, and patched it with JB Water Weld. Not the greatest fix, but it will hold me over until i find a nice rust free tank.

When I first put the ecu in, I made the mistake of thinking I can tune the blackbox like Dsmlink and not use a maf at all. I wired in my 3 bar GM map sensor and the GM iat sensor, flashed ceddy mods with big maps and sd, scaled my 1600cc injectors and tried to start it. Cranked but didn't want to start at all. I found out my harness wasn't making connection sometimes due to the way i wired it, and I also feared i wired something wrong, so I towed it up to my garage (I was working on it at my house in the cold the whole time) and decided to hardwire the 2g ecu plugs to the car. After hardwiring, the car would crank and start up then immediately die. I chased the issue down for about a week and it turned out to be the egr that I thought was blocked off, in fact wasn't. I know some people just make a block off gasket and leave the egr in place so I thought nothing of it until I couldn't think of anything else.

At this point in time, I blocked the egr off with a proper blockoff plate, and the car finally idling by itself, but ran very rich. I let it alone for about a week as I was relentlessly researching scaling and latencies and tuning guides for the blackbox. I came to the conclusion the car needed to be maf tuned first in order to get the injector settings right and the ve table built. I wired the maf, flashed the basic ceddy mods to the ecu and tried starting it. Cranked but didn't fire. Plugged in my gm iat and unplugged the maf, flashed back my previous tune, same thing. I couldn't understand why the car ran fine the day before on the same tune but wouldnt start today after wiring in the maf.

Fearing again that I wired something wrong, I called my buddy to come to my garage the other night so I have a second set of eyes to point out anything I missed. I switched to my friends dsmlink ecu and scaled the injectors and switched back to the maf, seeing if it would start on it being its the last thing I wired before the car wouldn't run. Sure enough it fired right up with dsmlink. It ran like crap and threw a code for injector 2 malfunction. We found out number 2 and 4 injector clips were broken inside where the pin ends. It bent one pin on both injectors. I had 2 injector clips laying around and soldered them in, fired the car up and ran perfect, just a little rich. 15 minutes of messing with Dsmlink I had the car idling perfect.

Last night I went up to work on it, switched back to the blackbox ecu and flashed back the maf tune, and also lowered the dead time on the injectors a bit. Fired up first try. It ran for a bit, it was a little rich so I lowered the dead times again. This time it was damn near perfect. I couldn't take any logs because of evoscan acting up, so being i had nothing to go off of to further tune it I installed my catch can and slim fan. The next time I go up to the garage i hope to get some logs and finish tuning it and finish my side exit exhaust.

I know the car looks rough but its a work in progress. I also am relocating the battery, so that's why the battery is sitting like that in the pics, I don't have a tray for it.

 

[onefast2gdsm]

Current mod list:

7 bolt block/3 bolt rear
Holset hx35 w/ bep housing
DKS 272 cams
Ported evo3 exhaust manifold
Act 2600
1g Dejon intake pipe (temporary because of maf)
Punishment fmic
Side exit exhaust
Catch can
3 bar map
Gm iat
Turbosmart 40mm wastegate
Poly motor mounts
1600cc injectors
Dw300 fuel pump
Fuelab afpr
Coilovers

 

[onefast2gdsm]

It stalls at the end of the video but I changed the deadtimes after this and it stays running now. This was the other night, still havent been up to see if I can get evoscan to log.

 

[onefast2gdsm]

Yesterday i finished my side exit exhaust. I will take more pics but here it is with the bumper on

 

[@Talon_Gram]

looking good, love seeing 1g builds.

 

[onefast2gdsm]

Thank you. Lots of work still needs to be done but taking it one step at a time.

 

[onefast2gdsm]

Update: I was at the garage working on it last night and I'm getting nowhere with the tune. It is still idling rich then leaning out and stalling.

 

[onefast2gdsm]

3/4/16-3/21/16

I installed PTE1200cc injectors to rule out injectors being the problem. They are behaving a lot better than the 1600s.
I realized my front o2 sensor voltage was over 1 volt (2.2 volts) when in closed loop. The car would run perfect in open loop and when i switched it to closed loop it would die. I then realized when I got my lc1 wideband that i reprogrammed both outputs to be 5 volts.

I reprogrammed the lc1 to the factory settings, and now the car runs in closed loop like it should. I was having issues with my upper intercooler pipe where the iat bung was welded, it had a boost leak and had it rewelded 3 times and it leaked everytime, so I bought a punishment fmic kit from the person I bought the Talon and laser from. Im using the piping from the kit on the Talon and using the core on the laser when I start to build it. I also changed all 16 valve stem seals and the valve cover gasket due to oil seeping out of the runners on the turbo manifold. I also put my pcv valve back in and replaced all coupler clamps with t bolt clamps. I need to do throttle body shaft seals yet.

Now I have the car idling perfect. When I rev it in neutral it has a slight misfire. When i go to drive and release the clutch it misfires really bad until it goes over 2000 rpm then it clears up and drives fine. I have replaced the coil pack, spark plugs, power transistor and inspected the spark plug wires. It has gotten a lot better but still not 100%.

Today I am installing a Tial 38mm wastegate and my buddy sent me spark plug wires to try they should be here this weekend.

 

[onefast2gdsm]

Short video of it idling and a pic of the new wastegate! Im able to drive it kind of. Misfires but clears up after a few seconds.

 

[onefast2gdsm]

Update: Got the Talon registered and insured. I have been driving it for a couple days now. I believe I have a faulty front right wheel bearing. Also, the more I drive the car the better it runs, the misifre is still there but not nearly as bad as it was. I still need to do some tuning but it looks like things are finally looking up.