1992 Typhoon 0546 rebuild

Quickstop [UK]

Combating adversyty.
Re: 1992 Typhoon 0539 rebuild

Re: 1992 Typhoon 0539 rebuild

Wow what a build.. Great work!!

I am now dizzy after literally reading thru all 18 pages of this thread I stumbled upon about an hour and a half ago. Lol.

My hats off to your patience and your wallet sir! What a ride that truck has been on!

I wish I had the time/patience and ridiculous amt. of $$ that cost you.

Fantastic truck. :tup::tup:

Thanks guys - I have doubted my sanity and my resolve faltered but the people on this site helped me a lot and comments such as yours are part of it.

I still have some way to go. Slow and steady wins the race!
 

Quickstop [UK]

Combating adversyty.
1992 Typhoon 0546 rebuild

Still left to do....

replace rear carpet - charcoal - anyone know where to source it from?
box in battery with stock looking battery compartment like bezerk has in his - need charcoal vinyl - any ideas?
install battery kill switch
more grounds directly from the engine to the battery - make up some cables
port match and paint/powdercoat intake plenum - Keith? :D
install heater hoses and connect the core - need the hoses or new ones...
test blower motor/replace
refurbish the alternator with a 140A kit (as recommended by Keith)
install an overhead console one day - where to get one?
silence the exhaust leaks from the crossover
install ALKYCONTROL kit - dial it in!!
isolate and remove the squeaking/clanking from the front suspension
BOV install - got the unit, need hoses/solenoid and control system
lower IC hotwire - maybe a fan?
reattach the heated rear windscreen connector
install new motors/rails for the side windows
reverse light install/rear fog lamp
alarm install/immobilser/remote start - compustar SS
fix central locking system
replace the side window seals
replace the cracked dash pad
install rear wedges to align the pinion angle

There are a couple of other things that need doing but this list is smaller than the one a few pages ago...
 

bundie

New member
Re: 1992 Typhoon 0539 rebuild

Re: 1992 Typhoon 0539 rebuild

BOV install - got the unit, need hoses/solenoid and control system


uhhhh....

mount it with the right spring and put vacuum line on it...
 

Quickstop [UK]

Combating adversyty.
Re: 1992 Typhoon 0539 rebuild

Re: 1992 Typhoon 0539 rebuild

BOV install - got the unit, need hoses/solenoid and control system


uhhhh....

mount it with the right spring and put vacuum line on it...

Need a different unit. Flange is too big for my turbo-IC pipe.

:D
 

bundie

New member
Re: 1992 Typhoon 0539 rebuild

Re: 1992 Typhoon 0539 rebuild

i welded a 25mm flange on the rpm hardpipe
 

Quickstop [UK]

Combating adversyty.
Re: 1992 Typhoon 0539 rebuild

Re: 1992 Typhoon 0539 rebuild

Still left to do....

replace rear carpet - charcoal - anyone know where to source it from?
box in battery with stock looking battery compartment like bezerk has in his - need charcoal vinyl -
install battery kill switch
more grounds directly from the engine to the battery - make up some cables
port match and paint/powdercoat intake plenum
install ALKYCONTROL kit wiring - hardware is already in...
BOV install - got the unit, need to work out where to install the flange
install new rails for the driver side windows
alarm install/immobilser/remote start - compustar SS
fix central locking system
replace the cracked dash pad
install rear wedges to align the pinion angle
replace hydroboost unit and master cylinder
replace the hydraulic lifters/remove lower intake
paint the rear wiper
install wing
replace red/blue AN fittings with black ones
weld collar/filler neck to intercooler
delete cruise control hoses and ABS lines
check headlight grounds, change bulbs
 

Quickstop [UK]

Combating adversyty.
Re: 1992 Typhoon 0539 rebuild

Re: 1992 Typhoon 0539 rebuild

Had a new friend come to stay.

We did the following:

rear lowering blocks
rear shocks
front shocks
PLX wideband install with gauge
Ostrich 2.0
and last but not least......... EGR delete.

We could have done more but the EGR was installed the wrong way - instead of blocking off the passage it provided a "WOT" passage. Truck idled lick shit and sounded terrible. We spent all day removing the WBO2 and installing the old NBO2, checking grounds, timing, plugs, ignition etc etc.... Turned the EGR around and it ran great. Stupid design from RPM... Why mill out the useless side?

