Wrench (1k)  Turbo System & Motor Build
  
Starting
The Motor Build

Click the thumbnails below to view a larger-sized image.
  

 
After
receiving the motor, it was stripped and the block was taken to small local machine shop.  Since I wanted to minimize, or avoid completely, the amount of machining necessary for this build, the owner of the shop give the bores a close inspection and measurement.
  

 
Since the motor had less than 20k on it, everything looked and measured as good as I expected.  If you view the larger photo, you can see the bore size measurements written on the deck.  A late model block ('98 and up) was intentionally selected because it was engineered to be significantly stiffer than models of prior years (as reported by several Saturn engineers).
  

 
To help the new rings seat properly, the cylinders were given a hone.  The tool was purchased for around $20 from a local Autozone, and good honing instructions were found HERE.
  

 
The process doesn't take very long, and if you follow the instructions, the end result looks great.
  

 
After I was sure that all work to the block was finished, it was taken to the local hose-it-yourself car wash.  I first hit it with a can of degreaser, and then blasted it with the high-pressure spray while rotating it on the engine stand.  Ten miles at 70 mph in the back of the truck followed up by an air hose dried it, and the cylinder liners were wiped down with engine oil to keep them from rusting.
  

 
A DOHC head was donated by a buddy who is a Saturn tech.  It came off a motor with a snapped timing chain and was in need of some service and TLC, but the price was right.  The tech installed a few new valves out of his spare parts drawer and gave everything else a close look and a clean bill of health. 
  

 
Here you easily see the difference between a stock piston rod and a Crower forged rod.
  

 
With the help of a ruler, it is easy to see the dish in the JE piston.  Use of these should lower the compression ration to around 8.5:1, which is very friendly to forced induction.
  

 
The Crower rod & JE piston combo sure looks nice.
  

 
I've decided to use a crankshaft from a '99+.  They're heavier, and from what I've heard from more than one Saturn engineer, stiffer and stronger.  That, combined with reduced harmonics due to better balance, should go a step further in prolonging the life of the bearings.  You can see the differences in the crankshafts in the photo - lightweight 93+ model is on top, and the heavier 99+ is on the bottom.
  

 
After the degreasing and pressure wash, the block looked sparkly-clean.  Here's a view of the underside prior to bearing and crankshaft installation.
  

 
I wanted to do a quick check on the fit of the oil cooler sandwich adaptor.  The design will allow the inlet/outlet ports to be positioned in any direction, and a couple of angle fittings will help keep the lines very close to the bottom of the motor.  For an item not specifically made for this car, the adaptor looks like it will fit and work perfectly.
  
  
Ok, it was time to switch gears - the motor internals will be put aside for a while in order to start work on everything that is external.


  

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