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#3312821 - 03/15/14 02:59 PM Project Malibu resurection: Death and rebirth
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
I bought a 1998 Malibu with a 2.4 last summer from a customer who didn't desire to fix it up after the engine began making some pretty serious lower end noise. I gave him scrap yard price- around 200.00 and drug it home until I could fix it. Well, that time has come. I want it to replace my wife's aging and soon to be ailing 1995 Grand Am, which I gave a new lease on life with a budget minded refreshed 3.1 (also poached from a customer)- can read about it HERE. The Grand Am was intended to last another 70k miles or so, or until something major happens to it. Well I've been getting leery of it so I'm upping the time line on the 'Bu...

In spite of the terrible lower end knock, it started easily and drove onto the trailer, then off again to it's resting place. I've moved it around a few times over the summer, then finally back on the trailer to haul it to the shop where I off loaded it and drove it inside. It was there that I began inspecting it for external damage because there was a trail of oil following me... Hoping for better than a hole in the block, I was rewarded by finding the oil pressure sending unit to be leaking BADLY. Pretty common on these and likely the cause of the Bu's untimely demise. I considered buying a reman engine, but that would be at least 2200.00 from my sources. Used is a gamble on this one and would need a certain things before even dropping it in the car. The nearest one was a 100+ miles away and 600.00. So by the time I bought fuel for my friend's truck and lunch for both of us, I'd have 700.00 wrapped up in it and still need to replace the oil pump, water pump and timing set.


Here it is, just after I started working on it. I took the photo as an afterthought- you'll notice that this will be a common theme on this project. Sometimes I get started and forget to take pics as I pass various stages.



Here I've got some things taken off and am ready to really dig in!


A bad pic, but here it's almost ready to take flight via the engine hoist.


So once I was able to get the engine out, I took the pad off, expecting the worst. What I found was pretty impressive!


and YIKES!!! Yes, that's bearing... Rod bearing to be precise.


I took the balance shaft assembly and oil pump off so I could get to the bum rod. The nuts were suspiciously loose and the journal was hit pretty hard.


I called a machine shop who told me that they could do the crank for less than 200 bux. A reman crank and bearings is 500.00 through Rock Auto. Hmmm. Tough choice.



I'll have some more pictures in a little while- as I've got to go for now. They'll be interesting for sure...
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

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#3312834 - 03/15/14 03:11 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
gregk24 Offline


Registered: 04/13/13
Posts: 3059
Loc: FL, USA
Ouch, very common on these old GM 2.4's though.
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#3312844 - 03/15/14 03:23 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
satinsilver Offline


Registered: 01/24/08
Posts: 2915
Loc: Ohio
Nice that it's not covered in rust like my friend's 1999 Malibu. It ran for a long time though with very little maintenance, 200k when it was in an accident.

How many miles on the car?

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#3312886 - 03/15/14 04:04 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
SF0059 Offline


Registered: 08/06/12
Posts: 483
Loc: Lynchburg, VA, USA
Nice work so far. I'm looking forward to the next installment!
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2014 Honda Odyssey EX-L/RES: 20K mi, TGMO 0W-20 & A02
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#3312893 - 03/15/14 04:18 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
spavel6 Offline


Registered: 11/25/11
Posts: 61
Loc: Boston, MA
Around here, these motors go for about $300-400. Surprised they are so expensive out your way..
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2005 MB E320 4-M 88k M1 0W40
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#3312967 - 03/15/14 05:49 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
2010_FX4 Offline


Registered: 09/26/10
Posts: 3158
Loc: USA
Originally Posted By: The_Eric
I called a machine shop who told me that they could do the crank for less than 200 bux. A reman crank and bearings is 500.00 through Rock Auto. Hmmm. Tough choice.
Unless the shop has a horrible track record or the crank is beyond hope, I would just turn the crank, buy some new bearings and save a few hundred in the process.
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#3312981 - 03/15/14 06:17 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
CHARLIEBRONSON21 Offline


Registered: 08/28/13
Posts: 521
Loc: MEMPHIS, TN
The space in there makes me jealous a bit
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#3313067 - 03/15/14 08:09 PM Re: Project Malibu resurection: Death and rebirth [Re: CHARLIEBRONSON21]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
Originally Posted By: satinsilver
Nice that it's not covered in rust like my friend's 1999 Malibu. It ran for a long time though with very little maintenance, 200k when it was in an accident.

