Rebuilding an XR4TI

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merk23literturbo
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Re: Rebuilding an XR4TI

Post by merk23literturbo »

Don't get new part-itis. If the tank is good use it. Open the locking ring carefully with a hammer and flat punch and lots of rust penetrant. If your careful you will not damage the ring. New rings are available if it's trash. If the tank is rusty have it cleaned or clean it yourself.
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DPDISXR4Ti
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Re: Rebuilding an XR4TI

Post by DPDISXR4Ti »

cmanreinhart wrote:Image
Like Don said, the tank may very well be usable. Remove all the pads, power wash it, hit it with a wire brush, power wash again, etch, paint, and then re-apply the pads in roughly the same locations. Pay particular attention for rust-perforation to the area under the rear long pad, just above the overlapping seam; that's where they often fail.

Lost in the above was removing the fuel pump module and cleaning the inside. I've done that with a power washer as well on a hot day on a hot driveway.

P.S. Nice mud-wasp nest. :haha
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Re: Rebuilding an XR4TI

Post by boost_is_fun »

Sweet XR. Mine is my first car as well, though my dad bought a b5 a4 that I've been driving since I didn't want to risk driving my merkur to UT from CO, especially since I don't have tools here to fix it. Yours is going to be far cooler than mine. mine is an 89 with 254000 miles, I want to top mount intercool it, rebuild the turbo, and put a manual boost controller in.

Good luck on your project!
Connor
'89 XR 254000 miles. Stock (until spring, then poor college student mods begin)
'99 Audi B5 A4 2.8 v6 (Technically my dad's, but he doesn't drive it)
Since I'm a Noob, i'll put an apology for dumb questions down here. I'm 19 and completely self-taught
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Re: Rebuilding an XR4TI

Post by cmanreinhart »

merk23literturbo wrote:Don't get new part-itis. If the tank is good use it. Open the locking ring carefully with a hammer and flat punch and lots of rust penetrant. If your careful you will not damage the ring. New rings are available if it's trash. If the tank is rusty have it cleaned or clean it yourself.
DPDISXR4Ti wrote:
cmanreinhart wrote:Image
Like Don said, the tank may very well be usable. Remove all the pads, power wash it, hit it with a wire brush, power wash again, etch, paint, and then re-apply the pads in roughly the same locations. Pay particular attention for rust-perforation to the area under the rear long pad, just above the overlapping seam; that's where they often fail.

Lost in the above was removing the fuel pump module and cleaning the inside. I've done that with a power washer as well on a hot day on a hot driveway.

P.S. Nice mud-wasp nest. :haha
Thanks for tips guys, I guess I should probably try and get the sender but its been so darn cold here in Michigan. But I kinda rather not skimp on fuel related parts... Oh yeah and thanks Brad for noticing the mud-wasp nest I was waiting for some one to say something.
-Conner
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Re: Rebuilding an XR4TI

Post by cmanreinhart »

boost_is_fun wrote:Sweet XR. Mine is my first car as well, though my dad bought a b5 a4 that I've been driving since I didn't want to risk driving my merkur to UT from CO, especially since I don't have tools here to fix it. Yours is going to be far cooler than mine. mine is an 89 with 254000 miles, I want to top mount intercool it, rebuild the turbo, and put a manual boost controller in.

Good luck on your project!
Thanks! It's cool to hear another younger guy that's into the XR's (where a rare bread these days). Oh yeah and my Conner aswell but with an "er" on the end. Looking forward to hear what types of mods you do to your XR and Welcome to the Forum! :cheers
-Conner
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Re: Rebuilding an XR4TI

Post by In XS 7 »

You can get the tank done, I get a new ring for the sender unit at O'rellys it was for an 87-93 Mustang I guess (it is exactly the same size and shape) here are some pics of my tank before and after.

Image

Image

Image

Image

Image
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Re: Rebuilding an XR4TI

Post by boost_is_fun »

cmanreinhart wrote: Looking forward to hear what types of mods you do to your XR and Welcome to the Forum! :cheers
Well, if people are interested in my banged up car( I hit a deer last winter :frown ), i'll be sure to post what I do to it, but I won't be home until April, so until then I'll just have to satisfy myself by watching other people's projects come along. :)
Thanks for the welcome!
Connor
'89 XR 254000 miles. Stock (until spring, then poor college student mods begin)
'99 Audi B5 A4 2.8 v6 (Technically my dad's, but he doesn't drive it)
Since I'm a Noob, i'll put an apology for dumb questions down here. I'm 19 and completely self-taught
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Re: Rebuilding an XR4TI

Post by cmanreinhart »

Quick little update alittle while back I fabed up a oil-feed line using the using the same steps and materials from a past thread: viewtopic.php?f=44&t=7851 It worked out pretty well and the result was pretty satisfying
Image

In other news I had the chance to go to the North American Auto-Show. I gotta say the New Ford Gt is a pretty damn good looking car im just not to sure why they decided to put a 3.5L V6 Ecoboost engine in it but its probably just a marketing sceem to sell more ecoboost products. But new Mustang GT350R has some funky wing that looks like its hovering over the trunk. It almost has some ricey over tones to it but im sure people in the 80s thought the same thing about the XR's bi-wing.
Image

Image
Last edited by cmanreinhart on Wed Jan 28, 2015 10:29 pm, edited 1 time in total.
-Conner
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Re: Rebuilding an XR4TI

