Blackcrow64's Talon TSi AWD Project Progress Thread... (SOLD)

hmm my bet is it is an unattached vaccuum hose that runs from the TB. It could be the one to the FPR, or one of them that goes from the Intake manifold. I would check all those nipples first. If you have a stethescope you can listen around in areas that works well.
Checked every nipple on the thing. Even compared it to an extra IM off the car to see if I was overlooking something but nothing. TB is completely sealed unless the gasket is leaking... But the leak is louder than the motor and I don't think the gasket could be leaking that bad but maybe... I might try some RTV on there to see if that makes a difference...

Found that the IM gasket wasn't flush and had a wrinkle in it which caused the leaks... Also found two missing bolts in the turbo compressor housing... Fixed it all and it runs! Took a few trys but it finally started idling on it's own after adjusting the fuel... Now all I need to do is get a new power steering pump and fix all the awful leaks... Had it run for about 30 minutes with no problems aside from a major leak. Stupid fuel pump lines are leaking horrible right on top of the pump housing. Blah... Stupid cars... But at least it's running!!! =)
Mozilla/5.0 (iPhone; U; CPU iPhone OS 3_1 like Mac OS X; en-us) AppleWebKit/528.18 (KHTML, like Gecko) Version/4.0 Mobile/7C144 Safari/528.16

Good job man, glad to hear its running.

Ok, so on Sunday I went and worked on this thing again and tore off the intake manifold, throttle body and upper intercooler pipe... Went over everything and found some junk on the IM flange that could have caused a leak. Sanded it all smooth and then used silicone on the gaskets there and on the TB and am hoping that takes care of the vacuum leaks I had... Still gotta solve the fuel pump leak... It is fine at an idle and lower RPM. Once I start to make boost it sprays and leaks like crazy... Also am having an issue with some electronics inside the car... Need to do some rewiring this winter on it. Definitely did a sloppy job on that stuff and need to fix it... Also going to do some undercoat work on it this winter along with suspension and new wheels next spring... Anywho... Hmmm... We'll see what happens where when I go work on it some more. Hoping I can get this fuel pump leak solved. I don't wanna drive it and deprive it of fuel while boosting. Anybody parting out an AWD 2g? I sure could use the fuel pump housing/sending unit...

The best thing about the winter is that your able to focus on getting all those odds and ends cleaned up that you've been procrastinating about throughout the year. You said the fuel pump is leaking, is it the line that comes right out of the fuel pump or are you talking about the sending unit where it attaches the seal is shot?

The best thing about the winter is that your able to focus on getting all those odds and ends cleaned up that you've been procrastinating about throughout the year. You said the fuel pump is leaking, is it the line that comes right out of the fuel pump or are you talking about the sending unit where it attaches the seal is shot?

The feed line out the top of the sending unit is leaking where it meets the rubber line. Sprays out all around it... If I can't get it solved I may just run a braided line the whole way from the sending unit to the fuel rail and just use an aftermarket filter rather than the stock one...

Thats what I was going to suggest. I remember seeing something in the vfaq before that showed how to fix a broken fuel line that goes right through the sending unit. You can get to the sending unit from the back seat can't you?

Thats what I was going to suggest. I remember seeing something in the vfaq before that showed how to fix a broken fuel line that goes right through the sending unit. You can get to the sending unit from the back seat can't you?

Yes I can. If you happen to come across that article again please hit me up with it. I'm debating a few ways of going about this whole process, none which will be fun or easy. lol...

This isn't the exact site but the same idea

http://www.3si.org/forum/f1/how-fix-fuel-tank-studs-convert-fuel-pump-assy-420892/

This isn't the exact site but the same idea

http://www.3si.org/forum/f1/how-fix-fuel-tank-studs-convert-fuel-pump-assy-420892/

Ah... Yeah, that's exactly what I was gonna do with AN fittings. Was hoping there would be an easier/cheaper way but oh well. I'll just do it right so I know I won't have to worry about it again.

Yeah that looks like a 1 time deal, once it's done then you don't have to worry about it again.

Ya, i broke that hose as well, a replacement from mitsu is $75 which isnt cheap either

Atleast its running now... that car has put you through hell dude.
You just have a few kinks to work out and perhaps everything will be working smoothly

Tomorrow is supposed to be 70 and sunny out and I don't have to work! It will definitely be a good day to get things done on it... Hopefully get everything fixed up and drive it as long as the fuel line is done leaking... Will know more once I start it up again and test some things out...

Good Luck dude, I have high hopes if that gives you any confidence!