How many miles on the car?


To be honest, I'm a little fuzzy on the actual mileage. I think it's around 174k though- really, it's in decent shape for the miles, and has at least 100k less than my wife's current ride.


Originally Posted By: 2010_FX4
Originally Posted By: The_Eric
I called a machine shop who told me that they could do the crank for less than 200 bux. A reman crank and bearings is 500.00 through Rock Auto. Hmmm. Tough choice.
Unless the shop has a horrible track record or the crank is beyond hope, I would just turn the crank, buy some new bearings and save a few hundred in the process.


I know the interwebs is a terrible place when it comes to conveying emotions or inflection, but there was sarcasm in it. In fact, the crank is over there now, done. The machinist said that it was really close to cleaning at .010", so I'm sure he took it .020" under. Really, except for that one journal, the crank looked really good.

Originally Posted By: CHARLIEBRONSON21
The space in there makes me jealous a bit


I just wish that we had the whole building to work out of. It looks big, and at 48 x 80, it's not small, but half of it used as cold storage. What you don't see in there is the BIG 4WD tractor just out of the frame that's taking up a pretty sizable chunk of floor space.
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

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#3313101 - 03/15/14 08:59 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
artificialist Offline


Registered: 09/23/07
Posts: 6953
Loc: Florida
So to save this engine, are you going to hone the bores with the engine in the car, and re-ring the engine, or are you going to have your machinist rebore the engine, and have you fit oversize pistons and rings?
_________________________
2010 Lancer Ralliart Sportback

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#3313184 - 03/15/14 10:09 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
Now for the rest of the pictures that I have taken so far.


This is another rod journal- really, not too bad for 174K miles.



Of course, the first thing I did was to pull the wounded piston and rod out. It is the only one that can be removed from the bottom. Since there was no bearing the piston was able to come in contact with the crank. Rod is toast also. See anything wrong with the cap???




I was going to just throw a crank in it initially, but after seeing that it needed a rod and piston, I decided to go all in and toss a set of rings at it too.

Once I got the engine completely stripped down, I was better able to inspect the cylinders. No detectable ring ridge and still some cross hatch. The wounded piston left it's mark (literally) on the cylinder, but nothing serious. What I didn't get a photo of is after I honed it. Once I started running the hone through it, I was able to see that there was a very slight ridge. A few minutes of light work with the ridge reamer took care of most of it and I was able to get the cylinders honed. I'll probably have the machine shop surface the block and maybe go through the head to... Not sure yet.




Here is what it looked like before I sent most of it off to be cleaned... I'll do some of it on house- like the pistons and some small parts.




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

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#3313186 - 03/15/14 10:10 PM Re: Project Malibu resurection: Death and rebirth [Re: gregk24]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
Originally Posted By: gregk24
Ouch, very common on these old GM 2.4's though.


Any idea of the actual cause of it? Some light reading on the interweb suggested low oil levels would do this.
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

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#3313201 - 03/15/14 10:27 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
dishdude Offline


Registered: 11/14/08
Posts: 3363
Loc: Phoenix
Originally Posted By: The_Eric
Originally Posted By: gregk24
Ouch, very common on these old GM 2.4's though.


Any idea of the actual cause of it? Some light reading on the interweb suggested low oil levels would do this.


Greg takes any opportunity to bash GM he can, and really doesn't have a lot of automotive knowledge. Any engine you run low on oil is going to spin a rod, and I think you were on the right track with the bad sending unit being partially to blame. Driver probably never checked the oil.

Thanks for the pics, can't wait to see the progress!

