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Thread: 1991 Dodge Spirit ES Turbo 5spd Project

  1. #1
    Slugmobile & MeanMini Caretaker Turbo Mopar Contributor wheming's Avatar
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    1991 Dodge Spirit ES Turbo 5spd Project

    There hasn't been a build thread on my '91 Spirit ES since the old SDML days. This car was built more than 20 years ago as the project started right after i purchased in 1996.

    I'll try to update more with the current build configuration, but it hasn't changed much in the last dozen or more years.

    The current effort has been to finally figure out why it was only intermittently starting, and the traveler was displaying a code. As it turns out, the 20 year old Ed Peters Viper Pump was bad.

    https://youtu.be/e4pyvrdN8Zs

    I just replaced with a GCA761, Walbro 255lph HP for the NSRT4, mounted in a TU101 pump module.
    What came out was mounted in the old style hanger.
    Old:
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    Also found the hose ruptured in the tank.
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    Here's the new pump, and module.
    The new TU101 module came with a pump, but the pump discharge was broken right off.
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    Both new pumps side by side:
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    Had to solder the wires since they both had different connectors:
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    Fully assembled module:
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    And even managed to get it all installed in the car!
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    I do need to try finding a new connector for the fuel pump. The outdide of the connector is broken and there is no locking clip. Is this connector used anywhere else on the car? It has a key on the bottom. Some of those other 2 wire connectors have them on the sides.
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    I'll have to get some fresh gas so I can test. I didn't want to reuse this old gas i removed. I replaced the fuel filter and a piece of fuel hose also.
    If i have time, I'll try to get some fuel tomorrow. I have some in a 5 gal jug, but can't remember where it came from. So I'll just use it in the mower.
    Last edited by wheming; 07-16-2018 at 09:22 PM.
    Wayne H.

    '91 Dodge Spirit ES 2.5L turbo 5spd
    '05 PT GT 2.4T HO autostick
    '89 Plymouth Acclaim 2.5L turbo auto, "Slugmobile" yes, THE Slugmobile!
    '89 Dodge Caravan SE 2.5L turbo auto, "Mean Mini" yes, Gus' Mean Mini! (Current best 11.7786@113.04 mph! - Jan 15th, 2017 Fayetteville Dragway, NC)
    MeanMini dragracing videos: https://www.youtube.com/playlist?lis...URZLB1RxGYF6vw
    and other cars, trucks and motorcycles
    https://www.youtube.com/user/SlugmobileMeanMini

  2. #2
    Supporting Member II Turbo Mopar Contributor Shadow's Avatar
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    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    Nice catch! Intermittent issues are often the hardest to find.


    Are you sure the pump was shot? Looks like the fuel hose is just old and worn out?


    I've actually never seen an MP S60 pump ever go bad. Closest is one that the sock came apart on and pieces of it went into the pump and jammed it.


    Whatever pump that's hiding in that sock looks too small to be a Bosch S60, they're pretty big monsters vs the stock pumps.

    Robert Mclellan
    http://www.youtube.com/watch?v=wambNdfnu5M
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  3. #3

    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    So if you have an old style hanger, do you have a matching old style tank with a "sump" in it? I would guess yes unless you were having stalling issues on turns. I bought a Daytona with blown engine that I believe was caused by the sump coming loose and fuel sloshing away from the pump on turns...

    So then the question would be, how well does the new style setup work with a sump?

    On the connector, when I last looked (~year ago) I didn't find one explicitly listed. Ended up getting a pig tail from a junkyard car. Looked through a couple cars before finding one in good condition.

  4. #4
    Slugmobile & MeanMini Caretaker Turbo Mopar Contributor wheming's Avatar
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    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    Quote Originally Posted by Shadow View Post
    Nice catch! Intermittent issues are often the hardest to find.


    Are you sure the pump was shot? Looks like the fuel hose is just old and worn out?


    I've actually never seen an MP S60 pump ever go bad. Closest is one that the sock came apart on and pieces of it went into the pump and jammed it.


    Whatever pump that's hiding in that sock looks too small to be a Bosch S60, they're pretty big monsters vs the stock pumps.
    Thanks Rob.
    The pump would not prime. I hit the tank a few times and got it to prime and start. In the video the car was running anf the pump stopped. Would not restart until i hit the tank again.
    The pump i removed was a Walbro GSS307.


