Handyman Dan's TSI Project

[Handyman Dan]

I am restoring a 1987 rio red tsi, I have owned this car for 11 years, it has been in storage for the past 10 years, I am now bringing it back to life. Here is a picture of the car.


982 985

983 984

I am building a custom MPFI intake for the engine and will be using a Megasquirt ECM to control the engine. Every drive train component will be upgraded with 1988 parts. I will be making post of my progress.

[Handyman Dan]

I removed the gas tank. The gas in it was bad so I drained it and pressure washed it then I put in a cup of small ball bearings and shook the tank for a good long while then got all of them out and pressured washed it again. Then I treated it with a rust treatment. I feel that it is in good usable condition now. I then painted and put it all back together using a good fuel pump which will be a primer pump.

241http://thestarquestclub.com/forums/images/misc/pencil.png242

I also cleaned the under body above the gas tank and every else around that area and then undercoated the area.

[Handyman Dan]

I removed the 1987 components and will be installing the bigger and beefier 1988 axles and rear end.
I cleaned all the underbody around this area including the rear wheel wells and then undercoated the areas cleaned. I will be installing a Mookeeh MK1 Master Polyurethane Suspension Bushing kit. I install new rear brake rotors. I also rebuilt both CV axles and installed new silicone bellows on them. I also installed a new ST rear sway bar. I also installed new bearings and seals in the hubs. I have also installed new seals in the rearend for the axels. Here are some pictures.

243 245

246 247

248 249

[Handyman Dan]

I will be keeping the A/C system intact. I have replaced the two rubber lines and installed a new receiver dryer and also a new expansion valve. I have replaced all the o-rings with new ones.

986 987

[Handyman Dan]

The engine has a new njv head, new crankshaft, new wiesco pistons, new Schneider cam and valve springs, ARP head studs and rod bolts, oil pump, balance shaft elimination kit, along with everything else that would go along with a complete rebuild.

988 989 990 991 992 993


http://thestarquestclub.com/forums/images/misc/pencil.png

[Handyman Dan]

I have rebuilt all the cailpiers, installed braided stainless steel brake lines and remover the ABS system. I have also rebuilt the master clyinder and installed new rotors and brake pads.

1504 1505 1506

http://thestarquestclub.com/forums/images/misc/pencil.png

[Handyman Dan]

I have been working on the intake and fuel railfor some time and it is now finished. The pictures will tell the story.

48094808480748064805480448034802
48014821
http://thestarquestclub.com/forums/images/misc/pencil.png

[Handyman Dan]

Here is the finished intake.

481948184817481648154814
http://thestarquestclub.com/forums/images/misc/pencil.png

[Handyman Dan]

Here is one of the polished rims

4820

[Handyman Dan]

Here is my coil on plug setup that I made for the car.

48244823
4822
http://thestarquestclub.com

[Handyman Dan]

I rebuilt the wiper motor and cleaned the wipre linkage and transmissions so they work freely like new now.

48264825
http://thestarquestclub.com

[Handyman Dan]

This is the CAS sensor that I made for the engine.

4828
4827
http://thestarquestclub.com

[Handyman Dan]

Here is the oil cooler that I will be using.
4829
http://thestarquestclub.com

[Handyman Dan]

This is a Griffin custom made radiator for the car. It has two 1.5 inch flues which makes it 3 inches thick.
4830
http://thestarquestclub.com

[Handyman Dan]

I have got my Garrett turbo back from Mike turbo today. I feel good!
Here are some pictures of it along with the orignal turbo.
Here is some spec.

compressor wheel Dia.
exducer is 76 mm
inducer is 57.7 mm
trim is 52
A/R is .50

turbine wheel Dia.
exducer is 64.3
inducer is 73.3
trim is 68
A/R is .63

this turbo will be good for 320 to 525 HP
this is simlar to a Garrett GT3776 turbo

4831 4832 4833 4834 4835

[Handyman Dan]

Here is my CRYO2 intercooler the measurements of the core is 24" wide x 10" tall x 3.5" thick with 3" inlet and outlet. It dose also have a spray bar mounted on it. Is weighs 18 LBs.
This intercooler is good for 800 HP

4836 4837

[Handyman Dan]

The pictures will tell all.

