Recent Topics
Proud of My Dad
by Phishin
10/31/14 07:06 AM
google earth does not show Panoramio photos
by Trav
10/31/14 07:06 AM
Philips 9012 in '05 Corolla?
by lukejo
10/31/14 06:16 AM
new GM 4.3L V-6
by used_0il
10/31/14 03:02 AM
2015 Accord Hybrid
by Ewag2983
10/31/14 02:24 AM
Sausage
by Charlie1935
10/31/14 12:00 AM
Storing Car in Storage Facility
by cutlassvillager
10/30/14 11:51 PM
04 santa fe 3.5l, info re oil/miles is unknown
by chado_skins
10/30/14 11:47 PM
Mobil 1 0w-40 OK for Winter in VQ35HR?
by cutlassvillager
10/30/14 11:29 PM
Pardner Protector
by buck91
10/30/14 10:54 PM
Vortec 4.3l v6 oil recommendation
by gmgoodwrencher
10/30/14 10:53 PM
Oil change or wait??
by Rolla07
10/30/14 10:38 PM
Newest Members
Thourun, Zach72, SandCastle, ymc226, redwoods73
51758 Registered Users
Who's Online
84 registered (2sld3kf2bt, afoulk, 3800Series, 3311, 943kgt, 9 invisible), 1107 Guests and 143 Spiders online.
Key: Admin, Global Mod, Mod
Forum Stats
51758 Members
64 Forums
221448 Topics
3501967 Posts

Max Online: 2862 @ 07/07/14 03:10 PM
Donate to BITOG

Page 2 of 5 < 1 2 3 4 5 >
Topic Options
#3313593 - 03/16/14 11:54 AM Re: Project Malibu resurection: Death and rebirth [Re: cptbarkey]
The_Eric Online   content


Registered: 03/31/10
Posts: 3381
Loc: Iowa
Originally Posted By: terry274
There is a vent in the passenger side of the trunk, behind the carpet, that tends to leak. Check the jack and spare tire for rust. It is difficult to stop the leak, apparently the rear tire sprays water into the vent.
I never did get it to stop leaking on my daughters car.


Terry, thanks for the tip! I'll be sure to look into that.






Originally Posted By: Kruse
Originally Posted By: The_Eric

I've made some purchases through Rock Auto and Ebay, as well as the machine shop, including rings, a piston, connecting rod, full gasket set, timing set with GMB water pump, head bolts, O2 sensor, belt, tensioner, thermostat, t-stat housing (water neck) and a few other things. Close monitoring of Rock Auto's shipping (thanks to the warnings of sharp eyed BITOG members) made sure I didn't get bent over the barrel as well as comparison shopping and discount codes helped keep the cost down.


I avoid ebay for engine parts because the seller might do a rebox. And unless the project that I work on has to time table, I'm starting to avoid RockAuto. Most parts that I now order from RockAuto on Saturday or Sunday don't make it to my doorstep for almost a week. They are also starting to push the "DNJ" brand of engine components instead of the older name brands.
Have you ever used Northern Auto out of Sioux City? (Google them) They have a nice catalog they can mail you, a usable web site, have excellent phone service (just talked to one of their guys yesterday), and they ship promptly. They also use name brand parts on their rebuild kits.


I'm kind of rolling the dice on this one, hoping that the DNJ products are just major manu reboxes. Looking at the file photo of their full gasket set makes me think so... Time will tell.

Thank you for the heads up on Northern Auto, I had heard about them and have since forgotten. I will keep them in mind for future purchases.


Originally Posted By: cptbarkey
i love these threads, keep us updated!

GMB is a very good brand, i've ordered a few timing belt kits with GMB parts and they work well.


Will do! I too have heard good things and had a few good experiences with GMB, and hopefully this won't be any different. Especially since it is timing chain driven. I sent a message to the seller on e-bay asking the country of origin- the reply was Korea. Certainly better than China...
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

Top
#3313802 - 03/16/14 02:12 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
tswm Offline


Registered: 02/13/14
Posts: 55
Loc: California
Wonderful project, please keep us updated on your progress.

I have a question.
What would be your approach in dropping in your engine?
Supposing that you assemble the long block outside, with the 2 lifting eyes tightened onto the sides of the cylinder head. In that case, I've often wondered, because of the weight of the short block, could there be too much stress (I mean stretching in the wrong direction) exerted on the head bolts and their threads? So that the clamping force/pressure between the head and the short block is significantly (and possibly permanently) lessened?

Top
#3313962 - 03/16/14 04:34 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
ls1mike Offline


Registered: 06/14/08
Posts: 3108
Loc: Bremerton Wa
Looks like lots of work! Enjoy! Love the photos...and the project.
Keeps us up to date.
_________________________
Mike
00 Trans Am
02 Silverado 2500HD
04 Grand Prix GTP
13 Equinox
12 Passport TT

Top
#3314832 - 03/17/14 11:36 AM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
threeputtpar Offline


Registered: 08/04/11
Posts: 1586
Loc: Appleton, WI
I'll be keeping an eye on this thread. Brings back memories of the 2.4 I had in a 1996 Sunfire GT. This was back when I didn't go over 3k miles in an OC, so I never had a problem. Traded it in with 165k on it and still ran great.

