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 Post subject: New AB GSR Project
PostPosted: 09 Nov 2013, 01:15 
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Your car: 1985 AB GSL-R
1988 Starion GSR-VR
0-PSI wrote:
Allow me to introduce another forgotten 80's hatch saved from rotting away in the wrong hands or an early grave at SIMS Metal. In this case, a 1985 AB Cordia GSR which I picked up in November of last year. Whilst on the hunt, I came across this example on eBay & immediately made contact with the owner. It was a local car with the 1 owner since new & completely unmodified. The perfect base for a freshen up & a return to it's former glory.

For those of you who haven't come across my other AB Cordia build thread, it has now been abandon & used as a parts car for this new project.

Moving along, I had already arranged to check it out with the owner a week before the auctions end to get an idea of the extent of the rust & mechanical issues which was the main reason he was letting it go. Regardless of it's downfalls, I bought with the intentions of restoring to an extent & rebuilding.

After the initial start-up & test drive it was straight away apparent that the tired 4G62 was sick - unstable idle, 0 boost, noisy driveshafts, stalling, missing & smokey, leaky injectors & the list continued. Still mostly common issues. Despite this, it made the 30 minute drive back home + fuel stop. Once she was up & going & sitting on a consistent speed it was smooth sailing. And everything worked, including the ice cold A/C.

This would be the last day of it's current running condition.

After taking ownership I let it sit for a good few months as I focused on getting my other car up to scratch. Fast forward to June of this year I was ready to get stuck back into it again. As it goes, I got more done in as little as a week than I have in almost the 12 months of owning it. Before going on a hiatus though I had already started pulling the engine down & had the head rebuilt. So all that was left was a good days work of disconnecting lines & the shitload of vacuum hoses, inlet manifold & engine mounts for the bottom end ready to be removed.

As of today, I'm going through the 'what should be' a relatively short process of restoring engine parts. However I certainly chose the best month to be painting with Melbourne's cold & wet Winter which has dragged things out a bit. Nonetheless, I have almost a car load of refurbished parts now. The bottom end has been removed however & now waiting to be carted off to be rebuilt.

Pre-purchase auction photos:

Image

Image

Image

Image

Image

Modifications/Maintenance List:

Exterior:
- Refurb'd bumpers & rear apron
- Spare refurb'd GSR front lip fitted
- Spare refurb'd front tow hook fitted
- New aftermarket headlights
- Original side decals

Engine/Maintenance:
- Refurbished engine-bay parts & components (90% complete)
- Reconditioned cylinder head
- New brake master
- New Gates water pump [05/02/15]
- Rebuilt/high flowed TC06
- New PCV valve
- New coolant temp sensor
- Replacement stock exhaust manifold
- Gates accessory belts [07/07/14] & timing belts [05/02/15]
- New rack boots

Exhaust:
- Stock exhaust

Gearbox/Driveline:
- New Exedy MBK-6276HD clutch [05/02/15]
- Flywheel machined [30/01/16]
- Reconditioned drive shafts [04/02/15]

Brakes:
- TN Magna front brake upgrade: RDA slotted & dimpled front rotors & TRW pads [17/08/14]
- RDA rear drums & shoes [01/09/14]

Suspension:
- SuperPro front bush kit [07/07/14]
- Font lowered King springs & Monroe shocks [23/06/14]
- Custom strut tower brace [23/06/14]

Wheels/Tyres:
- Polished 14" AC wheels 195/65/14 tyres
- GMB rear wheel bearings

Interior:
- AB interior
- Magna rear view mirror

Build Period: Early November 2013


The AB GSR shell was scrapped as of 2015 when it was used as a donor car for the now GSL to GSR swap.

1985 AB Cordia GSL:

Long term restoration project which started in 2011. Family owned car since the mid 90's, which my grandfather bought for my grandmother.

Off the road for 2 years due to a minor front end accident between 2009-2010, it was my duty to save it from being scrapped as it's then current state was completely salvageable.

It is now undergoing a full GSR conversion.