4838 4839
http://thestarquestclub.com/forums/images/misc/pencil.png

[Handyman Dan]

I installed new u-joints in the drive shaft.

4840

http://thestarquestclub.com

[Handyman Dan]

I have the Walbo fuel pump and filter mounted to a plate just behind the rearend, and also mounted the fuel pressure regulator.

4841 4842 4843

http://thestarquestclub.com

[Handyman Dan]

I have checked the coupling in the tube on the rearend housing. It looks good, no wear. I cleaned and relubed it.
4844 4845
http://thestarquestclub.com

[Handyman Dan]

Here is some pictures of the new fuel injectors and the new clutch master and slave clyinders and a few new fuseable links.
4849 4848

4847 4846
http://thestarquestclub.com

[Handyman Dan]

Here is the new Eibach springs, struts, bellows and bumpers that will going on the car.
4850 4852
4851 4853
http://thestarquestclub.com

[Handyman Dan]

Here are some pictures of the new intake on the engine.
Also a picture of the throttle body.

4854 4855

4856 4857
4858
http://thestarquestclub.com/forums/images/misc/pencil.png

[Handyman Dan]

Here are the ST swaybar that I will be using under the car.
4859

[Handyman Dan]

Here are some pictures of odd parts.

4860 4861 4862

4863 4864

[Handyman Dan]

We can not go without a starter and Findaza flywheel. Here they are.

4865 4866

4867
http://thestarquestclub.com

[Handyman Dan]

I have built a Mega-Squirt-II V.3.0 for the car. I am using Extra code Rel 3.0..3s
I used 4 of the Bosch BIP373 ignition modules for the Coil On Plug setup sequential ignition system .
I have used a jbperf peak and hold board for the sequential fuel injection system.
I have a AEM UEGO controller for the wide band EGO.
I am using GM CLT, IAT, TPS, IAC stepper, Knock,
Hall effect cam sensor,
36-1 crank wheel with a ford VR pickup
Map Daddy 4 Bar MAP Sensor with Barometric Correction
I have the electronic boost control solenoid but haven't decided to use it yet.

4868 4871 4869 4870
http://thestarquestclub.com/forums/images/misc/pencil.png

[Handyman Dan]

I bought a new Toshiba laptop to use with the car to program the MicroSquirt.
Also can be used to monitor all of the engine controls.
I am thinking of how I could build it into the dash of the car somehow. Dose anyone have any ideas how to do this? Let me know your ideas.

4872

[Handyman Dan]

I have been told that it is a bad idea to use copper tubing for fuel line on an automobile, it may crack or split from vibration. Well I do not want to take any chances with the copper so I have ordered some fuel Injection Hose today to replace the copper tubing. Here is what I ordered.
Goodyear's Fuel Injection Hose is designed to perform with new unleaded fuels as well as with Ethanol and Methanol blends. Its Hypalon®. cover is oil and gasoline resistant and withstands exposure to grease, ozone and coolants. Plus, a Fluorel®. line resists deterioration from oxidized gas which forms in fuel injection systems. Meets or exceeds SAE specifications J30R9 and GM 6163." Fluorel is the same material as Viton. Working pressure is 135 psi and burst pressure is 900 psi. Not approved for submersion in fuel. Not approved for propane or natural gas.
http://thestarquestclub.com

[Handyman Dan]

Wow what a dirty job, polishing rims. The 4 rims are almost done. I had new tires installed on the rims over the weekend in hopes of getting the car off the jack stands soon.

4987 4988
http://thestarquestclub.com/forums/images/misc/pencil.png

[Handyman Dan]

I installed new rear speakers in the car

[Handyman Dan]

I was able to prep and paint the bumpers and the side rear view mirrors and the three rear spoiler pieces today. The plastic parts were faded so I decided to paint them so that they would match the original paint on the rest of the car. The rear spoiler parts (3) were a pain to remove but I got them all off so that I could paint them.

