New/Old Project

[PKFIRE]

Just throwing this out here since it is non-Ford related. I started on my 1991 Dodge Spirit Rt again. I'm not in hurry to complete it but if there is any interest I'll start posting some info and pictures of my progress. I'm planning to get the car running before November since that is when local Turbo Dodge guys meet up for the end of the season.

[aperacer]

that is one of those 2.2 multi valve turbo cars? those were bad cars... and you never saw it coming... i would like to see the progress on it...

[PKFIRE]

http://www.supercars.net/garages/Dodge%20Spirit%20RT/2v2.html

It's the 2.2 Turbo T3 Intercooled version that they only produced 1399 in 2 years. It comes from the factory with 224hp and 0-60 runs of 5.8 seconds and a qrt mile of 14.5@97(car and driver). My car went the best of 14.9 missing 4th at 90mph with new tires beating the guy in the ion who laughed at my car during Import Day (typical scenario) and 15.3@95.67 stock with crappy dry rotted tires and 2.5 60'. Anyway I lost an oil pump awhile back that ended up chewing up my entire block and stock turbo. I believe the head wasn't hurt but if it is it's probably the lifters which luckly a company decided to make aftermarket ones for around 400 dollars set of 16. Dodge sells them as an assembly with the rockers for 160 a piece and that adds up quickly. The tranny failed but was fixed less than 1000 miles before the motor went.



New parts since I bought the car in 2002

Motor
Since the T3 block is so hard to find I picked up a common 2.5 block from a running Shelby Daytona. I'm going to plug some holes since the spirit Rt does not have a distributor and I'm taking the balancing shafts out of it which usually results in about 5 hp gain and I don't have to put them back in,lol. This block not having the same nickel grade as a T3 but is cast iron is still stout. I'm also using the T2 rods from this motor since they are safe up near the 400 hp range though people have pulled more power out of these with good results. I believe the 10 second omni running around uses them and he's in 400+whp range. I'm not planning to go more than probably 300-320hp at the crank but getting it running is what I want more than power right now.

Turbo
I went with a 46 trim T3 Garret since it works well with this motor and clears the transmission without having to cut out a notch. A 50 trim you have to. I stuck with the stock .48ar exhaust side since I don't have to modify anything to make it fit. I had the wheel cut on it. Since the exhaust side is small the turbo would be choked up pass the mid 300hp range. The Stock turbo is good to about 275-290 hp.

Transmission
Had this rebuilt which I wish I would have just picked up a used one out of state somewhere.

Clutch
Duel friction Centerforce

Intercooler
Volvo -> probably going with one of ebay specials eventually

Exhaust-
Had a small stock 1 7/8"

Went with a hi flow 2.5 inch cat and 2.5 pipe with no muffler done by tri state muffler.

Wheels
I have good tires on it but the rims have faded. I’d like to get these wheels repainted or lighter weight aftermarket wheels.

I sold the heavy aftermarket wheels I had on the car and a set of tires for them to fund the car.

[MrsAPE]

different project but those cars were great sleepers!! love to see pics etc as you go on.

[R825OH]

That s a great project Joe keep us informed!

[Evil_Capri]

Yeah, keep us posted!

[DeckerEnt]

That s a great project Joe keep us informed!

You just like it cause he said Volvo. LOL
I was a mopar guy before I got turned into a ford guy. Let the updating begin.
Keith

[PKFIRE]

Last night I checked out my 3 of my T3 rods. They look good with the cross hatch still showing. I think I'm going to reuse them and from what my brother said that the fourth one actually not at my house and in his possession is good also. Tonight if it is sunny I may paint the block which will be gloss black. If I don't get to this tonight because of the gym I will be painting it this weekend before I help my buddy with his Turbo Dodge Saturday.

Here is the list of stuff I had to buy from FWD performance to put the motor back together.

1T-3 Head GasketFWD 43-0181FWD 43-0181
2T-3 Valve cover GasketsFWD 43-0182FWD 43-0182
1Cam Seal / Intermediate Shaft SealFWD 44-0352FWD 44-0352
1ARP Rod BoltsFWD 39-0233FWD 39-0233
1Melling High-Volume Oil PumpFWD 44-0446FWD 44-0446
1Gasket Set 89-up LowerFWD 44-0353FWD 44-0353
1T-3 PCV GrommetFWD 43-0189FWD 43-0189
1Clevite 77 Main Bearings (.25mm)FWD 37-0337FWD 37-0337
1Clevite 77 Rod bearings (.50mm)FWD 37-0334FWD 37-0334
1Sealed Power Rings (STD)FWD 37-0271FWD 37-0271


BTW this Dodge drove me to buy a Ford Mustang,lol.