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#3313356 - 03/16/14 07:38 AM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
terry274 Online   content


Registered: 10/16/10
Posts: 76
Loc: TN
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.
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2005 Ford F150

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#3313381 - 03/16/14 08:07 AM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
Kruse Offline


Registered: 10/05/05
Posts: 3094
Loc: Kansas
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.

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#3313546 - 03/16/14 11:26 AM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
cptbarkey Offline


Registered: 02/27/12
Posts: 1237
Loc: texas
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.
_________________________
2011 toyota sienna
2014 ram 1500
2000 nissan xterra (project)

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#3313593 - 03/16/14 11:54 AM Re: Project Malibu resurection: Death and rebirth [Re: cptbarkey]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
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

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#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?

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


Registered: 06/14/08
Posts: 3182
Loc: In the Garage...
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

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


Registered: 08/04/11
Posts: 1613
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!)
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#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.
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Hyundai Accent 2012

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


Registered: 03/31/10
Posts: 3476
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

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


Registered: 12/16/12
Posts: 847
Loc: Oregon coast
Is this a different engine than the quad four?
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#3316371 - 03/18/14 10:31 PM Re: Project Malibu resurection: Death and rebirth [Re: asand1]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
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

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


Registered: 03/31/10
Posts: 3476
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

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


Registered: 08/04/11
Posts: 1613
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!)
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#3316943 - 03/19/14 12:28 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
ls1mike Offline


Registered: 06/14/08
Posts: 3182
Loc: In the Garage...
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

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


Registered: 03/31/10
Posts: 3476
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

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


Registered: 03/31/10
Posts: 3476
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

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


Registered: 03/31/10
Posts: 3476
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

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


Registered: 03/31/10
Posts: 3476
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

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#3319656 - 03/22/14 10:27 AM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
pottymouth Offline


Registered: 01/24/08
Posts: 483
Loc: NJ
Originally Posted By: The_Eric

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.


You have the right idea.

I've seen people invest more than double the value of a car then be surprised when they can't get the money back later. You're working on a car that will provide safe, reliable transportation when done, but is not a particularly valuable or desirable car. Why dump a dollar more into it than you have to?

I used to be one of those, "as long as I'm in there, I might was well replace this, this and that..." guys myself. I've learned to be realistic about what I'm working on and make smart decisions, not emotional ones. No more fixing things that aren't broken for me.

Glad you're putting this Chevy back on the road. Way too many cars go to the crusher prematurely because owners do not maintain them.

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#3319725 - 03/22/14 11:33 AM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
Kruse Offline


Registered: 10/05/05
Posts: 3094
Loc: Kansas
Originally Posted By: The_Eric
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.


Thanks for telling us the truth about parts from DNJ. I will be doing a complete overhaul on a Ford 3.8 V6 in about a month. Rock Auto has been pushing DMJ and it's hard to pass up the prices on DNJ components, especially when they are about half the price of older name-brand parts. My overhaul kit will be purchased from Northern Auto next week and the components will be more familiar names, even if some of the parts are not made in North America.
You have just convinced me to stay away from DNJ. I will still order from Rock Auto, but I do now know of one brand to stay away from.

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#3319767 - 03/22/14 12:36 PM Re: Project Malibu resurection: Death and rebirth [Re: Kruse]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
Originally Posted By: pottymouth
Originally Posted By: The_Eric

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.


You have the right idea.

I've seen people invest more than double the value of a car then be surprised when they can't get the money back later. You're working on a car that will provide safe, reliable transportation when done, but is not a particularly valuable or desirable car. Why dump a dollar more into it than you have to?

I used to be one of those, "as long as I'm in there, I might was well replace this, this and that..." guys myself. I've learned to be realistic about what I'm working on and make smart decisions, not emotional ones. No more fixing things that aren't broken for me.

Glad you're putting this Chevy back on the road. Way too many cars go to the crusher prematurely because owners do not maintain them.


You hit the nail on the head.

At the rate I'm going, I may or may not be able to recover my money/make a profit from this car in a private sale, but that's not the goal. The goal, like you said is for a safe, dependable car. So far, it makes good financial sense and is on track to being a very cheap car to drive.