We took off some horrible red stripes and buffed it out...

Before:

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After:

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Went for a ride, boost launching a good running stock truck was a lot of fun but.... some engineering in the style acknowledging African Engineering Standards cause a few issues!

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The last one caused all the issues. Cable ties pulling the water hose away from the alt and an undiagnosed motor mount issue meant that when the boost happened, the hose pulled the radiator and cracked it. We ended up spending a while fixing the leak.

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Worryingly, we also found this....

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Will see how it goes. Great weekend, cool truck and a new friend and SyTy owner in the UK.
 

TYTILIDIE

METH HEAD
Re: 1992 Typhoon 0539 rebuild

Re: 1992 Typhoon 0539 rebuild

Man that wheel looks awful. Buff job turned out good. When are you going to get the rest of your stuff done?
 

Quickstop [UK]

Combating adversyty.
Re: 1992 Typhoon 0539 rebuild

Re: 1992 Typhoon 0539 rebuild

You mean the turbo or the rims? :D

The turbo spools and the truck pulls but there has to be some power loss associated with it.

The rims speak for themselves... :barf: but the owner (MDH) is getting stockers on there asap.

As for me, the three big jobs are:

Hydroboost, lifters (850s to replace the 875s), upper intake port matching and powdercoating and the upgraded IC welding.

I have 3 days before my gf arrives so will start in earnest tomorrow! I have some time in the summer as well. It makes such a difference to have the truck in my own garage with all the parts/spares/tools I have...

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The truck has been away for nearly 2 years and been to Holland and across the Atlantic twice. Pretty glad to have it back here and have enjoyed working on the Syclone and mine.
 

Quickstop [UK]

Combating adversyty.
Re: 1992 Typhoon 0539 rebuild

Re: 1992 Typhoon 0539 rebuild

steering locking mechanism

This Christmas was a busy time as MDH came down and we removed his stock TC to replace it with the Hughes 3000 from 1BADV6. It took all day but the difference it made to the truck was like night and day.

With the 20G and stock stall, it ran slowly off the line. With the 3k stall he was spinning all four tyres.

Pretty amazing stuff!

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Quickstop [UK]

Combating adversyty.
Re: 1992 Typhoon 0539 rebuild

Re: 1992 Typhoon 0539 rebuild

Mentioned above were the troubles I had with the steering mechanism that turned out to be due to the fact that the locking ring was missing. This was very frustrating. I now need to source a locking ring and get the tool to remove and replace it.

Seeing as I couldn't get the steering to work properly, I decided to install the LEDs that I had purchased. The gauges were a bit dim with the stock bulbs and having seen other LED conversions, I was very impressed.

One thing worth noting - the blue bulb holders are easy to disassemble if you take your time. You basically have to unfold the wires at the bottom and then pull out the terminals and therefore allowing the bulb to be removed. Brute force may ruin them.

I tried to get spares for the bulb holders but the sizes are 3/8" and 1/2". I got the 3/8" ones and these are for the smaller bulbs. At $7 for the larger, they're not cheap.

Also, for the Canadian/Standard S10 cluster, you'll need a shorter bulb than the one pictured as it hits the back of the console as it is. I had to leave one out but the LEDs were so bright that it wasn't noiceable.

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The results speak for themselves:

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I made the classic mistake of having the LED polarity reversed on the SES light so had to take the dash out again. Oops.

I then wanted to make sure that the other gauges worked properly. I was able to confirm that the indicators, hi/low beam, SES, and brake lights were all correct. Annoyingly, the battery warning light didn't light up so I started trying to fault find.

After about an hour I discovered that the harness from the factory didn't even include the pin/wire for the warning light. GM quality control was truly awful in 1992.

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Pin 3 (3rd from the right, lower row) is the correct place on the dash. Note there are only two connections. Infuriating. :rant: I'm now wondering if there is a way I can wire it up to work properly...

Also while I was in there, I discovered that someone has wired in a relay to the stock harness and I am not 100% certain what it does. All lights seem to work properly though, finally.