Modifications/Maintenance list as of [19/01/16]

Exterior:
- Genuine FOHA rear spoiler [13/02/16]
- NOS Mazda yellow fog light kit complete with light covers
- New windscreen & trim clips
- GSR front tow hook
- GSR front lip
- Factory mud guards
- Window tint
- New aftermarket headlights
- Arctic white halogens w/ heavy duty harness

Engine Type:
- 4G37 to 4G62T engine conversion

Engine Mods/Maintenance:
- One-off custom stainless water pipe [22/02/16]
- Reconditioned head [--/--/15]
- New OEM AB injectors
- New aftermarket head gasket
- New OEM valve cover gasket
- New OEM timing belt tensioners
- New OEM crankshaft seal [31/01/16]
- New OEM rear main seal [03/02/16]
- New OEM rear main seal gasket [23/02/16]
- New OEM turbo oil return tube gaskets [03/02/16]
- New 35mm Welch plugs [04/02/16]
- New brake master
- New Gates water pump [05/02/15]
- Rebuilt/high flowed TC06
- New PCV valve
- New coolant temp sensor
- Gates accessory belts [07/07/14]
- Gates timing belts [05/02/15]

Gearbox/Driveline:
- New Exedy MBK-6276HD clutch [05/02/15]
- Flywheel machined [30/01/16]
- Cable clutch retained
- New OEM input shaft seal
- Reconditioned drive shafts [04/02/15]

Exhaust:
- Factory GSR exhaust system / cleaned rust-treated & painted

Brakes:
- New master cylinder
- TN Magna front brakes w/ RDA slotted/dimpled rotors & TRW pads
- New RDA rear brake drums & shoes
- New GMB rear wheel bearings

Suspension:
- Rebuild power steering rack [03/03/16]
- New tie rod ends
- New OEM rear trailing arm grommet
- Monroe GT front struts & rear shocks
- King springs front & Pedders rear

Wheels/Tyres:
- Factory 14" AC wheels
- 195/65/14 tyres

Interior:
- AB/AC GSR interior
- AA GSR steering wheel
- Factory air con (added)
- Factory power windows w/ Starion switches (added)
- GSL door lights w/ Magna red lens covers (added)
- Magna rear vision mirror
- Remade boot floor

Build Period: Mid 2011

In it's original state:

Image

Cheers,
Mike


Last edited by 0-PSI on 05 Jun 2016, 11:24, edited 34 times in total.

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 Post subject: Re: New AB GSR Project
PostPosted: 09 Nov 2013, 02:01 
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1988 Starion GSR-VR
Introduction aside, I have spent the last few days really giving this a massive clean up inside & out. The months the car wasn't driven it must have been sitting under & tree with the windows open. Interior filthy but cleaned up nice & in good condition too aside from the major bolster tear on the drivers seat. So.. Anyone selling an AB drivers seat??

Next was the door jambs & exterior. Lots of moss, minor surface rust & caked on dirt. I still haven't quite finished 100% as I've been going from cosmetics to mechanical trying to fit as much in one day as a shift worker possibly can.

The LHS tail light had a rough sikaflex job with it oozing out the sides & onto the lens. Removed, cleaned up & killed some rust while I was at it too (under the lower left corner of the light, usual rust spot I think..)

One thing I can't handle looking at is the Cordia's crumbling, falling apart rear view vision mirrors. So off to the wreckers today & got myself another mirror from a TP Magna (nice black casing) one of my more favourable interior mods, sad but true :lol: it was also a good opp to remove the old e-TAG holders sitting so ugly on the windscreen.

Couple of before photos to keep this update interesting!

Knew I kept a spare for a reason

Image

Wheel caps before some black paint treatment

Image

Rocker cover gasket kit & Magna mirror

Image

Few basic replacements (no coolant visible, water looks slightly on the rusty side...)

Image


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 Post subject: Re: New AB GSR Project
PostPosted: 09 Nov 2013, 08:59 
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Your car: DOHC 2.3 VR4 85 AB GSR
Immaculate Stock 86 AC GSR
Well done Mike...........will be keeping an eye on progress.