Originally Posted By: Kruse
Originally Posted By: The_Eric
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.


Thanks for telling us the truth about parts from DNJ. I will be doing a complete overhaul on a Ford 3.8 V6 in about a month. Rock Auto has been pushing DMJ and it's hard to pass up the prices on DNJ components, especially when they are about half the price of older name-brand parts. My overhaul kit will be purchased from Northern Auto next week and the components will be more familiar names, even if some of the parts are not made in North America.
You have just convinced me to stay away from DNJ. I will still order from Rock Auto, but I do now know of one brand to stay away from.


I have nothing to hide. If anything, I'd like this to be a guide for others. What to look for, what to do and what not to buy.

The gasket set, so far, shows promise. It looks to be a well made set. Time will tell. Heck, even the rings could have been a good set and the manufacturer accidentally included an oversize on the expander. It doesn't matter- they made me nervous. I am willing/able to tear most anything down to repair or replace something, but that is not one. Unless of course I'm getting paid to do it.

Also, Kruse: Thank you for reminding me of Northern Auto! You saved the day on the rings.
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

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#3319856 - 03/22/14 02:48 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
ls1mike Offline


Registered: 06/14/08
Posts: 3182
Loc: In the Garage...
Looks great Eric!

Thanks for the tip on the light.

I like florescent as well.
_________________________
Mike
00 Trans Am
02 Silverado 2500HD
04 Grand Prix GTP
13 Equinox
12 Passport TT

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#3320274 - 03/22/14 09:15 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
artificialist Offline


Registered: 09/23/07
Posts: 6953
Loc: Florida
I live near an independent parts store that sells DNJ kits. You will always see one there because they ship them everywhere. The parts in those kits seem almost random. The timing belt, timing belt pulleys, timing idlers, and water pumps would be made by different companies, and different countries which seemed extremely weird to me. Some of the parts came from China. It made me decide not to use DNJ.

Every time I saw one, it would have NPR/Nippon Piston Ring labeled rings in it. That was the OE supplier to many car companies.
_________________________
2010 Lancer Ralliart Sportback

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#3320951 - 03/23/14 02:31 PM Re: Project Malibu resurection: Death and rebirth [Re: dishdude]
gregk24 Offline


Registered: 04/13/13
Posts: 3059
Loc: FL, USA
Originally Posted By: dishdude
Originally Posted By: The_Eric
Originally Posted By: gregk24
Ouch, very common on these old GM 2.4's though.


Any idea of the actual cause of it? Some light reading on the interweb suggested low oil levels would do this.


Greg takes any opportunity to bash GM he can, and really doesn't have a lot of automotive knowledge. Any engine you run low on oil is going to spin a rod, and I think you were on the right track with the bad sending unit being partially to blame. Driver probably never checked the oil.

Thanks for the pics, can't wait to see the progress!


Really? We own two GM's and one Honda. I do know however that these older 2.4's do have issues spinning bearings. It usually happens when the engine is run low on oil (that would happen to almost any engine), or under high RPM, in such case it starves certain bearings of oil. Read up on it, on these 2.4's its not a matter of if, its a matter of when. Many make it to respectably high miles before it happens though.
_________________________
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#3322578 - 03/24/14 10:25 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
Update: Finally got the correct connecting rod, and the proper rings showed up today too. One more thing to note about the DNJ rings- they weren't the same exact design as the OE. The inside of the top ring of the OE set was rounded and the inside of the DNJ replacements were pretty much square. That was another reason I was unsure about running them, but neglected to mention it in the other post. The Mahle replacements do have the same configuration as the OE.

I didn't photograph all the steps as I was kind of rushing, so you'll have to make due with two... Sorry.

Here the pistons are installed and the rod caps are tied firmly to the crank. I already have the balance shaft assembly installed and timed to the crank- what a mess, hope it's close enough! There are no index lines, splines or keys. The gear is retained only by bolt tension and timing is a bit tricky without the factory tools.