Is this the first 2.4 you've had? Don't know if you know of the problem areas or not, but the plastic piece that the ignition coils are bolted into is a weak point in the ignition system. Also, the thermostat is in the stupidest place possible. I had to replace the water pump on mine, and it was a chore to get at it with the engine in the car. Same with the thermo.
_________________________
2013 Honda Odyssey Touring Elite - QSUD 5W-30 and Bosch 3323 (living on the edge!)
2003 Audi A6 2.7t - M1 0W-40 and DW-30257

Top
#3314871 - 03/17/14 12:12 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
accent2012 Offline


Registered: 02/08/12
Posts: 441
Loc: Orlando, FL
I love threads like these. It's an adventure of what you are going through! Good luck!

I never really had problems with Rockauto. Although it has been a long time ago when I ordered an actual part for my nissan, an upper timing chain tensioner and it worked great. Although i did order a gasket set that was slightly off and had to get one from bennett auto supply instead. Otherwise, I get my airfilters through them.
_________________________
Hyundai Accent 2012

Top
#3315418 - 03/17/14 10:18 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Online   content


Registered: 03/31/10
Posts: 3381
Loc: Iowa
threeputtpar, yes I have some experience with them, albeit not much. My wife had one in a 97 Sunfire. That thing sure would scoot! I would love to drive it with a manual transmission...

As a mechanic, I've done some work to them- timing chain, cylinder head and cooling system work. I'll agree- that stat/water pump is just about the worst location someone could dream up! I have a new OEM one coming and don't intend to fool with it, unless needed. No preventative maintenance there!



A small update:

The water tube from the lower radiator hose to the t-stat was a nit rusty, and not wanting any issues, I blasted it and sent to the powder coater.

I also cleaned up the belt tensioner mount and throttle body (having a bead blaster is really nice!), as well as got the pistons about 90% clean. I'll hit them again when my ultra sonic cleaner shows up. I talked to the machinist this morning and I'm on deck... Told him to surface the block and do the valves and head surface. May be done this week, though he's not sure.


Also: Kudos to fellow member Trav for helping me out with rebuilding my fuel injectors!




_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

Top
#3315677 - 03/18/14 10:29 AM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
asand1 Offline


Registered: 12/16/12
Posts: 818
Loc: Oregon coast
Is this a different engine than the quad four?
_________________________
Download Infinity/Mazda/NISSAN Factory Service Manual here

1996 Maxima 300K
2008 Uplander 80K

Top
#3316371 - 03/18/14 10:31 PM Re: Project Malibu resurection: Death and rebirth [Re: asand1]
The_Eric Online   content


Registered: 03/31/10
Posts: 3381
Loc: Iowa
Originally Posted By: asand1
Is this a different engine than the quad four?


Yes, slightly. The Quad 4 was the original, and this engine shares many things in common with the Quad 4, but is called the "Twin Cam" I believe they built and tuned this engine to have a bit more low end torque. The Quad made good power, but only higher up. This engine has a bit smaller bore and longer stroke, with a more torque friendly head.
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

Top
#3316378 - 03/18/14 10:40 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Online   content


Registered: 03/31/10
Posts: 3381
Loc: Iowa
The block showed up today, along with the timing cover and oil pan. I was busy doing brake work and cleaning parts, so not too much action yet.

A pic of the block:



And another showing my ridge ream and hone job, as well as the machinist's surfacing work:





And finally, just for those who think that there's an over abundance of room, a picture of my car and it's stable mate... My friend and I are replacing hub seals and a few gears/bearings in it... Yes, the L/F set of duals is off, that's why it's so far back. Believe it or not, we were able to take them off by hand. It's powered by a 390 odd HP (re-powered to 360HP + 10%) 855 Cummins.

_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

Top
#3316801 - 03/19/14 10:59 AM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
threeputtpar Offline


Registered: 08/04/11
Posts: 1586
Loc: Appleton, WI
Originally Posted By: The_Eric
A pic of the block:





Ahhh, so that's where the starter would have been. Over the 7 years I owned the Sunfire, I never could find where the starter was. I was afraid of it failing like many of my previous cars and costing me a fortune to replace at a shop, but luckily it never gave up the ghost.

Also, I'd love to have as much room as you have even with that big ol tractor in there. I have a 2 car garage that has the equivilant of a small Toys R Us in it right now. This summer might be a good time to have a surprise garage sale before my wife buys anything else.
_________________________
2013 Honda Odyssey Touring Elite - QSUD 5W-30 and Bosch 3323 (living on the edge!)
2003 Audi A6 2.7t - M1 0W-40 and DW-30257

Top
#3316943 - 03/19/14 12:28 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
ls1mike Offline


Registered: 06/14/08
Posts: 3108
Loc: Bremerton Wa
Looking good man!

I have to ask the big light on the hood? Where did you get that?