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 Post subject: Re: New AB GSR Project
PostPosted: 09 Nov 2013, 19:01 
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1988 Starion GSR-VR
Thanks Andrew. Hoping to make some progress on it each day, if all goes to plan I'll take it in for the roadworthy in another month.


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 Post subject: Re: New AB GSR Project
PostPosted: 09 Nov 2013, 19:11 
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1988 Starion GSR-VR
Ran across another minor problem today to delay setting the TPS.. not getting any correct readings on the multimeter even after adjusting it in either direction I decided to remove it & have a look inside only to find this:

Image

Snapped clean off, no wonder turning the TPS had no effect. So I've got it glueing overnight until I place it back onto the shaft & have another go at setting it right tomorrow.


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 Post subject: Re: New AB GSR Project
PostPosted: 09 Nov 2013, 20:31 
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Your car: DOHC 2.3 VR4 85 AB GSR
Immaculate Stock 86 AC GSR
Those shafts are ABS plastic............very hard to glue back without re-breaking......only thing I have found for plastics is Rapid-Fix 2 part superglue..........I have many spares.......should I just send you a box?

Here is your completed cross over pipe, bare metaled, etch and primed :

Image

Image

I included a new seal............nice and tight in my TC06 housing:

Image

Sorry about the small dent........didn't see it until it was painted. :(


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 Post subject: Re: New AB GSR Project
PostPosted: 10 Nov 2013, 01:10 
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1988 Starion GSR-VR
Andrew that looks sensational! :mrgreen: no worries about the dent, the finish on it is just awesome! And maybe a few spares would come in handy for the TPS if you have some I'll gladly throw in some more cash on top.

I'll know tomorrow if the plastic holds up after fiddling around with adjusting, fingers crossed.

..Really looking forward to getting that pipe in the mail now :mrgreen:


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 Post subject: Re: New AB GSR Project
PostPosted: 11 Nov 2013, 19:24 
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1988 Starion GSR-VR
Changed the fuel filter, fitted new vac lines & threw some fresh plugs in today while putting the TPS back together. Still haven't adjusted it per factory setting but just to have the idle close to normal. It now revs freely without any flat spot & driveability has improved drastically. Still not making boost however...

I also checked for error codes & received this:

2. Ignition Pulse
3. Air Flow Sensor
5. Throttle Position Sensor
6. ISC Motor Position Switch

I can understand I may getting 5 & 6 due to not having the TPS in 99.9% order, but where to start with the ignition pulse? And the air flow sensor, possibly just needs a clean? I've yet to check it anyway. Are they common to become faulty?


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 Post subject: Re: New AB GSR Project
PostPosted: 11 Nov 2013, 19:37 
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Your car: DOHC 2.3 VR4 85 AB GSR
Immaculate Stock 86 AC GSR
Humm.......can't see why you have error code 2 if the car is running, this is the "pulse" from the coil........the airflow sensors do bugger up, cleaning them may help.......but, with your split induction pipe this error may still remain, mainly due to extra air bypassing the flow meter causing the engine to run rich.

I would set the TPOS remove the battery lead and re-check error codes...........it's time consuming but worth it in the end.

If you still don't have boost check the EGR valve that it's not stuck open, the one way valve to the gearbox and check the brake hose for splits on the manifold connection.

A quick and easy way to tell is remove the wastegate rubber hose, plug it at the compressor end, then drive...if boost cut doesn't happen....then suspect the turbo. (May have a cracked exhaust housing or seized wastegate)


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 Post subject: Re: New AB GSR Project
PostPosted: 14 Nov 2013, 20:29 
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1988 Starion GSR-VR
Had some relatively normal weather in Melbourne today so I made the most & got some things done.

Removed & fully cleaned the EGR

Image

After:

Image

Repainted crossover pipe thanks to Andrew, fitted with new seal. Looking great! Also fitted a new silicone hose & new PCV valve as seen. Currently also waiting on a new coolant temp sensor.

Image

Fixed the damage on the rear apron where it had been hit now ready for colour more than likely in satin black

Image

Front lip & side pieces also repainted & ready to be reinstalled

Image

Also picked up this old Blitz boost gauge, still need to run through cabin & mount somewhere discreetly possibly in the space next to the cigarette lighter.