    Quote Originally Posted by c2xejk View Post
    So if you have an old style hanger, do you have a matching old style tank with a "sump" in it? I would guess yes unless you were having stalling issues on turns. I bought a Daytona with blown engine that I believe was caused by the sump coming loose and fuel sloshing away from the pump on turns...

    So then the question would be, how well does the new style setup work with a sump?

    On the connector, when I last looked (~year ago) I didn't find one explicitly listed. Ended up getting a pig tail from a junkyard car. Looked through a couple cars before finding one in good condition.
    The tank is the stock 91, so there was no built in sump.
    What i found when mocking up on the van was the pump module would not install in a sumped tank.
    Wayne H.

    '91 Dodge Spirit ES 2.5L turbo 5spd
    '05 PT GT 2.4T HO autostick
    '89 Plymouth Acclaim 2.5L turbo auto, "Slugmobile" yes, THE Slugmobile!
    '89 Dodge Caravan SE 2.5L turbo auto, "Mean Mini" yes, Gus' Mean Mini! (Current best 11.7786@113.04 mph! - Jan 15th, 2017 Fayetteville Dragway, NC)
    MeanMini dragracing videos: https://www.youtube.com/playlist?lis...URZLB1RxGYF6vw
    and other cars, trucks and motorcycles
    https://www.youtube.com/user/SlugmobileMeanMini

  5. #5
    Slugmobile & MeanMini Caretaker Turbo Mopar Contributor wheming's Avatar
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    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    Here's a pic of the pump that was bad.
    Click image for larger version. 

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    Wayne H.

    '91 Dodge Spirit ES 2.5L turbo 5spd
    '05 PT GT 2.4T HO autostick
    '89 Plymouth Acclaim 2.5L turbo auto, "Slugmobile" yes, THE Slugmobile!
    '89 Dodge Caravan SE 2.5L turbo auto, "Mean Mini" yes, Gus' Mean Mini! (Current best 11.7786@113.04 mph! - Jan 15th, 2017 Fayetteville Dragway, NC)
    MeanMini dragracing videos: https://www.youtube.com/playlist?lis...URZLB1RxGYF6vw
    and other cars, trucks and motorcycles
    https://www.youtube.com/user/SlugmobileMeanMini

  6. #6
    Slugmobile & MeanMini Caretaker Turbo Mopar Contributor wheming's Avatar
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    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    Here's a shot of the tank inside. These were when i removed the pump. I cleaned the smsl debris out before installing new pump module.

    Click image for larger version. 

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    Click image for larger version. 

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    Wayne H.

    '91 Dodge Spirit ES 2.5L turbo 5spd
    '05 PT GT 2.4T HO autostick
    '89 Plymouth Acclaim 2.5L turbo auto, "Slugmobile" yes, THE Slugmobile!
    '89 Dodge Caravan SE 2.5L turbo auto, "Mean Mini" yes, Gus' Mean Mini! (Current best 11.7786@113.04 mph! - Jan 15th, 2017 Fayetteville Dragway, NC)
    MeanMini dragracing videos: https://www.youtube.com/playlist?lis...URZLB1RxGYF6vw
    and other cars, trucks and motorcycles
    https://www.youtube.com/user/SlugmobileMeanMini

  7. #7
    Supporting Member II Turbo Mopar Contributor Shadow's Avatar
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    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    I've never held a pump that was taken out of an actual Viper, so I can't really say.

    But the S60 Bosch pump was always called "Viper fuel pump" and it looks nothing like that! (Not to mention it ain't a Walbro!)

    Robert Mclellan
    http://www.youtube.com/watch?v=wambNdfnu5M
    10.04 @ 143.28mph (144.82 highest mph)
    Worlds fastest 8v MTX Shelby Charger
    Manitoba's Fastest 4cyl!
    8 valve, No Nitrous!
    New clutch combo is the SH!T!

  8. #8
    Slugmobile & MeanMini Caretaker Turbo Mopar Contributor wheming's Avatar
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    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    I could only find Viper fuel pumps on RockAuto up to 1996, which all showed inline pumps.
    So not really sure.
    GSS307 is listed as 255lph though.