Bill, us Volvo guys have to stick together. If you find a B230 turbo car btw that hasn't been cannibalized let me know from any local junk yards. I need turbo parts.

[PKFIRE]

The first picture is my already machined steel crank.

The second picture shows the crank gear that wouldn't come off the old crank. I had to break it in half to get it off but I didn't feel bad because you can buy one new for 10 dollars . Now the T3 one is not made anymore and very hard to get a hold of. Luckly I found a used one for only 25 dollars.

The third picture is one of the rods that I will take to a machine shop to put in my new ARP studs.

The fourth picture is my block that I painted gloss black.

[PKFIRE]

New ARP studs are installed on the rods.

I brought home all the hardware that I though I did a good job marking but they some how got out of the bucket I put them in. Maybe it got kicked over. I'm glad for one thing is that my ARP studs with hardware was found. I thought I lost some fasteners. Saturday I'll be installing the crank, and pistons into the block. Also cleaning and painting more parts.

Also I picked up a new intercooler. It is the same intercooler that is used in the Nobles which is pressure tested to 2 bar. I'll just have to block one inlet hole since there are 2. I got a killer deal on it also.

[MrsAPE]

busy busy!!

[PKFIRE]

My brother and a buddy came over yesterday to help me install the crank, new oil pump, rods, plug the oil hole for the balance shafts since it is not needed anymore and the pistons. Everything went together nicely with good clearance. I have the rest of the parts I wanted to clean and get painted which I did this morning to install on the block. So now it is time for me to sort through what bolt goes where and next week if I have time I should have the head and turbo installed on the block.

[PKFIRE]

Well I finally installed the head and pulleys onto the block. Everything is painted now. Pretty much I need to find some bolts for the Valve covers and new studs to mount the turbo onto the exhaust manifold. Maybe today I'll put the oil pan on. I need to buy a belt tensioner gauge. I have no idea where to buy one around here for a decent price. I may just have to order one.

[PKFIRE]

I'll download some pics later.

[PKFIRE]

I'm missing one part to get the engine completed and it called a water diverter. Chrysler stop production on this part but I was lucky enough to find someone with one. Of course this part had to be T3 specific. A week or two I will be recieving the new part once I send the check.

[DeckerEnt]

Sweet. That thing is coming right along.
Keith

[PKFIRE]

I just received the water diverter and a cam belt gauge by fedex. I guess I'll do some grinding on the block to make it fit this weekend. I'm not 100% sure I'll get the car running before November but it's nice seeing that I'm getting something accomplished. I just don't want to hurry anything if I don't have to.

[PKFIRE]

Installed my water diverter, water pump, oil pan, turbo and tighten bunch of stuff to spec today. Aligned the cams and crank when I installed the timing belt. I forgot how hard it is to put the stupid thing on. I need to check deflection on the belt before I go any further.

Now I just have to install the assessory pullies/power steering pump and misc hoses on the engine. Then it will be time to mount into the car once I figure out a way to bring it from where I got it stored to my house.

[PKFIRE]

New pics


http://img522.imageshack.us/img522/2984/dsc01211bd9.jpg (http://imageshack.us)
http://img522.imageshack.us/img522/dsc01211bd9.jpg/1/w800.png (http://g.imageshack.us/img522/dsc01211bd9.jpg/1/)

http://img60.imageshack.us/img60/6343/dsc01212zh8.jpg (http://imageshack.us)
http://img60.imageshack.us/img60/dsc01212zh8.jpg/1/w800.png (http://g.imageshack.us/img60/dsc01212zh8.jpg/1/)

[DeckerEnt]

That belt system looks too cool to cover up. Leave it open.
Keith

[MrsAPE]

Sure is pretty!!

[PKFIRE]

It's funny what a can of brake cleaner, and couple of cans of spray paint can do,lol. Once I install the motor I'm going get the rest of grease off the head, intake, and where ever else I can get to with a steamer.

[1992MustangDW]

this is def going to be a cool car, cant wait

[PKFIRE]

Free time! I took off this week and had sometime to finish my motor. Installed the waterpump, steel braided lines and finally mounted the motor into the car with the help of my brother and dad. The intercooler in the picture is being replaced.
http://img246.imageshack.us/img246/1935/dsc01401re7.jpg (http://imageshack.us)

[R825OH]

Cool Joe, was wondering about this car the other day.!

