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.






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.



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.

[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.

[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.

[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.

[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.

[Handyman Dan]

Here is the finished intake.

[Handyman Dan]

Here is one of the polished rims

[Handyman Dan]

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



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