Just about to start taking it apart:

 

Disconnecting the strut fron the hub, so I can get the axle out:

A few pics of his engine after we got it out and on a engine stand. Massive oil burner, a common problem with Saturn engines of this year range it seems:

One thing that surprises me is that these engines use one tiny ass throttle body, you can kinda see it in the pics. Almost half the size opening as our B20a's. The exhaust manifold also has really small runners and the ports on the head are small as well. I bet with I/H/E, a larger throttle body, and ported head these things could pick up some nice HP.

 

Got the tanny off the engine. Bit of an oil leak? Uh... YEAH. I put some shop rags in the openeings for the axles and then cleaned the thing meticuously in a parts washer.Got every bit of dirt and oil off it:

Before:

After:

We use 10W30 in our manual trannys, Saturns use ATF hehe. The manual tranny weighs about as much as ours do maybe 60-70 lbs.:

 

Heres a pic of after we removed the valve cover and timing gear cover, 125HP DOHC 1.9L 16-Valve. Doesnt have rocker arms though, there are little round caps that sit right on top of the valve springs and the camshafts actuate those directly:

 

Ye olde empty bay pics:

 

After we stripped the block I rolled it outside and we sprayed then scrubbed it real good with solvent, got it pretty clean:

 

Open deck design:

Afterwards I ran a hone though the cylinders real quick. Then I installed the crankshaft and we stuck the rods and new pistons in with new bearings.

New crankshaft seal, flywheel side:

New seal in the timing cover, the oil pump is also built into this part:

Random pic of the intake manifold, you can also see one of the cams and the round caps that ride ontop the valves:

 

Our first attempt at installing the head met with failure as one of the headbolts snapped. Although the genuine Saturn manual doesnt mention it, dont try and reuse the old headbolts, get new ones:

 

After we got new headbolts we managed to install the head, here I am torquing the timing chain tensioner:

 

Here it is with the timing chain installed, ready to get everything else put back on:

 

My friend had to work so I finished putting it all together, nice and clean. After wards I put the flywheel and new clutch kit on and wrestled with getting the tranny on for a little bit.

 

Here we are dropping it back in, its a bitch because the beams on either side of the bay are narrower than the whole engine/tranny assembly. So you to tilt the engine a lot toward the tranny side to get it in/out:

 

Here it is in and all buttoned up late that night, were all ready to start it up but forgot the oil! Doh, had to wait till the next day. It started right up and has been running good since.

Here be the Saturn the day we got it running after being cleaned up because we got it all dirty. :-)