Project Saturn SW2

Actually, looks like the 99 still had the first clutch design:

http://www.saturnwiki.net/index.php/Swap_Guide#Clutch

Yea they didn't go to the more horrible clutch design until model year 2000. And also, looking at the header on your engine, that factory header you bought won't fit, unless you get the flange from the cast manifold that's on there cut off and welded to the header. '91-early '99 had 5-bolt exhaust headers, late '99s-'02 had 9-bolts. Hooray for mid-year changes.

Twin_Cam wrote: Yea they didn't go to the more horrible clutch design until model year 2000. And also, looking at the header on your engine, that factory header you bought won't fit, unless you get the flange from the cast manifold that's on there cut off and welded to the header. '91-early '99 had 5-bolt exhaust headers, late '99s-'02 had 9-bolts. Hooray for mid-year changes.

Look closely. His car has a 5 bolt head with the 9-bolt manifold on it

ProDarwin wrote:

Twin_Cam wrote: Yea they didn't go to the more horrible clutch design until model year 2000. And also, looking at the header on your engine, that factory header you bought won't fit, unless you get the flange from the cast manifold that's on there cut off and welded to the header. '91-early '99 had 5-bolt exhaust headers, late '99s-'02 had 9-bolts. Hooray for mid-year changes.

Look closely. His car has a 5 bolt head with the 9-bolt manifold on it

its a 1998 engine best i can tell so yes, 5 bolt head.

Well i figured i would drop in and give an update:

• transmission was pressure washed and cleaned as best i could. Had and still has "liver spots" in the aluminum. Ill deal with it. Still have to clear coat it for some zing and protection.

• engine was cleaned with much cleaner, tooth brushes/ acid brushes, and spent so much time on it. Still however there are stains? in the aluminum. Clear coated the engine, black spray paint on the accessories. I think it came out pretty good. Dunno if im using that header yet or not. No provision for air pump like the other one.

• Cleaned up the intake manifold and spruced it up a bit. Turned out better then i thought it would. Im happy

• Also the engine bay was totally cleaned out/up and then i painted everything. This pic is not the greatest but you get the idea.

BIG NEWS Also put in my order for all the engine related parts. They should be comin in by the weekend

Unfortunately i will be out of town this weekend...

But now that everything has been overboardly cleaned up things can start going together.

Also i mentioned that i clear coated some parts earlier. I have done this on many cars at this point and it always works well. Just some Krylon/ Rustoleum Clear spray paint and spray over well anything. It keeps things shiny and clean looking and protects grime from getting into the pores of the metel and discoloring it. Well at least this is my theory. Like i said it keeps things looking fresh and clean. I have done, brake master cylinders, A/C hard lines, engine blocks, trans cases, engine accessories. Never had any bad side effects.

Anyhow thats the latest update.

Sounds good can't wait for the next update

FYI, on a '99 you can remove the airpump as only some '99s had it. Just run a non-airpump computer and throw that crap in the trash.

This is awesome. You're doing everything I wanted to do to the Saturn I inherited, only you have the garage space and free time to do it.

This is def awesome. Makes me want a Saturn as a daily beater. Better on the MPGs too.

ProDarwin wrote: FYI, on a '99 you can remove the airpump as only some '99s had it. Just run a non-airpump computer and throw that crap in the trash.

Hmmmm. interesting never heard this. More info/link? Is this something i can use a Tech2 on to "turn off"?

also thought of throwing in a manual steering rack. Pros/Cons?

Declutters the engine bay....

All i need to do is take out the old rack, pump, lines and swap in the manual rack.?

I'm not too knowledgeable about the air pumps - I've never done it myself. I know it can be done though, even with a simple reflash. Not sure if a Tech2 can do it or not:

http://www.sixthsphere.com/forum/showthread.php/60515-Removing-air-pump

http://www.sixthsphere.com/forum/showthread.php/71791-2000-PCM-ECU-Model-Numbers

The manual rack has a terrible steering ratio.

The one in your car is 3.0 turns lock to lock The manual is 4.0 The SC2 rack is 2.6

You can also de-power the rack and run a powered rack as a manual, but I prefer to keep the PS.

ProDarwin wrote: You can also de-power the rack and run a powered rack as a manual, but I prefer to keep the PS.

This. Just loop the lines out of the rack, and remove the pump. Not sure what kind of belt nonsense you'll have to deal with, of course.

Took off the side cover from the transmission and was relieved to see that my gears are bolted on and not pressed on.

SO----> im swappin out 5th gear for one from a SOHC engine/trans car for lower RPM on highway Oh and cleaned stuff up a bit

Also the first batch of parts came in: cooling hoses clutch, hydraulic system stuff, water pump/tensioner, tune up stuff (plugs, wires, etc) rebuilt alt and starter and who knows what else

While you have that trans 1/2 apart, yank the diff out and weld the pin.

ProDarwin wrote: While you have that trans 1/2 apart, yank the diff out and weld the pin.

This. It's the Achilles heel of Saturn transmissions.

Good call on the SOHC 5th, too. A friend of mine did this to his SC2, and was instantly over 40mpg on the highway. Not quite as good mileage as the full SOHC setup, but darn close. Goes to show that most of the SOHC's fuel economy advantage is in the gearing rather than the motor. Sure, it'll be a dog if you floor it in 5th, but that's just a convenient excuse for blipping a downshift.

Is that an Informative Canoe?

lol I realize now that once the canoe post is gone, my post seems entirely irrelevant - nothing to see here, carry on

UPDATE:

This past saturday i was able to clean the oil pan sealing surface and also the underside of the block.

Tonight, i was able to throw some rtv on it and put it all together. Torqued it to spec and everything was good.

Also was at pull a part on friday and got my 5th gear swap gears for $8. Tonight i also installed that into the trans, resealed it and torqued it and all was good.

Productive night. No pictures though...sorry.

Moving along, a bit slow but its going

Well today i had a day off so off to the garage to get some work done.

Threw together the the tensioner, idler pulley, new front crank seal, water pump, thermostat and rebuilt alternator.

Also installed the intake manifold

Then went to the back of the motor and installed a new flywheel, pressure plate and all that jazz.

Got the trans prepped for install too. New throw out bearing and all cleaned up and ready to drive.

Back to the garage

When you finish playing with everything else, don't forget to get a pair of SEATS!!!! Saturns were made to be inexpensive people movers- with the emphasis on inexpensive-so comfortable seats weren't even considered. Nice work so far.

^I think that's a personal preference thing. My butt has done probably 200K miles in Saturn seats and never had an issue. I did put a Sparco Sprint in my 94SL2 and it was way more uncomfortable than the stock seats were.

Note that the Sx1 seats and Sx2 seats are different. Sx2 seats have adjustable lumbar and butt support.