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Bought in Iraq, ready to upgrade when I'm back! My 91 Talon TSI Build Log

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Scuba_Steve

10+ Year Contributor
152
1
May 28, 2009
Colorado Spring, Colorado
Hi everyone,
My name is Steve, and I am glad to be a new member to this board. I don't have a huge amount of automotive experience, and I have never touched a DSM vehicle, so I admit I have quite a lot to learn. Luckily, thanks to message boards such as this one, so much information is easily accessible. I have been reading for weeks now!

I am in the Army stationed at Ft. Hood, TX, although I am currently in Iraq. Some of my other hobbies include family time, video games, guns, scuba diving, and my 120 gallon coral reef aquarium.

So what got me interested in DSM. As of a few weeks ago, I hadn't even heard the term before. I had decided that when I got home from Iraq this deployment, I wanted to have a sports car/project car waiting on me. I had been looking for that perfect buy for the perfect price for a while. My wife told me they were having an auction on post for cars that had been put into storage, but not claimed for years. So I had her get me a list of everything sporty with a manual transmission. The only thing that really stood out were 4 eagle talons. I had remembered an old friend raving about his former AWD talon that he drag raced (street). So after doing some research I found that the TSI AWD was definitely the way for me to go. Only one of those talons met that bill. A 1991 with quite possibly the worst paint job known to man. IMO, I perfect little sleeper to get my hands dirty with. Being an auction, I figured I could get it for a steal! I was shocked when she told me that one of the 100 or so car dealers buying everything in sight paid over $1200 for it. Now this is a car with an unknown history, horrible tires, no radio, and bone stock. Thank god, probably not the best car anyways; now at least, I had my sights set. Back to the searching process...

Only a few weeks later, I had finally found something on Craigslist. It was the exact same car, only better in nearly every way imaginable. Again, thank god I didn't buy the first one! A few days, and $1400 later, that car was sitting in my driveway, waiting for my return!

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So on to the car... After all, the intention of this thread is to be my build log, not only my introduction. As I stated, the car is a 1991 Eagle Talon TSI AWD. Now I haven't actually seen many of these features, so I'm going by the description given to me and the observations of my wife who has limited experience with cars. From what I can tell, the car is very far down the upgrade path, near stage 2. First of all, I was told that most of the emissions were bypassed. In Texas, we have vehicle inspections, but it is just visual and a brake test. Next, Autometer boost and AFR gauges in a pillar dual pod. So as far as I know, only wbo2 and maybe egt are needed. The next part leads me to my first very newbieish question.

1. The car has a Megan Racing 3" cat back exhaust. Nothing is said about the cat itself. How is this normally installed onto a stock 2.5" cat?

Regardless I definitely have the intention of replacing the rest of the exhaust with 3" pipe. I was told he was informed by the state inspectors there is a suspected hole in the stock downpipe. They can tell this by the sound it is making, therefore it is not passing inspection.

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Logging and A/F comes next. The car has what appears to be an S-AFC. The only actual text on the face is Apex-i, and for a bit, I thought it was a V-AFC. I was looking at pictures of an S-AFC II (I was told it was second gen), and it didn't look right, then I saw the V-AFC and freaked out a little. :p I'm going to have my wife check the sensor settings to find out for sure. Included was some type of palm pda, although I still haven't gotten specifics on that. I assume that it is fully setup for monitoring.

2. It was advertised as having a "socketable ECU". Someone please fill me in on exactly what that should mean, although I have a pretty good idea.

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Next, I was told the engine was professionally rebuilt about 1000 miles ago, a $1200 job. I am having one problem with that statement now that I can see it better.

3. Shouldn't a few of these parts be cleaner than they are on a newly rebuilt engine?

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I plan on finding a 2g manifold to replace the nasty looking one pictured. The turbo is hard to see in the pictures, but I am told it is a MHI EVO 16G turbo. My wife said she could not find any markings on it to properly identify it.

4. What should I have her look for specifically to help identify it correctly?

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Lastly, the car has Eibach drop springs. I have read this can actually be a bad thing, but hopefully with proper adjustments I can make it good. The seller did inform me of a few problems that would have to be taken care of soon. Front ball joints, tie rod ends, struts, and the right outer half shaft boot.

5. Does the car only have 2 of each of these things, and is there any reason I should also replace the left half shaft boot as well?

So onto my plans for the car immediately after I return. I want the car to be running in the best shape it can be, and me not have any questions on when things were last done.

I. Change fluids
a. Oil
b. Tranny
c. Transfer case
d. Diff
e. Antifreeze
II. Replace belts
a. Timing
b. Balance shaft
c. Others if needed
III. Replace filters
a. Air
b. Fuel
c. Oil
IV. Replace ignition parts
a. Spark plugs
V. Replace steering parts
a. Front tie rod ends
VI. Replace suspension parts
a. Front struts
b. Front ball joints
VII. Replace drivetrain parts
a. Front half shaft boot
VIII. Replace exhaust parts
a. Exhaust manifold
b. Wideband O2 sensor
c. Downpipe
d. Catalytic converter
IX. Replace intake parts
a. Intake pipe

6. Can anyone think of anything I missed, or any parts I missed that is needed for the changes above (that normally wouldn't be included with the part)?

Now this is all done on a very tight budget. I am estimating well under $1000 for all of the above work to be done myself. I realize this seems low, but I am pretty confident I can do it. Now I know there are still other upgrade that the car will need, but I have to start with what I can afford. With all that being said, I am going to wrap this up for now. I look forward to all of your responses!

P.S. As you can see, I have included all my questions in blue and numbered them for easy reference to the answers. I have a feeling Blue will be seen a lot, both in questions and... other things...
 

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my 90 isnt like that. its on top where i can look at it and get to it easier to squash it.
 
Hey Steve. Good to have you onboard, especially as you have the word "Scuba" in your username (am a dive instructor myself). You also need to get yourself stationed in Okinawa - decent car scene here and plenty of good JDM parts.
 
Hey Steve I'm at Fort Hood and I have a tester pipe instead of the cat, they don't know the diffrence at sprockets. As long as your lights horn and brakes work the old man there will pass you LOL. Hope this helps.
 
Thanks for the advice donswan! Unfortunately I have a dilemma. The inspection is expired, and has no post decals yet. I can't get plates/decals without an inspection, and I live off post. So I have no way to get it into sprockets. I didn't even know they did inspections though, so maybe I can find a way to get it on.

Are there any more dsmers at Hood as far as you know?
 
They will let you tow onto post without up to date tags, but if you go that route make sure you get a flat bed or a full length car trailer. When I needed to get my 240 inspected I took it to a shop on bussiness 190 and the guy just gave me the sticker. I can't remember the name of it of the top of my head but I do recall it being within a block or two of Pioneer loans office. I won't be back till September but if you need anything feel free to get in touch. Get home safe!
 
steve that relay box you took a pic of is your turbo waste gate control solenoid. this helped me out as far as figuring our what all the vac lines go to so I could find make sure I didnt have any boost leaks.
Taboo Speed Shop
 
Great site ZSpeed7, I have seen the first pic before. It is out of the Haynes manual. I would have never remembered though had I not seen them again.

Thanks for the advice jholmes, glad to see another local. I have all I need already to get it to pass though, so I will just have it assembled and be done with it.
 
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