5-Speed

Let the build thread begin! To start off, this is going to be more of a restoration thread more than anything. I am going to return the car basically back to stock and use it as my daily driver.

Here is what I am starting off with. Bought it in December of 2019 and didnt start working on it until August 2020. Things are going to progress fast from here.

2009 SS - 125K miles
- ZZP catless down pipe
- Injen piping
- Some sort of aftermarket heat exchanger
- Home made 3" exhaust (way too loud)
- Trifecta tuned
- H&R lowering springs
- AEM boost and AFR gauges mounted on a-pillar

I got the car for cheap since it had a blown engine. Seeing that I have built over 300 Ecotecs, I figured it would be no problem to bring this one back to life. After tearing the engine down, I see why it blew. Looks like one of the timing chain guides broke, guy kept driving, guide continued to break even more and ended up filling the pickup tube with so much plastic, it lost oil pressure. Only spun one rod bearing but all the other bearing were not far behind. The guy actually drove the car so much after the bearing spun that there was not even a bearing left.... It was impressive I must say. Despite how much metal went through the engine, everything else looked pretty good. Regardless, I am going to be replacing a ton of stuff.

- New LNF head (not reman)
- Newused take out pistons, crank and rods (run on a test stand for a couple hours)
- New chains and guides
- New lifters
- New bearings and rings
- All new gaskets
- Spec pressure plate, stock flywheel and clutch disk, also new.
- Used turbo from ECaulk (K04+)
- Putting the factory cat back on
- Ebay 3" stainless exhaust (should be nice and quiet)
- Still up in the air about using the Injen intake or going back to stock (have both)
- Flashed the ECU back to stock and will do a custom tune

Pretty much the only thing I am reusing is the block, cams, rockers and balance shafts. I was very surprised to see the car had a brand new clutch in it. Maybe had 500 miles on it before the engine blew. Anyways, I will get some pictures going pretty soon to see all the fun I am having.

ProfDNS

Nice to see a rebuild like this. Will be following!

63 Nova SS

iTrader: (3)

Eric and I both had K04+ turbo's. It's worth about 4-5lbs more airflow over the stock K04. Mine on E47 fuel was pretty quick.

5-Speed

Thanks! It should be a fun little project for me. I am not a fan of, just get a junk yard engine or just get a crate engine

Thats what I was hoping to hear! I wanted to keep the build CA smog legal so this is about as big of a turbo as I can go. I am keeping it on 91 for gas mileage sake and because I dont need any crazy power for a DD. When I want to go fast, I will take my Evo out. As long as this build hits 300 whp, I will be more than happy and it should get there no problem.

ECaulk

iTrader: (6)

You'll hit 300whp easy on 91 and still have room to go if you get bored. I was able to keep up with a pretty aggressive e85 tuned ko4 cobalt when I was on pump (he brake boosted I didnt)

I should get a thread going but I think I'll wait till I'm finished with the work.

michael23v

iTrader: (2)

This will be fun to follow. Good luck.

blu3_v1p3r

iTrader: (6)

I got 300whp on the stock turbo on 91, the stock cat might hold you back a little. Also it was a ZZP tune with no real data logging.

5-Speed

Thanks! And let's hope so.

Good to know. I think the k04+ should net me 20-30 more whp at the same boost level as a stock turbo.

I was going to post a picture of the car to start but its just a silver SS. We have all seen one already. It looks like all the others, I promise. Most of you have seen the process of removing an engine, so let's just skip that too.

What we are jumping into is the mess you are left with when the engine gets torn apart. Like so....




That was last night. I got off work tonight and went straight to engine building. Side note - I had everything cleaned, honed and measured at work today. I put about 2 hours into the build tonight and we are left with this. I don't mess around when it comes to engine building. They fly together.









Yes that is right, from bare block to almost long block in 2 hours.

blu3_v1p3r

iTrader: (6)

I don't have the confidence in myself to break down an engine and put it back together.