    Like I said, this was bought 20 years ago, and it was touted as the best at the time. I was told it had silver windings and special bearings so it wouldn't wear out.
    Wayne H.

    '91 Dodge Spirit ES 2.5L turbo 5spd
    '05 PT GT 2.4T HO autostick
    '89 Plymouth Acclaim 2.5L turbo auto, "Slugmobile" yes, THE Slugmobile!
    '89 Dodge Caravan SE 2.5L turbo auto, "Mean Mini" yes, Gus' Mean Mini! (Current best 11.7786@113.04 mph! - Jan 15th, 2017 Fayetteville Dragway, NC)
    MeanMini dragracing videos: https://www.youtube.com/playlist?lis...URZLB1RxGYF6vw
    and other cars, trucks and motorcycles
    https://www.youtube.com/user/SlugmobileMeanMini

  9. #9
    Super Moderator Turbo Mopar Staff contraption22's Avatar
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    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    I've had two Mopar S60 pumps fail. Nether had many hours on them. But the had lots of time between uses.
    Mike Marra
    1986 Plymouth Horizon GLMF "The Contraption" < entertaining sponsorship offers
    Project Log:
    http://www.turbo-mopar.com/forums/showthread.php?69708-The-Contraption-2013-14&highlight=

  10. #10
    Slugmobile & MeanMini Caretaker Turbo Mopar Contributor wheming's Avatar
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    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    Well decided to just put in a few gallons of what i had here. Used about 1.5 gallons of what came out (was a few months old) and about 1.5 gals of the recent mower gas.
    Primed with the key a few times and reset the computer to prime some more times until i heard some load on the pump. It doesn't sound like the old pump, or the walbro in the van, but maybe because it is in that module/reservoir.
    Cranked about one revolutiin and started right up!

    Looking things over, and found no leaks, not even one drop.
    It does appear i have an issue with my O2 sensor because it doesn't seem to be moving around enough or matching the Cyberdyne A/F gauge. A/F gauge showing 8-9 lights, but O2v on DRB only showing like .46-.51 and not dancing around enough once warmed.
    Next week I'll get 5 gals of fresh gas and look into the o2 sensor some more. This just has the stock narrowband, and it has been in there a while! I think i have a new one for the 89 2.5T, but not sure if 91 was different plug.

    https://youtu.be/VLpa0mcePkw
    Wayne H.

    '91 Dodge Spirit ES 2.5L turbo 5spd
    '05 PT GT 2.4T HO autostick
    '89 Plymouth Acclaim 2.5L turbo auto, "Slugmobile" yes, THE Slugmobile!
    '89 Dodge Caravan SE 2.5L turbo auto, "Mean Mini" yes, Gus' Mean Mini! (Current best 11.7786@113.04 mph! - Jan 15th, 2017 Fayetteville Dragway, NC)
    MeanMini dragracing videos: https://www.youtube.com/playlist?lis...URZLB1RxGYF6vw
    and other cars, trucks and motorcycles
    https://www.youtube.com/user/SlugmobileMeanMini

  11. #11

    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    Switching to a newer style O2 sensor would be a good idea... 89 should be a 3-wire (O2 signal, 2 wires for heater). The newer style adds a ground reference wire for improved accuracy...

  12. #12
    turbo addict
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    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    Quote Originally Posted by c2xejk View Post
    Switching to a newer style O2 sensor would be a good idea... 89 should be a 3-wire (O2 signal, 2 wires for heater). The newer style adds a ground reference wire for improved accuracy...
    89 and newer have 4 wires o2 sensors.

  13. #13
    Supporting Member II Turbo Mopar Contributor Shadow's Avatar
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    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    Quote Originally Posted by wheming View Post
    Cyberdyne A/F gauge
    Had to lol when I read that!

    Another item I use to order by the dozen and have Zero left on shelf. (maybe I find some hiding away somewhere? ;P)

    I never had an issue tuning on the narrowband with the Cyberdyne Gauge like so many others seemed to.

    When I made the switch to WB and did a BtB check with both operating the Cyberdyne was right where I expected it to be all the time....