Eff vacuum leaks... Put everything back on and the leak was just as bad still. Took it all off again and inspected everything and everything was sealed up perfect... I come to find out the one O ring on an injector had popped out of the head and the leak was right there... Fail... Now gotta put it all back on again this morning and hope that truly was the vacuum leak all this time...

Got my headliner all done yesterday too and it turned out really nice!

Ordered my new power steering pump and it'll be here Friday... Blah... This thing better start cuttin the crap and just run!

PICS....I wanna see the headliner.

Wow... I'm so sick of this car... The vacuum leak persists... I'm gonna freak out on this thing... :banghead:

I'm not really sure what to do now... I've had 3 people look at it to verify that I'm not crazy and that the flange and head are both level clear across the ports. Nothing is warped, nothing is cracked, everything is tight. Even put a brand new gasket in it today too. It's leaking between cylinders 3 and 4... I'm out of ideas... Gonna take it all off AGAIN for the millionth time and swap it with the intake manifold from my buddies spare motor and see if that fixes it... If not, I'm gonna push it off a cliff... Or maybe part it out and try to get some of my money back out of it...

That's stupid sucky, that car really needs to knock it off.

Ive never heard tell of such problems, I swear. I will give you 5k for the whole car :D

Yeah buddy, don't know what to tell you. My first galant had a persistent vacuum leak i never did find... as a matter of fact i sold it that way, never actually pulled vacuum at idle on the gauge. lol

Yeah buddy, don't know what to tell you. My first galant had a persistent vacuum leak i never did find... as a matter of fact i sold it that way, never actually pulled vacuum at idle on the gauge. lol

How did you keep it from stalling out from this? That's the biggest issue I'm having now that's keeping me from giving it a test drive so I can further tune it...

I have a hell of a time trying to find vacuum leaks good luck man. Got any up to date pics?

Set the idle a little higher :). Never did want to start in the first place though. Mine must not have been as large of a leak. The intake manifold I had had a vacuum nipple off it that wasn't listed in the book too. It was on the intake manifold dead center behind the valve cover.

Meh... I'll try to get some pics on Friday when I work on it Ned. Not a whole lot of updates though since the last batch... Well... Actually all my pics are missing so I need to fix that still...

I'll have to raise idle up some more I guess. Just sucks the flange is where it's leaking and causing 2 cylinders to run way lean. Once I boost it's gonna be rich instead. Stupid cars... I guess I'm gonna try another stock intake manifold on Friday and see if that fixes it. If not... Well then crap, my life sucks...

Can you see where its warped at? If so is it possible to shave off a tad to flush it up?

Silicon that bitch up

Ned, that's just the problem. It's not warped at all. I had two buddies and a machinist check it for me and none of us can figure out why it's leaking...

Jason, I tried that and it still didn't seal it. :(

Ultra Grey fixes everything....Im not even joking. Anyone want to take apart my 4g64? Lol, have fun.

That's great lol^^

One would think that this would be an easy fix. Wish I could be more help.

I bet something is missing or is being overlooked... something small.

If it's flat, there shouldn't be a problem.
Where it meets the head is flat?
If it were slightly warped and if it's siliconed up, there shouldn't be a problem.
The gasket is good?
Are all the bolts threading in properly?

If all those are right... it's got to be something else. Is there a crack on the manifold anywhere?

I rtv the shit out of stuff like that there's no point in risking a leak. I would pull it apart and make sure nothing is stopping it from sealing like a washer or a bracket that's in the way. then I would but a lot of rtv on both sides of the gasket and that will ensure a leak free seal. I figure you already know this but that's my 2 cents.

Both surfaces are perfectly flat. Went over everything with a straight edge and there are no dips or low spots. Both surfaces are perfectly clean and I had a brand new gasket. Used RTV on both sides of the gasket and then put it all back together and same results. The leak changes none and is in the exact same spot. I checked all over the IM for cracks in the flange and there are none. There's nothing in the way and the bolts are not bottoming out; already checked that... Tore it all apart again and tore the gasket because of the RTV so I bought a real nice one that has the individual rubber seals on each port and even it leaks the same... My next thing is to try another IM but if it still leaks then I'm left to assume that I'm never meant to drive this car again...

Can you see right where the leak is or are you going by feel?

If it were leaking between cylinders then it should be evident on the gasket. Do you torque everything down in the correct order? If you don't do that in the right order you may not get a good seal. Piston rings seal ok?