I think I would like one.
_________________________
Mike
00 Trans Am
02 Silverado 2500HD
04 Grand Prix GTP
13 Equinox
12 Passport TT

Top
#3317551 - 03/19/14 10:09 PM Re: Project Malibu resurection: Death and rebirth [Re: ls1mike]
The_Eric Online   content


Registered: 03/31/10
Posts: 3381
Loc: Iowa
Originally Posted By: ls1mike
Looking good man!

I have to ask the big light on the hood? Where did you get that?

I think I would like one.


I purchased that light off the Cornwell truck when they had a sale going, but it can be had from the local parts stores- you'll have to have them get you their tool sales catalog. NAPA will likely have them (catalogs- usually distributed to shops) or a regional parts house should have them too. Not sure about the other big name stores, since I rarely deal with them.

Here are examples. Underhood Light


Not sure what your preference is, but mine is a fluorescent, since I haven't quite warmed up to the LED ones yet. The LED lights seem to be all the rage, so if you want a fluorescent light, or a different hood attachment method, you may have to look a bit- but they're out there.
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

Top
#3317579 - 03/19/14 10:36 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Online   content


Registered: 03/31/10
Posts: 3381
Loc: Iowa
Today's progress:

The balance shaft assembly started off looking like this-



And ended up like this-


A thorough cleaning, new bearings (think small rod bearing) and attaching the new oil pump.

The three good piston and rod combos were a bit stiff and the full floating rod wouldn't move freely on the wrist pin so I drove the pins out.

They looked like this when I started on them-


Some Scotch Brite and light oil turned them into this-


I took a piece of steel dowel and wrapped just enough tape around it, so the wrist pin would slide on, but stay put. Then turned the drill press on and give it polish. The small end of the connecting rod got a similar treatment when I wrapped the rod with Scotch Brite and ran the con rod over it.

Some of you may ask "Why"? Why not buy a new this or that, or take it to the machine shop instead? Well, beside the obvious part- you know the rod missing a bearing, the engine was in pretty good shape. It wasn't showing any real odd wear. Sure, I can sink boatloads of $$$ into it, but it's not really broke... Too badly. So I don't want to spend the $$$ to fix it. And I can be really cheap.

It's like that Kenny Rogers song, "The Gambler". You've got to know when to hold 'em and know when to fold 'em...

I figured it today- If I spend 2500.00 on this project (hopefully less) and drive it for 50k miles, then it will cost us 5 cents per mile. If we spend say 20 grand on a new or lightly used car and drove it for 200k miles, we would spend 10 cents per mile. Heck, even if we spent 10k on a car, we would still have to drive it 200k to equal the value of the Malibu.

Either car will have some repairs and maintenance along the way, so I didn't factor that. It's a total wild card. But the way I see it is we are saving money by spending wisely and looking for good deals, VS buying a much newer, lower mileage, but more expensive car that may still need major repairs.
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

Top
#3317584 - 03/19/14 10:42 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Online   content


Registered: 03/31/10
Posts: 3381
Loc: Iowa
Also, I got the crank back today. I had the shop order a new piston and a replacement connecting rod. The problem was the rod was a different style- probably from an older 2.4, or maybe even a 2.3? Don't know. Will find out more tomorrow.
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

Top
#3319617 - 03/22/14 09:32 AM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Online   content


Registered: 03/31/10
Posts: 3381
Loc: Iowa
Well, not too much to show on this update. Still waiting on the connecting rod- they were able to find the correct one, but it won't be here until sometime Monday. I went to install the rings on the pistons (DNJ made in Taiwan from Rock Auto), but found that the expander ring for the oil control set was too big in circumference. I was going to either re-use the OE expander or MacGyver the new ones, but I lost all faith in the ring set and wound up replacing the whole set with a Mahle set from Northern Auto. I was hoping that the DNJ stuff was all re-box goods, but ended up being wrong. I rolled the dice and lost. I did call Rock Auto and they were cool about it. They have sent a FedEx call tag and will refund the purchase price and shipping on them. The new ring set did cost a few more $$$, but that is one thing that I don't want to cut corners on. I can justify cheaping out many things, but tearing down an engine completely to replace junk rings isn't one of them.

Also, the 'Bu got a bath yesterday... Just as I wheeled it out of the shop and started applying degreaser, we encountered hurricane force winds. Yeah, real fun when you're soaked, it's 50 degrees and the wind is so strong that it's blowing the degreaser across a field to the neighbor's house...


Here is a pic of the crankshaft nestled in the main bearings...




The main bearing caps with new bearings, coated in some Permatex Ultra Slick assembly lube:



Finally, even though I soaked the pistons and scrubbed them lightly, I thought that I would wash them up with soapy water. I used some LA's Totally Awesome in a 5 gallon bucket and exceedingly cold water from the outside spigot. I was absolutely amazed to say the least! I literally just dunked them in and swished them around to achieve this! I did end up using a wash rag and scrubbing them too for good measure though.

Before:



After:

_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

Top
Page 2 of 5 < 1 2 3 4 5 >