Here is the head just before I cranked it down to the block. Machinist did a nice job on the surface.




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

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#3323702 - 03/25/14 10:19 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
Another update: I skipped several photos today, as I was in a hurry. The engine is more or less screwed together and resting comfortably back in the car.



I'll add that I likely won't be using the DNJ gaskets again either. The set was missing the inner timing cover gasket, the oil/air separator gasket (not sure the after market even makes one) and a few misc. o-rings.

I picked up the water tube from the powder coater today and installed it with a new GM t-stat.

The e-bay timing set installed okay, but one of the guides wasn't made correctly- the hooks that fit into the timing cover were improperly spaced, so I modified them a bit.

Sigh... The things a person will go through to save money.
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

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#3323714 - 03/25/14 10:29 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
Kruse Offline


Registered: 10/05/05
Posts: 3094
Loc: Kansas
Originally Posted By: The_Eric

Sigh... The things a person will go through to save money.


A few weeks ago I looked at their website and I was not impressed. After your experience with them, I've probably sworn them off permanently.

http://www.enginecomponents.com/

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#3323716 - 03/25/14 10:32 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
hattaresguy Offline


Registered: 06/01/11
Posts: 5249
Loc: CT
Nice progress!

I have been looking on Amazon for deals on AC Delco parts, I have had a number of aftermarket parts fail on me quite young.

I had an aftermarket front wheel bearing on my truck fail after only 20k miles, the original had done 110k!


Edited by hattaresguy (03/25/14 10:33 PM)

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#3324092 - 03/26/14 11:02 AM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
L_Sludger Offline


Registered: 10/04/09
Posts: 2511
Loc: Ohio
You know, I've often found that genuine OEM engine parts from a discounter are generally worth the price in the long run.

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#3324847 - 03/26/14 10:27 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
Pretty much home, just need to sonic tank the injectors. Maybe with some luck I'll have it running tomorrow?

Today, I got most of the stuff hooked up- the lines and harness routed properly, and the alternator and belt tensioner bolted down. Just have to zip the exhaust flange tight and the bottom bolts on the A/C compressor.

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

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#3325045 - 03/27/14 07:29 AM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
ls1mike Offline


Registered: 06/14/08
Posts: 3182
Loc: In the Garage...
Getting close!

Looks good!

Until this last photo. I was wondering what the hole was on the front of the block.
_________________________
Mike
00 Trans Am
02 Silverado 2500HD
04 Grand Prix GTP
13 Equinox
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#3325057 - 03/27/14 07:45 AM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
Yeah, that's the oil/air separator. The DNJ gasket set was missing the gasket for it, so while the parts store looked for it, I kept working. I later called the dealer and they told me that it's obsolete and no other dealers have it. The parts store couldn't find it through Fel-Pro either, so last night I just broke out the can of Right Stuff and stuck it on.
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

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#3325152 - 03/27/14 09:28 AM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
ls1mike Offline


Registered: 06/14/08
Posts: 3182
Loc: In the Garage...
Ah the Right Stuff!

Love it!

When I had my TPI vette I used it on the intake. I had to remove when I did the storker motor. I couldn't get the dang intake off. I hooked the hoist up to it and applied a bit of pressure and left it over night. At some point that night it finally broke free!

Best gasket maker ever.
_________________________
Mike
00 Trans Am
02 Silverado 2500HD
04 Grand Prix GTP
13 Equinox
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#3325760 - 03/27/14 09:33 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
Well, the 'Bu lives again!

I got the injectors sonic tanked and finished some odds and ends, then cycled the key several times, and attempted to start. She fired right up with some lash adjuster (think lifter) noise, then hummed away.