4989 4990 4991 5007

[Handyman Dan]

I noticed a transmission leak today. the speedometer drive was seeping fluid so I pulled it and cleaned it up and installed new o-rings in it and resealed it. I installed it back in the transmission. I am getting close to getting the car off the jack stands and didn't want this little leak bothering me.

[Handyman Dan]

Here is some pictures of the car back together again. It gets to see direct daylight again.

4992 4994 4993 4997 4996 4995

[Handyman Dan]

Here is some pictures of the trunck area.

4998 4999 5003 5000 5004 5001 5005

[Handyman Dan]

Here is some pictures of the back seat area.

5008 5009 5010

[Handyman Dan]

I have ordered a stepper boost gage, fuel pressure gage, and MK1 STARION FRONT ADJUSTABLE PILLOW BALL CAMBER PLATES over the weekend.
I have the car running and don't want to drive it any untill I get the camber plates installed and have the car aligned so that I don't wear the new tires.
I am still working on the tune for the engine and I am at a point where I need to drive the car to get it tuned right.

[Handyman Dan]

I had the car alinged and here are some pictures of the bottom side I took while the TSI was on the rack.

5258 5266 5265 52675259 5262
5264 5263 5261
5260

[Handyman Dan]

I had the TSI on a Dyno for some tunning. We made 9 runs with it. The car is still running rich above 4500 RPM. The only thing I worked with was the fuel ve table. I didnt work with any AFR table or the igintion table. I blew off a charge hose at 22 PSI boost and had a exhaust leak at the wastegate valve so I called it a day. The testing was looking good up to that point.
If anyone has any good ignition and AFR tables that I could use as a good starting point please send them to daniel@thestarquestclub.com

http://www.thestarquestclub.com/images/P6123682.JPG

[Handyman Dan]

I have the touch screen monitor mounted. My control station is starting to come together.
This touch screen is a monitor for the MegaSquirt ECM and Tuner Studio, It will also work for a touch screen for any GPS software installed on the laptop.
I can say that I really like the touch screen it is nice and usuable.
I think it will be a fun addition to the car. You can change the programing of the ECM, monitor all the engine functions on it, you can also use it as a GPS unit and if you wanted to you could use it to play mp3 on it with windows media player. WOW I just thought of this you can use it to watch DVD also.

http://www.thestarquestclub.com/images/P7253742.JPG

http://www.thestarquestclub.com/images/P7253741.JPG

http://www.thestarquestclub.com/images/P7253743.JPG

http://www.thestarquestclub.com/images/P7253744.JPG

http://www.thestarquestclub.com/images/P7253745.JPG

http://www.thestarquestclub.com/images/P7253746.JPG

http://www.thestarquestclub.com/images/P7253747.JPG

http://www.thestarquestclub.com/images/P7253748.JPG

http://www.thestarquestclub.com/images/P7253749.JPG

http://www.thestarquestclub.com/images/P7253750.JPG

[Handyman Dan]

When I had the car on the dyno idling and while on the street at red lights I noticed that when idling for a few minutes the engine was getting warmer than I liked. So today I removed the two 10 inch electric fans I had on the radiator and installed four 7 inch 1550 CFM electric fans on the radiator. The car now will idle all day and will not get hot.

[Handyman Dan]

I charged the A/C today and it is cooling good. I had to feed power to the compressor clutch to engage it. I will look into why the compressor is not engaging when I have more time.

[Handyman Dan]

I have installed a adjustable cam gear and degreed the cam. Now that is done I can now adjust the cam to fine tune it to what works performs the best.

[Handyman Dan]

I have installed a new 100 Amp alternator to keep the voltage going to everything smoothly. I have pictures here. The Alt. with the green in the middle is the 100 Amp. that I have installed.

5421 5422 5423

[adoornbosc]

Wow I really liked looking at all you posted. Made me kinda jelous. I have a white 1988 Conquest that I would love to bring back to life. It has been sitting for the past 8 or 9 years. I don't want to get rid of it. I know the money I put into it I won't get back out of it. I don't want to take it to the junk yard. Everything you did to yours needs to be done to mine. I have had this car since around 1993.