If both surfaces are flat and you put gasket sealant on them then I highly doubt its still leaking. There is almost no way it could still be leaking after than. How are you testing to find the leaks

My dad swears by the soapy water method and I keep hearing that spraying some thing like starter fluid around the engine bay and when you hear the engine rev then that's where the vacuum leak is. Are you using a boost leak tester?

I am torquing them in the correct order per the book... I have used the soapy water deal while the car is idling and it sucks it right in there between cylinders 3 and 4... Even did a boost leak test and pressurized the system and you could hear/feel air coming out there... Yet it seals perfect when I have it off the car looking at it... Like I said, I even loaded it up with RTV to correct any slight dips there could be but it still failed. I have a machinist look at it too and he even said there's nothing wrong with either surface and he was baffled by it as well...

Tomorrow I will be swapping a IM from a stock 6 bolt that ran fine... If this don't fix it then I'm seriously gonna put a sledge through the windshield...

I really don't know what else to try after that?

Well no sledge through the windshield... Yet... So I think now I'm just going to smother the entire outside edge of the flange with RTV... Unless anybody else has any other ideas? I'm out of em and I'm not about to spend 500+ on a new aftermarket intake and that still not solve my problem... It makes no freakin sense at all...

Maybe check all the threads and screws that youre using and holes? After following this really thats the only thing I can see that may be a problem - even if its a shot in the dark.

I don't know man. Good luck

Are you saying that even w/ another intake manifold it is still leaking?

JB weld?

JB weld?

down here we just use duct tape. :sarcasmsign:

but seriously, at this point, you may just want to send it somewhere... :/ have it assembled, and then you won't have to worry about the issues. Trust me, there's nothing better than delegating your troubles with a little bit of $$

Trust me, there's nothing better than delegating your troubles with a little bit of $$

That's what I did when I couldn't get the back spark plug on my Explorer, I said screw that I'll let someone else do that.

but seriously, at this point, you may just want to send it somewhere... :/ have it assembled, and then you won't have to worry about the issues. Trust me, there's nothing better than delegating your troubles with a little bit of $$
I really wish I could... As of late, I'm very very tight on the cash flow and have been trying to spend minimal amount on the Talon since I have the Cobalt as the dd... It just sucks cause I know it has to be something simple and it's got me pulling my hair out cause of it... I really don't know what to do... And I most certainly don't trust taking it to a shop where some retard might take it out and beat on it once they get it running... I've heard too many horror stories about that kind of stuff...

Yeah, it would be necessary to find a shop that was respectful of your ride.

Wish I could help.

Yeah, I really need to get this stupid manifold problem solved but work has been crazy for me lately with not enough time off during daylight hours to do anything... I work again this weekend, but I'm hoping to get some work done on it next weekend since I have some time off for Thanksgiving... At least I did all the other small things last week on it and got some interior stuff finished up... Got some pictures I needed to post still too...

does this thing run yet?!?! you've had it down long enough i'm back into the broke down cycle. HA! :(

Pshh... Come on, of course it doesn't run still. lol...

I honestly have no clue what to do at this point. I'm just extremely frustrated with it still leaking at the intake manifold... Makes me wanna give up and start parting the POS out...

Let me know when you start pulling parts.

I'd like to think the solution will come to you, or you'll be able to save enough money to have someone do it for you.

if you give up hope you've wasted 2 years.

The boost is worth it my friend.

If he give up it's over 2 years. We should be more supportive. No part out.

Come spring, I'm going out there and fixing it

Oh don't worry, I'm sure I'll drive it soon enough... I doubt I'll go with the part out option... There are some developments happening as we speak...

I wouldn't part it out but if its something that any mechanic should be able to figure out.

DOOD

i demand an update

DOOD

i demand an update

My update is this...




The Talon has been under about 3 feet of snow for the last few months...


I'll go outside when the snow is gone again. lol...



I've just been entirely too busy with work and my business I've been trying to get launched here... Right now the financial situation has been my top priority since the Talon wants to be a little bitch and not run for me. lol... If things continue on how they are going then I may have my own place by this spring/summer and then I'll be able to work on it a ton more once I get everything settled in. :)

that's good news! hopefully i'm going back into my next "fixed" dsm cycle. turbo got kinda ... blown... in under 1k miles... likely the result of a weird oil pressure feed/return line setup. Fixing :D

Update:
























































































Not really. I just felt like screwing with you guys. lol.... :smooch:


Nah, I really am going to start working on it here now that nice weather is finally showing its face in Ohio... Plus I will have more free time to actually work on it too...