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The Missouri Project

tsi_tom\\\\s restoration

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#21 importwarrior

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Posted 29 January 2013 - 07:18 AM

looking good so far!

B-71 87 TSI ~ RIP
Black 87 Starion ~ Mess SOLD!!!
Proud New 89 slightly Rusted Fiji Owner !!!

The Ark was built by amateurs , the Titanic was built by Professionals.






#22 pc85

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Posted 10 February 2013 - 07:40 AM

Awesome progress, good luck hope it doesn't turn into The Misery Project, LOL.
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#23 techboy

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Posted 11 February 2013 - 10:38 PM

I like that block color Tom ... I debated doing a color like that myself, but went with black b/c I had so many other parts powder coated grey.  I didn't want everything to start to look the same and get lost.
1988 Starion ESi-R ... crushed by a tree 10/31/11 - back from the dead 8/2016
1988 Conquest TSi ... current driver - sold to Bigjoe 6/2016
1987 Conquest Flatty ... F/S thread - sold 8/2014
1987 Conquest TSi ... parts car - sold to Coldscrip 12/2011
1999 Eclipse 4G63 ... heavily modified.
Feeback Thread | Motor rebuild thread | Restoration thread

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#24 tsi_tom

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Posted 13 February 2013 - 08:02 PM

View Posttechboy, on 11 February 2013 - 10:38 PM, said:

I like that block color Tom ... I debated doing a color like that myself, but went with black b/c I had so many other parts powder coated grey.  I didn't want everything to start to look the same and get lost.

Thank you.  I used the same color Indiana used on one of his blocks. Duplicolor Cast Iron.  This Friday I will pickup the block from Automotive and Industrial.  They cleaned it again since I honed it.
Engine
20 over forged pistons
Stock injection system

My restoration project: The Missouri Project

#25 techboy

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Posted 27 February 2013 - 10:07 AM

Did cleaning it again take the paint off?  Some machine shops use some pretty aggressive chemicals to do cleaning ...
1988 Starion ESi-R ... crushed by a tree 10/31/11 - back from the dead 8/2016
1988 Conquest TSi ... current driver - sold to Bigjoe 6/2016
1987 Conquest Flatty ... F/S thread - sold 8/2014
1987 Conquest TSi ... parts car - sold to Coldscrip 12/2011
1999 Eclipse 4G63 ... heavily modified.
Feeback Thread | Motor rebuild thread | Restoration thread

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#26 tsi_tom

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Posted 27 February 2013 - 06:22 PM

View Posttechboy, on 27 February 2013 - 10:07 AM, said:

Did cleaning it again take the paint off?  Some machine shops use some pretty aggressive chemicals to do cleaning ...

No it didn't.  They didn't use the spray cabinet.  The spray cabinet has the harsh cleaning solution.
Engine
20 over forged pistons
Stock injection system

My restoration project: The Missouri Project

#27 tsi_tom

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Posted 05 March 2013 - 03:55 PM

I had the motor ready to be reassembled when I noticed a valley at the top of the number two cylinder wall.  I didn't see it before but this caused me concern because the valley is right at the top where the ignition would take place.  The machine shop wanted to bore it originally but said I would probably be ok.

So now the motor is back at the machine shop to be bored out.  They will rough bore it and then let me know what size pistons I need to order.

This is my third trip to the machine shop.  Third time's a charm!
Engine
20 over forged pistons
Stock injection system

My restoration project: The Missouri Project

#28 tsi_tom

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Posted 05 March 2013 - 09:08 PM

While I am waiting for the block to be bored I moved to the fuel system.

The car has been sitting for a long time.  I am sure the gas tank looks bad so....

I bought this awesome gas tank from MotoCam360 and replaced the pickup filter and the conical filter.

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Attached the new filter

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Replaced the conical filter.  This is a little unusual as the filter doesn't fit all the way into the pump.   I need to look at the parts manual again.

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Buttoned up the tank for a later install.  You can see their is a bent flange on the side of the tank even though the tank was packaged very well before shipping.

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All done

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Engine
20 over forged pistons
Stock injection system

My restoration project: The Missouri Project

#29 tsi_tom

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Posted 28 April 2013 - 07:30 PM

Got the block back from the machine shop.  This is the third trip to the machine shop.  Last change is to have the cylinders bored 20 over

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Also I got the exhaust manifold shaved

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And now to install the forged pistons!

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Engine
20 over forged pistons
Stock injection system

My restoration project: The Missouri Project

#30 randy

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Posted 28 April 2013 - 08:17 PM

Man the block looks good what kind of paint is that painted with?

#31 tsi_tom

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Posted 28 April 2013 - 09:29 PM

View Postrandy, on 28 April 2013 - 08:17 PM, said:

Man the block looks good what kind of paint is that painted with?

I used Duplicolor Cast Iron.
Engine
20 over forged pistons
Stock injection system

My restoration project: The Missouri Project

#32 tsi_tom

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Posted 28 April 2013 - 09:35 PM

Reassembly

Pistons installed

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Checked the rod journals with plastiguage

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Reinstalled the oil pump.  I am not sure how the cradle for the cam gear got so bent.

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Edited by tsi_tom, 30 March 2015 - 07:57 PM.