I am moving to Orlando FL this Nov. I'm going to have my Conquest shipped for 650.00 to my sister’s house in Orlando. My dad likes giving me a hard time over keeping this car. I'm going to through on some cheap tires up front for the trip down there.

Can I ask you, how much would you say you spent on bringing yours back to life.

[Handyman Dan]

Wow I really liked looking at all you posted. Made me kinda jelous. I have a white 1988 Conquest that I would love to bring back to life. It has been sitting for the past 8 or 9 years. I don't want to get rid of it. I know the money I put into it I won't get back out of it. I don't want to take it to the junk yard. Everything you did to yours needs to be done to mine. I have had this car since around 1993.

I am moving to Orlando FL this Nov. I'm going to have my Conquest shipped for 650.00 to my sister’s house in Orlando. My dad likes giving me a hard time over keeping this car. I'm going to through on some cheap tires up front for the trip down there.

Can I ask you, how much would you say you spent on bringing yours back to life.




Well to date I have about $7000+ invested in the car in parts. I have many hours of my time and sweat invested also. I will be glad when this project is done so that I can start enjoying it.
Good luck with your car and let me know if you need anything or any help.

[Handyman Dan]

It is a 8" desktop in car TFT-LCD Touch screen Monitor that I found on ebay for $130. I bought 2 of them so I would have a spare. They also had 7" monitors. It has a VGA plug that hooks to your computer monitor output, then it has a usb plug that you plug into your computer. It also has video and audio inputs, and it has a built in speaker. It has a cig. plug for the power. The software that comes with it is for the touch screen operation. The monitor looks to be of good quality. It has a digital Toshiba CMOS chip. I am really pleased with it.

[1988esi]

beautiful car i wat to do this to mine trying to do a little at a time were did you get your alt

[Handyman Dan]

beautiful car i wat to do this to mine trying to do a little at a time were did you get your alt
I got the alternator off ebay, it is a 100 amp and looks to be good quality. I paid $105 for it. here is a link to the sellers item. Mitsubishi Starion Conquest 100 Amp Alternator 87 88 89: eBay Motors (item 120621818802 end time Sep-26-10 19:03:20 PDT) (http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=120621818802)
Hope this helps you.
http://thestarquestclub.com/forums/mp3/Rollinstones-paintedblack.mp3

[Handyman Dan]

I got some time to work on the car today and have it running pretty good. I hope to get it out tomorow and do some road tunning on it.

[Handyman Dan]

Here is a update on my project. I have gotten the car running pretty good now. I found out that when I had the car on the dyno that the EDIS was running in the limp home mode. I had the ign timing advance set at 6 deg advance and had no timing advance. I have resolved that problem and the car is running well. I have been working on my VE, AFR and the IGN tables. I am still working on the tables but I am getting close now. The car is starting well and driving good and pulling really well, it has allot of power and really fast. I will go back to the dyno when I think that I have the tune really close to fine tune it.

[Handyman Dan]

The last time I drove the car was a few weeks back and while driving it I heard a loud bang. I was able to drive the car home and parked it until I have time to check everything out. Well today member Skarp came to my house and we went for a test drive and I had no boost. I put two and two together and knew what the loud bang was. I had blew off a charge hose from the output side of the intercooler. we installed the hose and was ready to go for a ride. I had been working on the tuning of my Megasquirt and tried to burn the last good tables to the megasquirt and the notebook and Tunerstudio acted strange and the car ran badly. So it was not much of a show and tell. We ended on our feet walking home. I have check the software and it looks that something went wrong with the software. I should be running Firmware MSExtra Serial303v but the MS is reporting Firmware MSExtra Seria. WOW it looks like I invented a new Firmware version. :becky: It looks like I have a corrupted MS so I will need to re-flash the MS and start over again. When I get through I will be an expert at all of this MS stuff. Ha Ha

[Handyman Dan]

