I bought a project 96 Saturn SC2 car. - Page 5

pinballlooking · 01-09-18, 08:53 PM

The reason I was replacing the timing cover was the other owner broke off the top right bolt ear.
They did not take out the middle bolt on the timing cover it is very hard to see if you don’t know it is there.
I used my band saw to cut the bolt ear off this nice shinny cover.
Today it warmed up so I broke out my welder and welded the cover bolt ear back on.

Top is welded (top bolt whole) bottom is before welding

We cleaned up the cam caps

Daox · 01-10-18, 08:41 AM

Very nice. How did you go about welding the aluminum?

pinballlooking · 01-10-18, 09:22 AM

I used my Hobart Mig 210 with spool gun. I made my Big Green Egg stand out of aluminum not that long ago. So I have welded a fair amount aluminum. This was thicker aluminum so it was not that bad to do.
I first cut off a bolt ear off and test welded it back on. That went well so I did the real one.

This saves getting a new one and that saves time and money. When I bought the spool gun I was hoping I could use it for other projects.

The only bummer is the one I has to fix was the dirty one. So my son is back to cleaning this one up.

pinballlooking · 01-10-18, 12:05 PM

I bought this valve tool the other day. The Saturn valve are down in the head and hard to get to.
This tool should make it much simpler.
Lisle 36050 Valve Keeper Remover and Installer Kit

https://www.youtube.com/watch?v=b1DmJQ4Fods

You don't have to use a hammer. You can just put pressure on it.

pinballlooking · 01-14-18, 01:02 PM

We ran the ridge reamer it had very little ridge.
The cylinders have been honed and the gasket surface was cleaned.
One step closer.

pinballlooking · 01-21-18, 11:06 PM

The valves are lapped. The head is cleaned up and the block is cleaned up.
I got the valve springs and retainers cleaned up and ready to install.

Block before and after

Head

ECTS was very bad I have a new one but this this is in bad shape.
(Coolant temp sensor in the head) this will make the car run very bad.
I have a new brass replacement.

Parts to rebuild the dog bone motor mounts.

jeff5may · 01-23-18, 08:32 AM

Yeah that coolant sensor was probably causing grief. A couple of my Saturn's had that problem. The one would try to overheat at drive through lines and stoplights. Always idled high around 1200 rpm and the radiator fan never turned on. At the time, nobody had a solid bronze sensor for a Saturn. I ended up using one for a cavalier or Malibu or something and it did wonders. Never tore up again.

While you have the block apart, take measurements of all the important stuff. These engines have super tight tolerances like a Honda. Especially the cylinders. If they are not all in spec, the (weaker than usual) rings will never seat, and the engine will let you know.

Somebody's gonna love or hate those dogbone inserts. If the stock ones were worn out at all, the new ones will make the pedal response much more like a trans am or Corvette. The tip mount stops the rattling and the other three keep the engine tight.

pinballlooking · 01-23-18, 10:12 AM

I will be measuring cylinders soon and checking ring end gap.
Just bought a set T-Bore Hole Gauges.

New ECTS

I will plastic gauging all the rod and main bearing caps.

Daox · 01-23-18, 06:12 PM

I once fixed a Saturn S series coolant temp sensor wiring. The wires going to the temp sensor just broke. The radiator fan was just running constantly.

pinballlooking · 01-29-18, 12:17 AM

The head now has valves/seals and lifters/cam shafts.

It is ready to go on the block. It is wrapped in plastic until then.
All the piston rods and main bearing caps are cleaned up.

One more step done.

I had two helpers today.

The T-Bore Hole Gauges are not good at all. Very hard to get a good reading form these.
I would not recommend getting theses.

01-09-18, 08:53 PM	#41
pinballlooking Super Moderator Join Date: Jun 2013 Location: SC Posts: 2,923 Thanks: 172 Thanked 564 Times in 463 Posts	The reason I was replacing the timing cover was the other owner broke off the top right bolt ear. They did not take out the middle bolt on the timing cover it is very hard to see if you don’t know it is there. I used my band saw to cut the bolt ear off this nice shinny cover. Today it warmed up so I broke out my welder and welded the cover bolt ear back on. Top is welded (top bolt whole) bottom is before welding We cleaned up the cam caps Attached Thumbnails __________________ Current project Aquaponics system , Passive Solar Greenhouse build To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Solar Install 12.5 Kwh- To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Mini Split installs - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. EV Chevy Volt - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts.

01-10-18, 08:41 AM	#42
Daox Administrator Join Date: Aug 2008 Location: Germantown, WI Posts: 5,525 Thanks: 1,162 Thanked 374 Times in 305 Posts	Very nice. How did you go about welding the aluminum? __________________ Current project - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. & To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts.