Tomorrow I'll get a little more serious about running it- I only ran it for a few minutes before throwing in the towel for the night.
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

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#3325802 - 03/27/14 10:19 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
ls1mike Offline


Registered: 06/14/08
Posts: 3182
Loc: In the Garage...
Good to hear. Like following it. Seems you busted it out pretty quickly.
_________________________
Mike
00 Trans Am
02 Silverado 2500HD
04 Grand Prix GTP
13 Equinox
12 Passport TT

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#3325831 - 03/27/14 10:42 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
Yeah, it went pretty well. The machine shop really knocked the stuff out for me- usually their turn around time is much longer. A few parts shortages but really, not bad. I wanted to get it done ASAP because spring is rapidly approaching and that means field work and planting, so we'll be REALLY busy fairly soon.

Maybe tomorrow I an get some video of it running. I was rushed again so, no pics or video footage.


Edited by The_Eric (03/27/14 10:44 PM)
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

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#3326749 - 03/28/14 09:05 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
Alright, a short video of the nearly completed Malibu project...

It seemed to run well, in spite of the fact that the gas is well over a year old at this point. I couldn't go very far since the car isn't insured yet. Just down to the end of the gravel road and back.

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

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#3326781 - 03/28/14 09:37 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
OVERKILL Online   content


Registered: 04/28/08
Posts: 26734
Loc: Ontario, Canada
Great work thumbsup
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#3326865 - 03/28/14 10:53 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
Thanks man!
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

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#3326962 - 03/29/14 02:44 AM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
ls1mike Offline


Registered: 06/14/08
Posts: 3182
Loc: In the Garage...
Nice! Glad to see it went so smoothly for you.
_________________________
Mike
00 Trans Am
02 Silverado 2500HD
04 Grand Prix GTP
13 Equinox
12 Passport TT

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#3327622 - 03/29/14 07:14 PM Re: Project Malibu resurection: Death and rebirth [Re: ls1mike]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
Originally Posted By: ls1mike
Nice! Glad to see it went so smoothly for you.


I am too. Everyone will make mistakes- and I haven't made any big ones for a LONG time, so I'm sure I'm due. Maybe next time...

Did you find a hood light you like yet?






In a little while, I will post up the cost of this project.

So far, there is at least 2100.00 in it, including purchase price of the car, so I'm slightly below the anticipated cost. This includes not only engine work, but brake work and transmission service.
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

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#3340582 - 04/12/14 10:19 AM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
A small update:

The car has about 500 miles on it so far. After about 80 miles or so, I changed the oil. It hasn't missed a beat so far and is running even better than when I first fired it. The timing set seems a bit noisy once fully warmed, so I'll keep an ear out for it.

My wife is taking it on it's first trip out of town as I type- I'll change the oil again this weekend.

We're looking to sell her Grand Am. Once sold I will likely replace the tires- General Ultimaxes. They're NOISY!

Still have to tally the parts and machine work. Will do that someday and post the final cost.
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

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#3340709 - 04/12/14 01:57 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
JustinH Offline


Registered: 04/17/04
Posts: 3292
Loc: Texas
Great thread, I loved the detail and the videos.

I think financially you are nuts putting money into a sub 1000 dollar car, unless it is a hobby for you.
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#3341186 - 04/13/14 03:49 AM Re: Project Malibu resurection: Death and rebirth [Re: JustinH]
asand1 Offline


Registered: 12/16/12
Posts: 847
Loc: Oregon coast
Originally Posted By: JustinH
I think financially you are nuts putting money into a sub 1000 dollar car, unless it is a hobby for you.


Financially he is wise. He paid $200 for this car. Lets just say he spent $400 on parts and machine work. He's only in $600.00 on a car that would likely fetch 2,000 on the used market. Give his intention of running it into
the ground, resale is not even a concern. He has spent less than half of the cars value, and will have a reliable daily driver for many years.
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#3341316 - 04/13/14 09:47 AM Re: Project Malibu resurection: Death and rebirth [Re: asand1]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
Originally Posted By: JustinH
Great thread, I loved the detail and the videos.

I think financially you are nuts putting money into a sub 1000 dollar car, unless it is a hobby for you.

Originally Posted By: asand1
Originally Posted By: JustinH
I think financially you are nuts putting money into a sub 1000 dollar car, unless it is a hobby for you.