Here is a write up on my CAS. :flypig: First off I do not remember what the CAS came off of. I took a shaft from a stock dist. and cut the shaft below the bushing/bearing at the top of the dist. Then I cut the Dist. housing from a stock dist. as close the bottom of the housing close to where the points would be and above the o ring on the housing. Keeping the bottom two pieces to use for the new CAS for the 2.6 engine. I then cut the top of the housing from the CAS similar to what I did with the stock dist. and cut the CAS shaft like I did with the stock dist. This time I kept the upper two parts to use with the 2.6 CAS. I did some carful measuring of the shaft and housings and then welded the shaft together keeping everything straight and machined everything to make a new CAS shaft. I then welded the upper CAS housing to the lower 2.6 dist. housing keeping everything straight and in place. All that I needed to do now was to install the new modded shaft in to the new moded housing and reinstall the stock gear. Violia a CAS for our 2.6 engines. The CAS has a 4 window and a two window optical sensor. Two sensors in one CAS. What I did was to bend up the small tab on the two window to make a 4-1 sensor that works with the MS to be able to do sequential injection and COP functions. It works great. Priceless. :happy:
6162 6163 6164
6165 61676168
6166 6161
I hope that this will help someone

[Handyman Dan]

I have opened my orignal site back up. If anyone would like to visite it here is the link. Home Page CONQUEST TSI, STARION (http://kf4eok.com)

[1988esi]

the cas setup is interesting have you installed it yet. what are you tuning the car with

[Handyman Dan]

I am running the CAS and I am using a megasquirt ECM I built for the engine control. This makes a nice setup for running sequential injection and COP.

6243 6244 6245

[Handyman Dan]

I had a meltdown of two coils. I have decided to go with a CNP (coil near plug) setup.

6242 6241 6240
6239

[Handyman Dan]

I have got the engine running on sequential injection and COP working. I have attached my .msq file for review from someone.
http://www.msextra.com/forums/styles/prosilver/imageset/icon_topic_attach.gif CurrentTune.msq (http://www.msextra.com/forums/download/file.php?id=16653)

I have the tooth #1 Angle(BTDC) set at 637.0 With the timming set to fixed this gives me a 10 Deg. BTDC with a timming light. I this correct? The engine seems to run ok, it idles much better now, reves ok, I haven't test drove the car with this setup as of yet. I did notice that I donot have the trigger wizard option with these settings. is this normal?
i also noticed that I have lost the option to set the injector PWM current limit settings. is this normal? Where or how do I set the PWM settings? I have low-z injectors and a jdperf Peak&Hold Injector Driver Board. I have decided to use a CNP (coil near plug) setup instead of the COP setup. The reason for this is that the coils #3 and #4 are to close to the turbo and exhaust system and I had a meltdown while getting the engine running. http://thestarquestclub.com/images/PB283965.JPG http://thestarquestclub.com/images/PB283965.JPG I have ordered some 2N4033 transistors and LS2 Yukon truck coils and harness to set up the CNP setup.
Thanks for any responses and help on checking out my progress.

[Handyman Dan]

I have decided to go with a coil near plug setup. It is like the setup on the new Corvettes, and Yukon’s. I will be using the LS2 truck coils with the heat sink on them part number D585. I have ordered the parts that I need to modify my MegaSquirt and the new coils and wiring harness for the coils and new plug wires. I am thinking of mounting the coils on the valve cover, if it will clear the hood, or maybe closer to the intake. I will see once I get all the parts and figure how to fabricate the coil mounting bracket. The LS2 truck coil is a really hot and good coil with a built in igniter. I will post pictures as I progress.

[Handyman Dan]

I am still working on the setup but I have got the coils mounted and I have modified the Megasquirt to drive the LS2 coils. I still need to finish the wiring harness and get it running.
Here are some pictures.
6290 6289
6291 6288

[skarp]

Very interesting Dan, thinking outside of the box.

Looking forward of seeing the car in person and going for ride.