5-Speed

I tell everyone that building an engine is simple. If you know how to measure things and read instructions, you can do it. Ecotecs are extremely simple and a great place to start. Dive in and you will find out how simple an engine really is.

ECaulk

iTrader: (6)

Damn, 2 h to get a long block together thats good time.

I agree the ecotec is a great platform to learn on, biggest suggestion is don't try to be like 5-speed and put it all together in 2 h. Take you time and plan for things to not go right or extra time to look up or double check a spec before proceeding.

blu3_v1p3r

iTrader: (6)

I have really though about. I don't have all the tools at home. I could probably do it. I take apart aircraft hydraulic systems and flight controls all the time. I probably have the ability to do it with some instruction/help. The downtime would be a problem for me. If my engine let's go I'd probably just pick up an LDK.

5-Speed

Haha well that is what happens when I have built too many of them. Maybe I am a bad example haha. But yes I agree, if its your first time, do not go fast. Take as much time as you can and double check every thing.

If you can rebuild hydraulic stuff then you can build an engine. Like you said, someone helping who knows what they are doing would be a huge benefit. You really dont need any special tools besides a ring compressor, TQ wrench and some good measuring devices.

USMCFieldMP

iTrader: (1)

I learned by reading the LSJ build book about 100 times (my OneDrive copy linked here) and by watching "Jafromobile" on YouTube. He's doing DSM stuff, but a lot of the principles are there. I think I started with video 15 on this playlist:

Turbo Hyundai Elantra Playlist

He goes through a lot of the specialty tools (from Harbor Freight) that you can use to blueprint an engine, too. A thousand measurements. Really not something that is 100% needed on a stock rebuild like 5-Speed is doing.

5-Speed

You know the best part about building an Ecotec is that you dont even need an engine stand! I typically build them on a bench but my bench has no more space due to Bug parts being everywhere.

I also received my freight shipment from Eric today haha. That was the last part I was waiting on. Will be back at this project tomorrow (kid duty tonight) and hopefully get it back on the cradle and ready to be lifted back in.





Thanks again Eric! I will be sure to put it to good use.

ProfDNS

Nice packaging

ECaulk

iTrader: (6)

I was trying to keep things from getting damaged seems like I managed to achieve that

ProfDNS

I wasn't trying to be sarcastic, it takes great care to ship something like that long distances. Indeed you were quite successful!

ECaulk

iTrader: (6)

Thanks, it was hard to tell via text in a forum comment

5-Speed

I agree! While I had a good laugh when I opened the box, it was better then what 99% of people have sent me. Made it in one piece and that all that matters. He at least warned me before it shipped haha.

blu3_v1p3r

iTrader: (6)

I seen a guy ship a head in a dog food bag.

5-Speed

Oh wow. I don't think I have a story that beats that haha. I have seen a lot of stuff come in packaged completely wrong but not that bad. Pretty impressive

BlackielawlessSS

iTrader: (1)

NIce! I will be following this resto!

5-Speed

Apparently even though I can build an engine pretty fast, I am really slow at bolting stuff on to the outside of the engine.... So ya, I did not get the engine back into the cradle as planned. However, I think it is ready to go back in. I will be back at it on Friday. Doesnt look like I will have time this weekend to finish it up though. Weekend got busy out of no where.

5-Speed

Alright, so I got the engine back in a couple days ago. That was pretty easy. But then the heat wave hit and motivation has gone out the window. Even at 8pm, its still 100° out. However, I did find some time to work on the car last night and had a couple questions for the experts. Pretty much, I need to know what wire is for the alternator and what wire is for the starter and if any of these are grounds.




So the one I have right above the ac pump, I think its a ground. Then the one I have going to the power terminal on the starter, I think that is actually for the alternator and the one sitting next to that goes to the starter. I cant find any other big wires near the alternator and it seems like the one I have going to the starter might be long enough to make it to the alternator. Any help would be great!