Financially he is wise. He paid $200 for this car. Lets just say he spent $400 on parts and machine work. He's only in $600.00 on a car that would likely fetch 2,000 on the used market. Give his intention of running it into
the ground, resale is not even a concern. He has spent less than half of the cars value, and will have a reliable daily driver for many years.


Indeed. I'm not looking to resell this car. It is going to get driven. If resell was my goal, then profit would likely be VERY hard to attain. I only wish I had just a grand into it. But even at the amount that I'm anticipating (not totaled yet), it still pencils out cheaper on a cost per projected miles driven basis than buying newer and better, then driving for 100k. Heck, I'm only wanting to get 50k more miles out this car. Now if we can sell her other car for a reasonable amount, then that will offset the cost of this project and drive the cost per mile down even more.

If you're capable and have the resources, there's plenty of value in an older car. For us the "value" is (hopefully) low cost of operation, no car payment and the flexibility to upgrade sooner, all for a relatively low input cost.
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

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#3341721 - 04/13/14 05:42 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
ls1mike Offline


Registered: 06/14/08
Posts: 3182
Loc: In the Garage...
Glad to hear it is running well!

Didn't get a light yet...Camping season so I don't spend much time in the Garage on the weekends, but I am going to look for one this evening.
_________________________
Mike
00 Trans Am
02 Silverado 2500HD
04 Grand Prix GTP
13 Equinox
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#3488547 - 09/20/14 03:24 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
Bumping this thread up with another update:

The 'Bu has 7,635 miles on it since it's re-birth, for a total of 180,188 miles and the engine hasn't missed a lick... Not one. It likes it's RPM for sure. It consumes no noticeable oil- none, nadda, zip, zero, in spite of having some light scoring from piston damage in hole #4.

Earlier in the thread, I mentioned a noisy timing set when hot- well figuring that I gambled and lost on that too, I ordered and installed a Cloyes set only to find the same thing! I was sure I had the problem correctly diagnosed because when I popped the timing cover off, the chain was loose enough to slap the timing chain housing. At that point I figured "What the heck" and planned to just run it. Well once I got a few more (progressively longer) oil changes ran through it, I dropped some QSUD (5w-30) in and at about that time, the noise largely disappeared! I still maintain that it was timing chain tensioner related though.

The A/C needs work (on the list) and it's getting shod with new Firestone Precision Touring tires next week, that way my better, fairer half can enjoy her newer ride in relative comfort and safety. The 4T40 trans suffers from the jerky shifting they are known for even though I completely replaced the fluid with Dex 6 and a bottle of Lubegaurd Red during the build. I also replaced one output shaft seal shortly after putting it in service.

Fuel economy is a bit of a sore spot. It really doesn't respond well to in town driving/short highwaytrips and comes in at 22-23 odd MPG. It seems to like stretching it's legs a bit on the highway and even if driving at higher speeds and somewhat aggressively (it is a Malibu after all, how aggressive can you get?), will still return 26mpg. The best it's seen has been 28mpg- all highway miles at or above 70mph with lots of full throttle blasts. I'm sure my wife will wring another 2-3 mpg out of it as she learns it's quirks. Even if it doesn't set the world on fire with astounding MPG numbers, it's still cheap to drive/own.

On the topic of cost- I never had run the numbers on cost to re-build the engine, replace the front brakes and all that other jazz... Not sure I ever will. If I had to guess though, I'd say it would be around 2600 dollars (including purchase), front brakes, transmission service work, engine mounts and so on. I just have to keep it all glued together for 42,365 or so miles!
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

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#3488899 - 09/20/14 10:42 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
hpb Offline


Registered: 08/28/14
Posts: 128
Loc: Tasmania, Australia
I just read the entire post - very well written, and a great job with the rebuild! I'm also a fan of keeping older, cheaper cars on the road. I've bought a few over the years for peanuts, fixed them up and used them for a couple of years, often selling for a small profit in the end. Mind you, I'm also lucky enough to have after hours access to a fully equipped workshop, with hoist, air compressor and tools, oxy set, etc. It makes life much easier!