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Unfortunately, the wheel is not aligned with the steering so that needs to be sorted out. I thought that the locking ring was keyed, along with the horn button thus preventing this sort of misalignment. I guess the wheel needs to come off again.
 

Quickstop [UK]

Combating adversyty.
Re: 1992 Typhoon 0539 rebuild

Re: 1992 Typhoon 0539 rebuild

Some other tasks that were completed were the stock dipstick install which necessitated removal of the passenger manifold and turbo.. Very annoying but essential to avoid trashing the dipstick tube.

People say that you can force it in but given the interference from the manifolds, I disagree. I have a picture of what the tube looks like if you try and go this route.

IMG_1095.jpg


Total butchery - not recommended.

I also installed new heat shields to prevent the plugs from burning.. (assuming I ever drive this truck again!)

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I also made the Typhoon an official resident by installing the sign above the garage. :D

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I got distracted and decided that I wanted more light so I spent a day wiring the garage with t3 extra fluorescent lights. They make quite a difference.

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After (not a great comparison but the truck looks good)

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A really minor thing - I now have a hood clip again! The gas struts for raising the hood are great but they are a bit low so I've been using the normal hood rod.

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Yeah, amazing right? :D Shame it is green :(
 
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Quickstop [UK]

Combating adversyty.
Re: 1992 Typhoon 0539 rebuild

Re: 1992 Typhoon 0539 rebuild

Another little project that has become more challenging than I expected is the calibration of the PCM-2000 TCU.

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I have a couple of issues with it:

1). I wired in the coolant sensor wire to the ECM in my truck and it is reading very high (140F when ambient was 47F.) I datalogged the sensor with another piece of software (TP RT) and verified that the ECM is receiving the correct temp. On disconnecting the sensor, the trans sees the temp go very cold so it is clearly on the same circuit. Can I set the sensor type? Why is the TCU not registering the same temperature?

I think this is a custom setting for the coolant sensor and I may have found it.

2). I would like to use one of the remaining Digital Outputs to control a relay for an electric fan. On the 4l80e harness, Digital Output 5 seemed available so I connected a wire to CPC 19 on the big connector and then to an auto/12v LED to test it.

The LED remained lit no matter what configuration I had the output set at. I was trying to make the output behave as Solenoid C so that the fan is on in 1st gear, P or N by editing the gear solenoid table.

No luck

3) Finally, despite the truck being in P, the trans seemed to think it was in 1st when I had it in the garage. I think this was due to the shifter being loose. The c-clip had come undone and it was all loose in there. New ones to go in.

One idea that I had suggested was to short circuit the lower IC pump and then use the relay to control the fan via the ECM.

Unfortunately, and please correct me if I am wrong, the relay is still used when you do the short circuit for the lower IC. Grounding it merely ground the relay circuit. I still need a separate control for the lower IC fan.

I have emailed Powertrain Control Solutions and asked them about the fan control so will update once I know.
 

Quickstop [UK]

Combating adversyty.
Re: 1992 Typhoon 0539 rebuild

Re: 1992 Typhoon 0539 rebuild

Christmas interupted my progress and I was very happy to receive a couple of SyTy related goodies...

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My girfriend had the sweatshirt custom made. The guy that makes them said he could do a run and make more for people if they were interested...

Also, and I am over the moon about this, I got...

edf36771.jpg


A MIG welder!

I don't yet know what I am going to do with this but this is an essential auto body skill that I really admire/envy in other people so I am hoping to learn to make some of my own pieces.

I may have to cut out some rust/fill some holes and there is always the possibility of a twin turbo setup :D

A CNC cutter and a lathe are probably the only two other items I need (read "want"). Maybe a powdercoating booth at some point as well ;).

Regardless, pretty awesome gift!
 

Quickstop [UK]

Combating adversyty.
Re: 1992 Typhoon 0539 rebuild

Re: 1992 Typhoon 0539 rebuild

My girlfriend wanted to take some artistic pictures of the truck so she (left) and my sister (right) came down while I was working on the truck and took some pictures.

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Some of them look really good!

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:D

Merry Christmas everyone!

:cmas:
 

bezerk

New member
Re: 1992 Typhoon 0539 rebuild

Re: 1992 Typhoon 0539 rebuild

that's alot in install deinstall stuff you got going on there :D
 
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