:photo:

[Handyman Dan]

Here is a list of some of the new parts I have used in building this car :

Engine:
MegaSquirt II Running Sequential Injection and CNP Setup with Wideband EGO and Boost Controll
New Crankshaft
New Wiesco Forged Pistons
New Oil Pump
New Adjustable Cam Gear
New Timing Kit
Recondition Rods
Garrett Turbo Rebuilt / Customized at Mikes Turbo MikeTurboInc The Home of World Fastest Turbos l 1-866-748-8726 (http://www.miketurboinc.com/index.html)
compressor wheel Dia.
exducer is 76 mm
inducer is 57.7 mm
trim is 52
A/R is .50
turbine wheel Dia.
exducer is 64.3
inducer is 73.3
trim is 68
A/R is .63
CRYO2 Intercooler. 24” Wide X 10” Tall X 3.5” Thick. With 3” inlet and outlets. With spray bar and Steel Braided line
Tube Exhaust Manifold SS
MK1 VR SENSOR BRACKET KIT
MOOKEEH MK1 CRANK PULLEY WITH EDIS TRIGGER WHEEL
ST Performance Fuel Pressure Regulator
ST Performance Fuel Filter
4 New Cooling Fans
A Large Oil Cooler with SS Braided Lines with AN Fittings
New 100 AMP Alternator
LS2 Yukon / Corvette Coils (4 of them)
Griffin custom made Radiator. It has two 1.5 inch flues which makes it 3 inches thick.
Custom made Multiport Intake Manifold with a 75 mm Throttle Body from a 32 valve Northstar engine, Powder Coated
Four Delphi FJ10455 75lb Injectors with new connectors
Custom made Cam Angle Sensor (CAS)
ARP Head Studs
ARP Rod Bolts
New Fuel Filter
Schneider 280F-14 U-FW Solid Follower Camshaft with new springs to match
New NON JET Valve Cylinder Head From Engine Machine Service (Dads)
New External 38mm Wastegate
New Blow Off Valve
2.5 Inch Exhaust - No Converters
Custom Hardpipes
Balance Shaft Eliminator
Powder Coated Valve Cover
New A/C receiver dryer and also a new expansion valve. I have replaced all the o-rings with new ones.
New Walbro 255 LPH fuel pump
New Silicone Heater Hoses

Drivetrain/Suspension:
5 Speed Manual Transmission
6 Bolt Axels and LSD
New CV- Joints Boots
New Wheel Bearings and Seals on ALL 4 Wheels
New Front and Rear Struts
New Bellows and Bumpers
All New Eibach Progressive Springs
Suspension Technqiues Front and Rear Sway Bar
New Polyurethane Sway Bar Bushings
New Polyurethane Endlink Bushings
Master Polyurethane Bushing Kit
MK1 STARION FRONT AND REAR ADJUSTABLE PILLOW BALL CAMBER PLATES
New Findaza Flywheel and puck Clutch and pilot bearing and release bearing
New Clutch Master Cylinder
New Clutch Slave Cylinder
New Brake Master Cylinder
Rebuilt all 4 Wheel Calipers
Slotted Front and Rear Rotors
Steel Braided Brake Lines
ABS Delete
New U-Joints
New Goodyear's Fuel Injection line from the gas tank to the engine

Interior:
Factory Radio
New rear Speakers
New stepper boost gage
New fuel pressure gage
New Innovative EGO Wideband Gauge and Sensor
Stock Radio
Trunk Mounted Battery
Rebuilt Wiper Motor and linkage and transmission


Exterior:
Polished Wheels
All New Tires
89 One Piece Airdam
Gas tank completely reconditioned and painted.

[Handyman Dan]

:yo: I worked on the A/C and have gotten it working like new and it blows clod air. I also have the vacume pump working now.

[Handyman Dan]

I rented a Dyno for 6 hours and here is the results.
http://thestarquestclub.com/images/mycar/TSI_Dyno.jpg

[skarp]

Nice numbers there, should have let me know I would have enjoyed going as well.

Now make my car do that! ha

sk

[Handyman Dan]

Here is some pictures of the insids of the car.

6522 6521 6520

6519 6518 6517

6516 6515 6514

6513 6512 6511

6510 6509 6508
http://thestarquestclub.com/forums/images/misc/pencil.png