[PKFIRE]

Today I installed the starter, front mount, Alternator, compressor for the AC, powersteering pump and mounted some odds and ends. I also went to Autozone and blew one of my gift cards on fluids for my car, and some kitty litter to clean up my mess,lol.

About one more day of work it should be running again. After I start it and everything is ok. I'll start trying to figure what I need to do to get the intercooler to mount up without cutting holes in the car and clean up the vacuum lines.

[PKFIRE]

The car lives again!!! I have a mess of vacuum lines hooked up to the MAP sensor, fuel pressure regulator and etc. I need to clean these up and I'm waiting on a catch can. I parked the car in the driveway to give the Mustang it's spot back.

[PKFIRE]

Pictures after Sunday’s festivities
http://img296.imageshack.us/img296/9416/pic2vp9.jpg (http://imageshack.us)
http://img296.imageshack.us/img296/8425/pic1dc5.jpg (http://imageshack.us)

[1992MustangDW]

that thing is a sleeeeeeper, sweet ride man.

[PKFIRE]

I just recieved my order intercooler piping, BOV, couplers, and T Bar clamps yesterday. Everything looked good until I found out that I received the wrong size T Bar clamps. The place I order them from is going to let me keep them and send me another 16 in the right size. I now have my catch can, breather, and vacuum lines. I also have my intercooler set up to be mounted.

I guess I'll have to drill two 2.5" holes behind the bumper to route the intercooler tubing. The Intercooler is longer than I expected. So once I am able to route the hoses and install another battery because mine is toast the car should be ready to drive.

[PKFIRE]

Just talked to the people who can a do mail order tune for my car. They said with what I have and with 15psi it's possible I could be making 300whp with the correct tune. The problem is I just intalled larger 42lb-min injectors and they too small for this application @ 15psi or higher. I probably will be running stock boost (11psi) and running the current larger injectors on this set up for awhile. I don't see why it wouldn't make 240-250whp the way it sits from what people are saying and seeing similar modification dyno slips.

[1992MustangDW]

man those are going to be good numbers

[PKFIRE]

man those are going to be good numbers

Not bad for what it is, they push about 190-195whp stock.

[Walter]

Looks cool. I had a 88 Shelby Z (TII) back in the day.

[ttop88]

I love these cars. I just sold my white R/T last month. Then two weeks ago I sold my 91ES. it was a turbo 2.5L 5 speed. I assume you talked to Cindy about a tune? She did a stage 5 for my es. 18lbs put 250hp to the wheels on a 8 valve.
As long as you have a 255lph pump and adjustable regulator I would bump it up to 13psi and gain another 15-20hp. I had planned to put a 75hp wet kit on mine, but instead of spraying the juice into the engine I was going to halo my intercooler with the NOS and use a Shark nozzle for the fuel. Put them on a WOT window switch to kick on when I hit 20psi and set my max boost at 25psi. That would not effect my gas mileage by having to use a huge injector and let me run an extra 7 psi when racing.

[PKFIRE]

http://img518.imageshack.us/img518/8389/dsc01442ci4.jpg (http://imageshack.us)

Installed the intercooler yesterday with some Home Depot Performance L brackets and CX turbo kit off ebay. What I like about the kit is the the pipe opening are flared and they give you 16 T bolt clamps. While under there I noticed that the oil turbo return line is dripping. So I'm going to go find a silicone replacement hose.

[PKFIRE]

I love these cars. I just sold my white R/T last month. Then two weeks ago I sold my 91ES. it was a turbo 2.5L 5 speed. I assume you talked to Cindy about a tune? She did a stage 5 for my es. 18lbs put 250hp to the wheels on a 8 valve.
As long as you have a 255lph pump and adjustable regulator I would bump it up to 13psi and gain another 15-20hp. I had planned to put a 75hp wet kit on mine, but instead of spraying the juice into the engine I was going to halo my intercooler with the NOS and use a Shark nozzle for the fuel. Put them on a WOT window switch to kick on when I hit 20psi and set my max boost at 25psi. That would not effect my gas mileage by having to use a huge injector and let me run an extra 7 psi when racing.

I talked to Cindy about the tune. My buddy has a chip burner but neither him or I looked into getting a default program for my car. I would really rather someone who tunes these cars everyday do my tune. Chips maybe cheep but for 200 dollars I'd rather be safe than sorry and that's why I'm going with her. I have the stock pump in the car still. I believe it is a 190lph pump in the RT.

