Another 2g project

[Jungy]

This is my 3rd 2g but first 4g63 powered car, I've had a fairly stock 2gnt and a pretty built 2gnt. Well this winter I picked up a 95' tsi awd rolling shell off here and have been working on cleaning it up and modifying it.

Well here she is when I picked it up.




Got home and started stripping it and cleaning the engine bay.



The engine bay was in kinda tough shape and the drivers side strut tower was rusting under the abs lines so I completely stripped the engine bay and primed and painted it.







Before I put the suspension on the car i wanted to do some prevenitive cleaning and under coating.





Now comes the fun stuff.








Motor in the car and wire tuck.




Mods:
Billet Holset HX40 in a BEP T3 .70 Housing
ERL T3 Manifold
ETS 10.5 Race FMIC
Greddy Type S BOV
Tial 38mm Wastegate
FP 4" Intake
JMF Race Manifold
1g Throttlebody
Bosch 1600's
Aeromotive FPR
255lph In-tank
255lph In-line
Moroso Catch Can
Odyssey PC680 Battery
Unorthodox UDP
Ecmlink V3
AEM 3.5 Bar MAP Sensor
GM IAT Sensor
Zietronix Zt-2 WB
Greddy Warning 60mm Boost, EGT, Oil Press Gauges
Greddy Profec B Spec 2
Greddy Full Auto Turbo Timer
6 Bolt Swap
Eagle Rods
8.3:1 Wiseco Pistons
ARP Main Studs
ARP L19 Headstuds
Felpro PT Headgasket
3g Lifters
FP Beehive Valve Springs
Delta K272 Cams
ACT Streetlite Flyweel
ACT 2600 PP
ACT Organic Street Disc
Power Slot Drilled Rotors
Stainless Braided Brake Lines
Koni Yellow Struts
Ground Control Coil Overs

[awd-drifter]

that's lookin' real good man. lots of work done to it damn...just love looking at the 4g63 engine on the engine stand.

[Constant_Project21]

Looks great, that's pretty much the same setup I would love to do on my 1g. Let me know how that ERL stainless cast manifold treats you, I have been thinking of getting one myself.

[scheides]

wtf are delta k272's, kelford rip-offs? Such a nice build and then skimp on the cams...that's my only complaint Cheap cams always seem to come back to bite you in the ass one way or another.

Looks damn good, I love the extra time/effort you took to really clean up the car. Can't wait to see it in person!

[C3L1CA]

The delta cams are the same thing as the FFWD regrind cams, they make power and are cheap.

Car looks good! Can't wait to see it all together and making some power.

[Jungy]

Thanks! Still isn't the best looking car on the outside but with time i'll get around to that too. The k272's are the same grind as the kelford 272's cut from fresh cores, not regrinds.

[goodhart]

Billet HX40?!?!?!


Looks good man!!

[Jungy]

Yep billet HX40, heres a crappy iphone pic of it:

[goodhart]

that thing is tits. I need to see this beast when you make the move to St. Cloud.

[A//// Guy]

Awesome work dude! Love the time and effort to make it clean and rust free!

[Goat Blower]

Looks real good.

[Kracka]

Very clean! Great work.

[Jungy]

As of today:


Fuel pump rewire and inline pump.



The faulty in tank fuel pump that Ive been waiting to get replaced.


All that's left till I can get the car tuned:
fill coolant, transmission, and t-case
modify down pipe for 3" v-band off turbo
fab dump tube for the wastegate
vac lines
fill with e85

[Jungy]

Well I haven't updated this in a while, the car is up and running now after its fair share of first start up issues I have all the leaks and every thing sorted out. The only problem i'm having now is I'm getting alot of hesitation/misfires while cruising at part throttle. I've tried new plugs, new wires, swapped coils, swapped transistors. Im going to add some ground wires from the block back to the battery and from the sensor grounds to the battery if that doesn't take care of it the next thing is the CAS.

[asshanson]

Sounds like my car on the 1600s. I switched to 1350's and the hesitation went away.

[Jungy]

I am running bosch 1600's but I don't know how this could be the typical injector stumble because it is really bad.

[Jungy]

I did a full tuck, shortened, and de-pinned the engine/ecu harness. I removed all the diagnostic connectors, a/c connectors, emission solenoid connectors, cruise control, and hard wired in the 1g CAS connector because the car is 6 bolt swapped. I've got a lot of hours of work into the harness with all the shortening and soldering of every connection.

Harness out of the car and ready to be torn apart.

Sorting wires.

Started at the ecu and worked my way to the engine side.



Part of the mess of wires I removed.

Working on cutting everything to length and soldering them back together.

All done just need to loom it!

Finished product.

[Goat Blower]

Clean work, looks good! I just swapped a stock wiring harness in place of my much hacked up one, I can attest to the amount of work of cleaning all of that up.

[tehehodi]

Jungy is the master of cleanliness! He does awesome work! Keep it up! and get that stuttering issue figured out or whatever it is!

[Jungy]

Looking at buying a set of Bluemax 1850's and an Easytune to take care of the bad stumble the car has. The car does not like to run on the 1600's at all.

This is old news but 2-3 weeks ago the car acted like the clutch was slipping and I had the car on stands replacing the t-case seal and the drive shaft would spin like butter and the rear wheels wouldnt move at all. Ended up finding the pass side rear axle popped out. I snapped her back in drained the diff, replaced my t-case seal, and put fresh fluid in the t-case and diff. No more leaks and no more free spinning like the clutch is slipping!


The dirty car before raising it up and putting winter wheels on.



The dirty car ready for winter with the nasty looking 1g wheels on it, Still need to remove the lip.