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Woober Goobers!
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Hope if Dave shows up at the next Danbo meet with the Saturn you don't try to open the hood and take a dump in the engine bay Chris! LOL!
 

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Garfield Rules
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9,144 Posts
Discussion Starter #22
Well I took a gamble on a junk yard engine and lost.....sort of. Got the "new" engine in and it has really low compression 50-60 PSI across the board. I put some oil in the cylinders and the #2 and #4 jumped up to over 120 but #1 and #3 were only getting to 70. Then I did a leak down test and it is leaking out of the exhaust valves. It has a 30 day warranty, but it will be more a hassle to pull it back out, rent another truck, haul it back to Columbia and get my money back or hope they got a better one. So i'm just gonna pull the head and rebuild it.
 

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Woober Goobers!
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Wait a sec....if cylinders #2/#4 come up in compression after putting oil in doesn't that point to ring/piston problems? And not valve problems? So rebuilding the head would take care of the other two cylinders but not 2/4?

What did you find with the original engine to be the problem? Wouldn't it be better to rebuild the original engine than the junkyard one?
 

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Garfield Rules
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9,144 Posts
Discussion Starter #24
Wait a sec....if cylinders #2/#4 come up in compression after putting oil in doesn't that point to ring/piston problems? And not valve problems? So rebuilding the head would take care of the other two cylinders but not 2/4?

What did you find with the original engine to be the problem? Wouldn't it be better to rebuild the original engine than the junkyard one?
Yes the oil sealed the rings of the 2 and 4 but i think that is cause 1 it sat for who knows how long and I soaked the pistons with carb cleaner to try and clean some of the carbon off. Ii think that may have taken some of the seal from the rings on those cylinders. The original engine had a bad rod bearing in the number 2 cylinder. It is at the junk yard now I turned it in for a core, so rthis junk yard engine is the only one I have right now.
 

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Garfield Rules
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Discussion Starter #25
Here's a little project i just started today. I got one headlight apart and just stuck the projector in there. I'm gonna have to get a different shrouds, and I want to paint the housing.
 

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Garfield Rules
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Discussion Starter #26
The budget build has gone off the rails. I finally pulled the head and the valves are extremely carboned up. But I did discover this

Since I was planning on pulling the pistons anyways. I've decided to pull the rest out and put it on an stand and do a full rebuild. I just ordered a dial bore gauge so I can get everything perfect and maybe get 100,000+ miles from this engine.
Meanwhile I'm working on other small mods. I added factory fog lights


and retrofitting projectors in the headlights

I mounted them to make sure the cut off line was level. Here is the finished product
 

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Garfield Rules
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9,144 Posts
Discussion Starter #27
So i got the engine rebuilt. got all new pistons cause on top of #3 being broken it had another crack and I found out it is a fairly common problem after Saturn redesigned them and made the top ring land smaller. plus the new ones already have the oil drain back holes the OE ones were lacking. Got a rebuild head it was cheaper to do that than to rebuild the one I had. Gonna drop it in today and finally get this thing on the road.


 

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get off my lawn
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it looks great, and a heck of a sweet job on the lights,,,
 

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Garfield Rules
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Discussion Starter #29
Thanks Tom.


SHE LIVES! It turned over 3 times and then fired right up. I am ecstatic right now. I drove it around the block and let it run through a couple heat cycles let the cooling fan come one and off twice. I got to pick up a couple qts of trans fluid it wasn't even on the dip stick.
 

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Woober Goobers!
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That engine block is so clean...did you send it out to get dipped or something?
 

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Garfield Rules
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Discussion Starter #31 (Edited)
That engine block is so clean...did you send it out to get dipped or something?
Ya that was not intended but worked in my favor. I took the block and crank to the machine shop to have the crank cleaned and polished and just to hone the cylinders. They said they will clean it to after honeing. Went to picked it up and they had coated the out side with some sealant or something. Only charged my $50 for the whole job. I'm definitely using that machine shop again.
 

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Woober Goobers!
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Still zipping around with the new engine? How's it running so far. Put any miles on it?
 

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Garfield Rules
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Discussion Starter #33
Still zipping around with the new engine? How's it running so far. Put any miles on it?
It's been running great. I've put almost 200 miles on it so far. The trans seems to have a couple issues I have to get sorted out. It sometimes slips going into 3rd, and the brakes need some attention. I had one leak from the radiator petcock but got that changed out and all is well there, but no other leaks. I'm back on the road and should be back Saturday I need to go to the junk yard and get a few things.
 

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Garfield Rules
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9,144 Posts
Discussion Starter #34
Engine has been running fantastic. I had a issue with the cluster lights not coming on. I figured it was just blown out bulbs so I replaced them and it still didn't work. Also my fuel gauge wouldn't show full after I filed up. I figured something was up with the cluster, so I got a new one from a Saturn Vue. I filed up before putting it in and the old one was between 1/3 and full. this one went straight to full.
 

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Registered
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13,702 Posts
We have had good luck with wife's 07 Ion, kind of like it but the instrument panel in middle of dash still takes some getting used to LOL!

Have had many of my courier buddies drive Saturn's and they all loved and swore by them, much more than Toy's and Honda's. Although no one ever touched my 01 M lol!
 
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