[PKFIRE]

http://img522.imageshack.us/img522/9348/dsc01495.jpg (http://img522.imageshack.us/my.php?image=dsc01495.jpg)

Well I thought I'd have the car be ready to drive today. Unfortunately when I pulled the car out of the garage I found a steady stream of oil dripping onto the driveway. I pulled the car back into the garage and I took off the serpentine belt, pullies, A/C and what ever was in the way of trying to get to see the bare side of the block. Below is what I found. Leaking front Camshaft Seal. I'll replace the Intake and exhaust Camshaft seal next weekend. I should be able get it back on the road after that.
http://img134.imageshack.us/img134/2466/dsc01496.jpg (http://img134.imageshack.us/my.php?image=dsc01496.jpg)
Note: the front of the head is still dirty. New oil was leaking at the bottom side of the seal. I spun the oil pump to confirm this after cleaning the area up with degreaser.

I removed my fog light brackets to install the bumper today. Everything fit well other then me fighting on putting the bumper back together and installing it into the car. I need to place the fasteners back on it.
http://img522.imageshack.us/img522/1224/dsc01500.jpg (http://img522.imageshack.us/my.php?image=dsc01500.jpg)

[Evil_Capri]

Dig it! Looking good! Hope you get the oil leaking situation under control.

[PKFIRE]

Dig it! Looking good! Hope you get the oil leaking situation under control.

Thanks bud, I'm hoping also.

[PKFIRE]

Well I guess I got the oil leaking problem solved and ended up with a bigger issue. I took it out on the road yesterday and the oil pump shaft sheared the gear on the new oil pump within 5 miles. I talked to some guys that have dealt with this on a turbododge forum and found out that I probably had improper belt tension and the harmonics causes premature failure(this seems to be fairly common). So I need to figure out how to adjust the cambelt correctly. I was reading 12.3NM where I need to be reading 10.8 on the gauge between the cam gears. The belt was very loose between the intake cam and the crank gear even with such a high reading. I'll have to loosen the rockers and retension like they said. I guess this is going to be a learning experience for me. My volvo on the other hand is tensioned by a spring and doesn't take much thought. This car is tightened by hand and obtaining the correct belt tension is very critical.

[PKFIRE]

This weekend I'll be pulling the motor out again. I guess I didn't turn the car off in time and scored the crank. Luckly even though the crank has been machined I should be able to have it turned down another .010" or even .020" if nessary. I guess live and learn. Next time I'll have the right belt tensioning guage and loosen rockers while tensioning the belt. The turbo is ok, I'll check the cams probably later today.

[R825OH]

Aw Man you were close too...

[PKFIRE]

Well I got a flat spot on one of my cam lobes and another one has a little bit of pitting. I'll have them regrind once I figure who I'm going have do it and how much it will cost. I wrote Delta Cams and Lonewolf performance by e-mail. I'm waiting on their reply now.
I say sometime this summer I'll have it done again,lol. As for now I put full coverage back on the Mustang which I wasn't planning to do until April to cheer me up.:bigthumb

[PKFIRE]

Pulled the motor this weekend and the exhaust cam. I need to pull some brackets loose to get the intake cam out. I still haven't decided who is going to do my cam regrind.

[PKFIRE]

Well it's running again. I need to get the old gas out of the tank and I'm probably going to buy a new radiator for it. I should be able to drive it soon.

[1992MustangDW]

very cool! I have always liked this build.

[PKFIRE]

I installed all the hoses, airfilter assy and now it won't start,lol. The Car is throwing a Hi/Low Coolant Temp code. This wouldn't cause it not to start. I'm borrowing my Buddies OBD 1 Scanner tonight. I think I'm having a Crank Sensor issue since I don't have spark.

[PKFIRE]

I installed all the hoses, airfilter assy and now it won't start,lol. The Car is throwing a Hi/Low Coolant Temp code. This wouldn't cause it not to start. I'm borrowing my Buddies OBD 1 Scanner tonight. I think I'm having a Crank Sensor issue since I don't have spark.

Crank Sensor issue, I managed to cut into the Signal, ground, and power wire when I was putting the car back together. I'm considering using a Hall Effect Sensor that has the same spacing but different Terminal if I can't solder this one back together. The Price difference is 40 dollars vs. 140 dollars (T3 Specific).

[PKFIRE]

I've decide with all the rework to go ahead and sell the car. If anyone is interested let me know. The car doesn't have any electrical issues but is having oil pump issues.

Let me know if anyone is interested.
http://img684.imageshack.us/img684/6733/dsc02056h.th.jpg (http://img684.imageshack.us/i/dsc02056h.jpg/)