With the car at normal operating temps I'm getting 70 cmHg, not sure if this vac reading is a little high?

Image

More painting to come tomorrow as the weather improves, updates will follow!


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 Post subject: Re: New AB GSR Project
PostPosted: 14 Nov 2013, 20:41 
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Immaculate Stock 86 AC GSR
Great progress Mike..........with your boost gauge is the engine running in that pic?

If so it's showing 19 cm/hg which is about right.......if it's off then the needle should read 0.

Loving your work........keep it up. :)


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 Post subject: Re: New AB GSR Project
PostPosted: 14 Nov 2013, 21:03 
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Cheers Andrew :D like I've said before your build thread for the AC is great to try & attempt to keep the standards & inspiration high for my own.

All of a sudden the needle is stuck on 19 cmHg now when the engine is off, I'm pretty certain it was on 0 when I picked it up, could be wrong though my memory is shot! With the engine cold it's dead on 60 cmHg, once warmed up it'll move to 70. So I guess if the needle is stuck in the wrong position & it's out by 19-20, taking it to 50 cmHg is that around normal?


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 Post subject: Re: New AB GSR Project
PostPosted: 14 Nov 2013, 21:19 
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No........I reckon that gauge is stuffed.....normal engine vacc should be between 20 -25 cmHg........can't see how your reading is sooooo high.

Does the needle remain steady or does it move around?


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 Post subject: Re: New AB GSR Project
PostPosted: 16 Nov 2013, 00:13 
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I got the needle reading back on zero today & re checked engine vacc, it's now sitting on 50 cmHg? Maybe it'll drop further once I set the TPS?

The needle keeps steady however there's a bit of a miss on idle every 10 seconds or so and as you'd guess the needle moves with it


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 Post subject: Re: New AB GSR Project
PostPosted: 16 Nov 2013, 17:15 
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There is something wrong there.

Give the engine a compression test.


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 Post subject: Re: New AB GSR Project
PostPosted: 18 Nov 2013, 20:50 
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Will be giving it a compression test tomorrow arvo & get back with the results... 28 degrees here today got a few more things done mostly more painting & cleaning up.

Front bar cleaned up & painted... the rear bar & lower apron are also back on no photo yet.

Image

Parker lights taken apart & cleaned, the usual dirt & grime build up around the edges does my head in to look at

Image

Aftermarket headlights added which I was lucky to have picked up with the new turbo & injectors, spare front lip & side pieces also fitted

Image

As well as a cleaned up & painted tow hook in HSV gold

Image

More to come tomorrow...


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 Post subject: Re: New AB GSR Project
PostPosted: 18 Nov 2013, 21:05 
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Immaculate Stock 86 AC GSR
Nice one Mike...........how did you remove the lens from the park lights without breaking them?

These are usually glued together with a hardening compound.

Bumper looks like new!


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 Post subject: Re: New AB GSR Project
PostPosted: 18 Nov 2013, 21:40 
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1988 Starion GSR-VR
Surprisingly the lens came off with next to no effort! Slight pry of the flat head on either side & they separated, may of just gotten lucky that they didn't break but really didn't feel like these lens was bonded all that well.

Thanks :) The bumper was in even better condition than the one on the GSL, minimal gouges & marks still some imperfections but it came up really well


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 Post subject: Re: New AB GSR Project
PostPosted: 20 Nov 2013, 17:14 
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1988 Starion GSR-VR
Compression test results...

Dry test:
1- 130
3- 140
4- 90
2- 125

Wet test:
1- 140
3- 150
4- 160
2- 165

Tested a few times & each time came back with very similar if not exactly the same readings. Guess it's time to start taking this thing apart to see what is going on... better yet, start putting money aside for a rebuild or replacement engine.


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 Post subject: Re: New AB GSR Project
PostPosted: 20 Nov 2013, 17:31 
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Immaculate Stock 86 AC GSR
Cylinder 4 either needs rings or it's broken a ring land from those readings.


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