Engine
20 over forged pistons
Stock injection system

My restoration project: The Missouri Project

#33 tsi_tom

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Posted 28 April 2013 - 09:40 PM

I had to make a decision today if I was going to use the balance shafts.  After thinking about it for a long time, taking into account the engine's previous condition, the balance shaft journal surfaces, talking to a lot of experienced people, and talking to the machine shop I decided to keep them.  The machine shop had already installed new balance shaft bearings on the first trip to the machine shop.
Engine
20 over forged pistons
Stock injection system

My restoration project: The Missouri Project

#34 tsi_tom

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Posted 13 May 2013 - 06:31 PM

In the past I bought two intakes with injectors that were said to run fine.  

I sent the injectors from the two intakes to https://www.rceng.com/

RC Fuel Injection called and said three were leaking externally.  Only one black injector was good to start the cleaning process.

Here is the report.  I find this amazing.  It is no wonder why some Conquest/Starions don't run correctly.

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The injector looks great!

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Three externally leaking injectors

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What I have to rebuild.  Looks like someone used JB Weld on the green injector.

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Engine
20 over forged pistons
Stock injection system

My restoration project: The Missouri Project

#35 techboy

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Posted 17 May 2013 - 11:26 AM

View Posttsi_tom, on 28 April 2013 - 09:40 PM, said:

I had to make a decision today if I was going to use the balance shafts.  After thinking about it for a long time, taking into account the engine's previous condition, the balance shaft journal surfaces, talking to a lot of experienced people, and talking to the machine shop I decided to keep them.  The machine shop had already installed new balance shaft bearings on the first trip to the machine shop.

Tom if you change your mind about those balance shafts let me know ... I have a spare elimination kit laying around.  I have them eliminated on my Quest and my Eclipse.  Don't even notice it on the Eclipse.  On the Quest you get some vibration.  My eclipse balance shaft seized, snapped the belt and caused a whole mess of damage this time last year.  Pretty much made my desicion for me.  Here's a post I put about it here:

http://www.starquest...topic=131581=
1988 Starion ESi-R ... crushed by a tree 10/31/11 - back from the dead 8/2016
1988 Conquest TSi ... current driver - sold to Bigjoe 6/2016
1987 Conquest Flatty ... F/S thread - sold 8/2014
1987 Conquest TSi ... parts car - sold to Coldscrip 12/2011
1999 Eclipse 4G63 ... heavily modified.
Feeback Thread | Motor rebuild thread | Restoration thread

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#36 mistapickles

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Posted 17 May 2013 - 12:29 PM

View Posttsi_tom, on 28 April 2013 - 09:40 PM, said:

I had to make a decision today if I was going to use the balance shafts.  After thinking about it for a long time, taking into account the engine's previous condition, the balance shaft journal surfaces, talking to a lot of experienced people, and talking to the machine shop I decided to keep them.  The machine shop had already installed new balance shaft bearings on the first trip to the machine shop.
Great decision to keep the shafts, you'll be happier with the drive and performance.  All in all looks like a top notch build you have so far...
86 Mitsubishi Starion; 89 engine, trans, rear end, spindles, wire harness and computer; 16g
[IMG]http://i383.photobuc...kles/JDANCE.gif

#37 tsi_tom

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Posted 18 May 2013 - 09:36 PM

View Posttechboy, on 17 May 2013 - 11:26 AM, said:

Tom if you change your mind about those balance shafts let me know ... I have a spare elimination kit laying around.  I have them eliminated on my Quest and my Eclipse.  Don't even notice it on the Eclipse.  On the Quest you get some vibration.  My eclipse balance shaft seized, snapped the belt and caused a whole mess of damage this time last year.  Pretty much made my desicion for me.  Here's a post I put about it here:

http://www.starquest...topic=131581=

Thank you for the option.  Greg from the machine shop said that the 2.0s do have the bearing shaft bearing issue.

View Postmistapickles, on 17 May 2013 - 12:29 PM, said:

Great decision to keep the shafts, you'll be happier with the drive and performance.  All in all looks like a top notch build you have so far...

Thanks for the compliment!
Engine
20 over forged pistons
Stock injection system

My restoration project: The Missouri Project

#38 tsi_tom

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Posted 18 May 2013 - 09:52 PM

I started to clean the oil cooler today.

Following the instructions from Starfighterpilot: http://www.starquest...hl=+oil +cooler

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I filled it a couple times with keronsene, shook it up, and dumped it out.  There was some debris.  The pot was cleaned before I dumped out the kerosense.

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I then blew out the cooler with compressed air.   Here is the result:

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Metal in the oil cooler:

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The oil cooler needs to be cleaned out when doing a rebuild. You don't want that going throught the oil system on your rebuild.

Now I am soaking the oil cooler in kerosene overnight.
Engine
20 over forged pistons
Stock injection system

My restoration project: The Missouri Project

#39 importwarrior

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Posted 18 May 2013 - 11:55 PM

That is exactly what happened to GreenStar's car. put in new engine and
never cleaned the turbo or oil cooler out. it then killed the new engine in short time
right after he sold it..

B-71 87 TSI ~ RIP
Black 87 Starion ~ Mess SOLD!!!
Proud New 89 slightly Rusted Fiji Owner !!!

The Ark was built by amateurs , the Titanic was built by Professionals.


#40 tsi_tom

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Posted 19 May 2013 - 08:53 PM

View Postimportwarrior, on 18 May 2013 - 11:55 PM, said:

That is exactly what happened to GreenStar's car. put in new engine and
never cleaned the turbo or oil cooler out. it then killed the new engine in short time
right after he sold it..

Getting the metal particles out is turning out to be a big job.  I have spent about 2 hours now flushing with kersosene and compressed air.  I think I will switch to hot water tomorrow.
Engine
20 over forged pistons
Stock injection system

My restoration project: The Missouri Project




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