    Robert Mclellan
    http://www.youtube.com/watch?v=wambNdfnu5M
    10.04 @ 143.28mph (144.82 highest mph)
    Worlds fastest 8v MTX Shelby Charger
    Manitoba's Fastest 4cyl!
    8 valve, No Nitrous!
    New clutch combo is the SH!T!

  14. #14
    Slugmobile & MeanMini Caretaker Turbo Mopar Contributor wheming's Avatar
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    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    Quote Originally Posted by Shadow View Post
    Had to lol when I read that!

    Another item I use to order by the dozen and have Zero left on shelf. (maybe I find some hiding away somewhere? ;P)

    I never had an issue tuning on the narrowband with the Cyberdyne Gauge like so many others seemed to.

    When I made the switch to WB and did a BtB check with both operating the Cyberdyne was right where I expected it to be all the time....
    I agree.
    I still have a Dawes Devices version A/F gauge on Slug and like it much better because it looks at an even narrower voltage band! Really only interested in seeing .8v and higher.
    I had bought one to install on my Spirit, but never did.

    That Cyberdyne was high tech 25 years ago when i installed my first one on my 85 New Yorker turbo I had!
    Wayne H.

    '91 Dodge Spirit ES 2.5L turbo 5spd
    '05 PT GT 2.4T HO autostick
    '89 Plymouth Acclaim 2.5L turbo auto, "Slugmobile" yes, THE Slugmobile!
    '89 Dodge Caravan SE 2.5L turbo auto, "Mean Mini" yes, Gus' Mean Mini! (Current best 11.7786@113.04 mph! - Jan 15th, 2017 Fayetteville Dragway, NC)
    MeanMini dragracing videos: https://www.youtube.com/playlist?lis...URZLB1RxGYF6vw
    and other cars, trucks and motorcycles
    https://www.youtube.com/user/SlugmobileMeanMini

  15. #15
    Supporting Member II Turbo Mopar Contributor iTurbo's Avatar
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    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    Quote Originally Posted by wheming View Post
    Looking things over, and found no leaks, not even one drop.
    It does appear i have an issue with my O2 sensor because it doesn't seem to be moving around enough or matching the Cyberdyne A/F gauge. A/F gauge showing 8-9 lights, but O2v on DRB only showing like .46-.51 and not dancing around enough once warmed.
    Next week I'll get 5 gals of fresh gas and look into the o2 sensor some more. This just has the stock narrowband, and it has been in there a while! I think i have a new one for the 89 2.5T, but not sure if 91 was different plug.

    https://youtu.be/VLpa0mcePkw
    Any pictures of the car itself? I always liked the '89-'92 Spirit ES turbo models. I'm still kicking myself for not buying a very nice one locally long ago.

    You bring up an important point (IMO) about the A/F gauge. A lot of people hate on narrow-band A/F gauges, but I have found them to be invaluable as far as a quick check on the overall running of the car. Watching the bounce characteristic and knowing what is normal and what is not is important.....maybe more important than what it says at WOT even. It is a good indicator as to things running 'normal' for me at least, so I like to have one.
    87 Shelby Lancer #127
    91 Dodge Spirit R/T
    08 Dodge Caliber SRT-4
    86 Dodge Omni GLH Turbo

  16. #16
    Slugmobile & MeanMini Caretaker Turbo Mopar Contributor wheming's Avatar
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    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    Quote Originally Posted by iTurbo View Post
    Any pictures of the car itself? I always liked the '89-'92 Spirit ES turbo models. I'm still kicking myself for not buying a very nice one locally long ago.

    You bring up an important point (IMO) about the A/F gauge. A lot of people hate on narrow-band A/F gauges, but I have found them to be invaluable as far as a quick check on the overall running of the car. Watching the bounce characteristic and knowing what is normal and what is not is important.....maybe more important than what it says at WOT even. It is a good indicator as to things running 'normal' for me at least, so I like to have one.
    I'll have to get some fresh ones in its present condition, but looking at some old ones nearly makes me cry.
    Does anyone recognize the house and cars in the first pic?

    When I have some time, I'm going to try compiling all my old website pages into a Google sites.
    But here's the two pages that had the Spirit.

    web.archive.org/web/20080504104437/http://home.netcom.com:80/~w.heming/spiritpage.html

    https://web.archive.org/web/20080630...iritstuff.htmlClick image for larger version. 

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    Wayne H.