Post by boost_is_fun »

cmanreinhart wrote: In other news I had the chance to go to the North American Auto-Show. I gotta the New Ford Gt os a pretty damn good looking car im just not to sure why they decided to put a 3.5L V6 Ecoboost engine in it but its probably just a marketing sceem to sell more ecoboost products. But new Mustang GT350R has some funky wing that looks like its hovering over the trunk. It almost has some ricey over tones to it but im sure people in the 80s thought the same thing about the XR's bi-wing.
That is a ricey looking wing, it doesn't really fit with the rest of the car. I'm not that surprised that they're doing a turbo v6 on the ford gt though. As long as they do it right it'll be fine.
Connor
'89 XR 254000 miles. Stock (until spring, then poor college student mods begin)
'99 Audi B5 A4 2.8 v6 (Technically my dad's, but he doesn't drive it)
Since I'm a Noob, i'll put an apology for dumb questions down here. I'm 19 and completely self-taught
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Re: Rebuilding an XR4TI

Post by Esteban »

Do NOT use teflon tape on the oil feed fitting. Many bad stories of it clogging up the oil passages in the turbo and frying it.
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John Brennan
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Re: Rebuilding an XR4TI

Post by John Brennan »

Very happy to see the return of the GT... can't wait to see what it does in competition! :headbang
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Re: Rebuilding an XR4TI

Post by boost_is_fun »

Esteban wrote:Do NOT use teflon tape on the oil feed fitting. Many bad stories of it clogging up the oil passages in the turbo and frying it.
I used tfe paste on a replacement oil feed fitting, since I couldn't get them to stop leaking any other way, teflon tape is broken up because of the tapered threads and doesn't work right, its also a bad idea for the reasons shown above.
Connor
'89 XR 254000 miles. Stock (until spring, then poor college student mods begin)
'99 Audi B5 A4 2.8 v6 (Technically my dad's, but he doesn't drive it)
Since I'm a Noob, i'll put an apology for dumb questions down here. I'm 19 and completely self-taught
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Re: Rebuilding an XR4TI

Post by cmanreinhart »

Esteban wrote:Do NOT use teflon tape on the oil feed fitting. Many bad stories of it clogging up the oil passages in the turbo and frying it.
boost_is_fun wrote:
Esteban wrote:Do NOT use teflon tape on the oil feed fitting. Many bad stories of it clogging up the oil passages in the turbo and frying it.
I used tfe paste on a replacement oil feed fitting, since I couldn't get them to stop leaking any other way, teflon tape is broken up because of the tapered threads and doesn't work right, its also a bad idea for the reasons shown above.


Thank you SO MUCH! For the tip (I think I would cry if my turbo blew) I will for sure use something else.... I suspect High Temp Loctite will work?
John Brennan wrote:Very happy to see the return of the GT... can't wait to see what it does in competition! :headbang
I am as well, I'm excited to see how it does in LeMans!
-Conner
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Re: Rebuilding an XR4TI

Post by boost_is_fun »

cmanreinhart wrote:
Thank you SO MUCH! For the tip (I think I would cry if my turbo blew) I will for sure use something else.... I suspect High Temp Loctite will work?
I'd be careful with loctite, it's supposed to be pretty permanent, and isn't really made for oil lines (i think). You can get TFE paste at pretty much any hardware store, its rated to 10,000 psi for gas and 2,000psi (i think) for liquids (might be the other way 'round). It's also rated to about 500 degrees. You can find it in the plumbing section and it costs about the same as a tube of loctite. It's a paste that gradually hardens but still stays as a viscous liquid, so its always removable, unlike loctite. I love the stuff, and have used it pretty frequently.
Connor
'89 XR 254000 miles. Stock (until spring, then poor college student mods begin)
'99 Audi B5 A4 2.8 v6 (Technically my dad's, but he doesn't drive it)
Since I'm a Noob, i'll put an apology for dumb questions down here. I'm 19 and completely self-taught
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Re: Rebuilding an XR4TI

Post by 2.3merkenjoyer »

That GT is super sexy... anyways, great job on the rebuild bud! I just turned 27 last weekend but I look 16 so... Enjoy it my friend, it speeds up, NO JOKE! :shock:

I have a 1989 Merk with 120,000 mi, did a similar build as you, engine jack, stand, lots of parts, all kinds of equipment sitting in my dads garage because of my addiction! :headbang I will post the whole build someday, it came out AWESOME! Oh, and it never ends with these cars, just so you know... worth the pride though! (sometimes I just sit in the car and marvel over how wonderful it is)

Do yourself a BIG favor and ditch that blue fel-pro rubber valve cover gasket and replace with updated gasket, which is rubber with metal reinforcement sandwiched in between. Its $50 but is reusable, last one you"ll ever buy. If you can't find the part # just message me. Look in FAQ section. The fel-pro gasket WILL leak oil, if not right from the start, eventually. Also, did you hone the cylinders before replacing piston rings? (dumb question but had to ask)

Now please post more pictures! Maybe even a video of the first start up!? Would love to see what that engine bay looks like now that the engines installed. Kick ass job dude!!

(2nd the PTFE paste on oil feed)

Btw, did you guys get any of the blizzard we got yesterday here in MA, 30"+ here, damn right I went for a drive!
1989 Merkur xr4t PIMP ECU, 24 PSI BOOST
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