Again, kudos!
_________________________
2010 Mazda CX9, 45000km - Nulon synthetic 5w30, Mazda filter
2002 Ford Falcon, 387000km - Frankenbrew, Ryco filter

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#3488917 - 09/20/14 11:11 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
Thanks man!

It really is nice to have all those resources available- it changes the job from un-doable or financially unsound to "No problem", and I consider myself very lucky to have all the things that I own or have access to!
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

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#3488933 - 09/20/14 11:47 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
ls1mike Offline


Registered: 06/14/08
Posts: 3182
Loc: In the Garage...
Glad to hear it working out for you! Thanks for the update.

Oh and I did get a light! Love it.
_________________________
Mike
00 Trans Am
02 Silverado 2500HD
04 Grand Prix GTP
13 Equinox
12 Passport TT

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#3488945 - 09/21/14 12:07 AM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
Great! It sure beats the heck out of the typical trouble lights, though they do have their place from time to time.

Also- they work really slick for interior work, just roll the windows down or open the doors and hang the light.
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

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#3488999 - 09/21/14 04:02 AM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
hpb Offline


Registered: 08/28/14
Posts: 128
Loc: Tasmania, Australia
Question, since we never saw that particular model in Oz, is the engine a GM design, or borrowed from elsewhere - it has a very Mitsubishi look to it?

And yes, having a full workshop at one's disposal is cool. As an ex-mechanic, it's nice to get stuck in and get grubby every now and then, takes me back to my 20's...which was almost half my lifetime ago now!
_________________________
2010 Mazda CX9, 45000km - Nulon synthetic 5w30, Mazda filter
2002 Ford Falcon, 387000km - Frankenbrew, Ryco filter

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#3489218 - 09/21/14 10:55 AM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
Here's some reading material on the Quad 4 and Twin Cam engines if you're interested.

Read here


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

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#3489579 - 09/21/14 08:39 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
HM12460 Offline


Registered: 05/26/07
Posts: 1486
Loc: West Michigan
Good job! An excellent thread to have followed. My John Deere hat is off to you sir!
_________________________
2003 Dodge Dakota
"Hot Rod Dodge"

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#3489606 - 09/21/14 09:01 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
hpb Offline


Registered: 08/28/14
Posts: 128
Loc: Tasmania, Australia
Thanks for the links, I now know lots about 80's and 90's GM fours!
_________________________
2010 Mazda CX9, 45000km - Nulon synthetic 5w30, Mazda filter
2002 Ford Falcon, 387000km - Frankenbrew, Ryco filter

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#3490467 - 09/22/14 08:06 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
hpb Offline


Registered: 08/28/14
Posts: 128
Loc: Tasmania, Australia
A little bit of trivia - we didn't get the Malibu in Oz, as in the 90's GM's (Holden) mid-size offering here was the Holden Apollo - a straight up re-badged Toyota Camry! (And possibly the most reliable car to ever wear a Holden badge!) And in the small car class, we got the Holden Nova, a.k.a Toyota Corolla.

Come to think of it, maybe the re-badging thing is worthy of a thread of its own, I'm sure there's many examples from all over the world.
_________________________
2010 Mazda CX9, 45000km - Nulon synthetic 5w30, Mazda filter
2002 Ford Falcon, 387000km - Frankenbrew, Ryco filter

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#3490574 - 09/22/14 09:41 PM Re: Project Malibu resurection: Death and rebirth [Re: The_Eric]
The_Eric Offline


Registered: 03/31/10
Posts: 3476
Loc: Iowa
You should, it would be interesting to hear from others outside the U.S. and piece together which cars are re-badged.

I think the Corolla was also re-badged by Chevrolet some years ago. Pontiac, another branch of GM has the Vibe, a Toyota Matrix with some minor changes.
_________________________
2001 Hyundai Elantra 2.0
1998 Chevy Malibu 2.4
1995 Pontiac Grand Am 3.1
1979 Ford F-150 351M

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