    '91 Dodge Spirit ES 2.5L turbo 5spd
    '05 PT GT 2.4T HO autostick
    '89 Plymouth Acclaim 2.5L turbo auto, "Slugmobile" yes, THE Slugmobile!
    '89 Dodge Caravan SE 2.5L turbo auto, "Mean Mini" yes, Gus' Mean Mini! (Current best 11.7786@113.04 mph! - Jan 15th, 2017 Fayetteville Dragway, NC)
    MeanMini dragracing videos: https://www.youtube.com/playlist?lis...URZLB1RxGYF6vw
    and other cars, trucks and motorcycles
    https://www.youtube.com/user/SlugmobileMeanMini

  17. #17
    Slugmobile & MeanMini Caretaker Turbo Mopar Contributor wheming's Avatar
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    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    Click image for larger version. 

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    Wayne H.

    '91 Dodge Spirit ES 2.5L turbo 5spd
    '05 PT GT 2.4T HO autostick
    '89 Plymouth Acclaim 2.5L turbo auto, "Slugmobile" yes, THE Slugmobile!
    '89 Dodge Caravan SE 2.5L turbo auto, "Mean Mini" yes, Gus' Mean Mini! (Current best 11.7786@113.04 mph! - Jan 15th, 2017 Fayetteville Dragway, NC)
    MeanMini dragracing videos: https://www.youtube.com/playlist?lis...URZLB1RxGYF6vw
    and other cars, trucks and motorcycles
    https://www.youtube.com/user/SlugmobileMeanMini

  18. #18
    Slugmobile & MeanMini Caretaker Turbo Mopar Contributor wheming's Avatar
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    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    Here are some more pics.
    Click image for larger version. 

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    Did an Acclaim tail light swap some years ago.
    Click image for larger version. 

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    Click image for larger version. 

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    I have the R/T seats.
    Click image for larger version. 

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    Engine bay
    Click image for larger version. 

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    Currently uses +20's and 2 cold start injectors.
    Click image for larger version. 

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    And a RRFPR
    Click image for larger version. 

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    Click image for larger version. 

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    Wayne H.

    '91 Dodge Spirit ES 2.5L turbo 5spd
    '05 PT GT 2.4T HO autostick
    '89 Plymouth Acclaim 2.5L turbo auto, "Slugmobile" yes, THE Slugmobile!
    '89 Dodge Caravan SE 2.5L turbo auto, "Mean Mini" yes, Gus' Mean Mini! (Current best 11.7786@113.04 mph! - Jan 15th, 2017 Fayetteville Dragway, NC)
    MeanMini dragracing videos: https://www.youtube.com/playlist?lis...URZLB1RxGYF6vw
    and other cars, trucks and motorcycles
    https://www.youtube.com/user/SlugmobileMeanMini

  19. #19
    Supporting Member II Turbo Mopar Contributor Shadow's Avatar
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    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    Wow, some Old School stuff going on right there!

    Looks like parking is pretty tight around your place Wayne....

    Robert Mclellan
    http://www.youtube.com/watch?v=wambNdfnu5M
    10.04 @ 143.28mph (144.82 highest mph)
    Worlds fastest 8v MTX Shelby Charger
    Manitoba's Fastest 4cyl!
    8 valve, No Nitrous!
    New clutch combo is the SH!T!

  20. #20
    Supporting Member II Turbo Mopar Contributor iTurbo's Avatar
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    Re: 1991 Dodge Spirit ES Turbo 5spd Project

    Quote Originally Posted by wheming View Post
    I'll have to get some fresh ones in its present condition, but looking at some old ones nearly makes me cry.
    Does anyone recognize the house and cars in the first pic?

    When I have some time, I'm going to try compiling all my old website pages into a Google sites.
    But here's the two pages that had the Spirit.

    web.archive.org/web/20080504104437/http://home.netcom.com:80/~w.heming/spiritpage.html

    https://web.archive.org/web/20080630...iritstuff.htmlClick image for larger version. 

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    Cool, thanks for sharing. Isn't that Gus's old "Blackie" in the first pic?
    87 Shelby Lancer #127
    91 Dodge Spirit R/T
    08 Dodge Caliber SRT-4
    86 Dodge Omni GLH Turbo

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