01-10-18, 09:22 AM	#43
pinballlooking Super Moderator Join Date: Jun 2013 Location: SC Posts: 2,923 Thanks: 172 Thanked 564 Times in 463 Posts	I used my Hobart Mig 210 with spool gun. I made my Big Green Egg stand out of aluminum not that long ago. So I have welded a fair amount aluminum. This was thicker aluminum so it was not that bad to do. I first cut off a bolt ear off and test welded it back on. That went well so I did the real one. This saves getting a new one and that saves time and money. When I bought the spool gun I was hoping I could use it for other projects. The only bummer is the one I has to fix was the dirty one. So my son is back to cleaning this one up. __________________ Current project Aquaponics system , Passive Solar Greenhouse build To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Solar Install 12.5 Kwh- To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Mini Split installs - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. EV Chevy Volt - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Last edited by pinballlooking; 01-10-18 at 12:43 PM..

01-14-18, 01:02 PM	#45
pinballlooking Super Moderator Join Date: Jun 2013 Location: SC Posts: 2,923 Thanks: 172 Thanked 564 Times in 463 Posts	We ran the ridge reamer it had very little ridge. The cylinders have been honed and the gasket surface was cleaned. One step closer. Attached Thumbnails __________________ Current project Aquaponics system , Passive Solar Greenhouse build To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Solar Install 12.5 Kwh- To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Mini Split installs - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. EV Chevy Volt - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts.

01-21-18, 11:06 PM	#46
pinballlooking Super Moderator Join Date: Jun 2013 Location: SC Posts: 2,923 Thanks: 172 Thanked 564 Times in 463 Posts	The valves are lapped. The head is cleaned up and the block is cleaned up. I got the valve springs and retainers cleaned up and ready to install. Block before and after Head ECTS was very bad I have a new one but this this is in bad shape. (Coolant temp sensor in the head) this will make the car run very bad. I have a new brass replacement. Parts to rebuild the dog bone motor mounts. Attached Thumbnails __________________ Current project Aquaponics system , Passive Solar Greenhouse build To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Solar Install 12.5 Kwh- To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Mini Split installs - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. EV Chevy Volt - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Last edited by pinballlooking; 01-23-18 at 11:07 AM..

01-23-18, 08:32 AM	#47
jeff5may Supreme EcoRenovator Join Date: Jan 2010 Location: elizabethtown, ky, USA Posts: 2,431 Thanks: 431 Thanked 619 Times in 517 Posts	Yeah that coolant sensor was probably causing grief. A couple of my Saturn's had that problem. The one would try to overheat at drive through lines and stoplights. Always idled high around 1200 rpm and the radiator fan never turned on. At the time, nobody had a solid bronze sensor for a Saturn. I ended up using one for a cavalier or Malibu or something and it did wonders. Never tore up again. While you have the block apart, take measurements of all the important stuff. These engines have super tight tolerances like a Honda. Especially the cylinders. If they are not all in spec, the (weaker than usual) rings will never seat, and the engine will let you know. Somebody's gonna love or hate those dogbone inserts. If the stock ones were worn out at all, the new ones will make the pedal response much more like a trans am or Corvette. The tip mount stops the rattling and the other three keep the engine tight.

01-23-18, 10:12 AM	#48
pinballlooking Super Moderator Join Date: Jun 2013 Location: SC Posts: 2,923 Thanks: 172 Thanked 564 Times in 463 Posts	I will be measuring cylinders soon and checking ring end gap. Just bought a set T-Bore Hole Gauges. New ECTS I will plastic gauging all the rod and main bearing caps. Attached Thumbnails __________________ Current project Aquaponics system , Passive Solar Greenhouse build To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Solar Install 12.5 Kwh- To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Mini Split installs - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. EV Chevy Volt - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Last edited by pinballlooking; 01-23-18 at 11:10 AM..

01-23-18, 06:12 PM	#49
Daox Administrator Join Date: Aug 2008 Location: Germantown, WI Posts: 5,525 Thanks: 1,162 Thanked 374 Times in 305 Posts	I once fixed a Saturn S series coolant temp sensor wiring. The wires going to the temp sensor just broke. The radiator fan was just running constantly. __________________ Current project - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. & To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts.

01-29-18, 12:17 AM	#50
pinballlooking Super Moderator Join Date: Jun 2013 Location: SC Posts: 2,923 Thanks: 172 Thanked 564 Times in 463 Posts	The head now has valves/seals and lifters/cam shafts. It is ready to go on the block. It is wrapped in plastic until then. All the piston rods and main bearing caps are cleaned up. One more step done. I had two helpers today. The T-Bore Hole Gauges are not good at all. Very hard to get a good reading form these. I would not recommend getting theses. Attached Thumbnails __________________ Current project Aquaponics system , Passive Solar Greenhouse build To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Solar Install 12.5 Kwh- To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Mini Split installs - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. EV Chevy Volt - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. Last edited by pinballlooking; 02-01-18 at 10:05 AM..