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Old 09-26-2005, 09:25 PM   #1
RalliArt16
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1996 SC1
1995 SC2
Default So it begins: Rebuilding a 1995 SC2

If you recall I purchased a '95 SC2 with approx. 100,000 miles from an unknown individual for $650. Basically, I plan to do a complete teardown and turn it into a beast. I have a '96 SC1 (which was been very good to me thus far) for my daily driver. If I have the necessary funds, time and knowledge, I plan to forge this baby and drop in a turbo.

I have a pretty decent garage with a fair amount of tools and a credit card for the tools I will need but don't have I am gonna hold on the engine hoist and stand until I get to the point where I actually need it. I plan on picking up FSMs from my local dealer sometime in the upcoming weeks.

Bear with me here. I am very busy with school and work on the weekends, so its gonna be a slow process. I will use any free time I have to get this project going, and be sure to take pictures. Unfortunately I dont have a dedicated digital camera, so I'll be using my Sony Ericsson Phone.

...
1996 SC1
1995 SC2

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Old 09-26-2005, 09:38 PM   #2
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Default Re: So it begins: Rebuilding a 1995 SC2

Day 1:

Pulled the car inside and took the hood off.

Took out the plugs to inspect them. Plugs from cyl's 2 and 3 were covered in oil, it was literally dripping off them. I suspect a cam cover gasket, no big deal.



Proceeded to remove front fenders, front bumper. Car placed on jackstands and wheels removed.


I was suprised at the tires. One tired was bald down the metal wire. The other 3 looked new but each tire was different from each other....


I was a little irritated when I realized a plastic bracket from the front bumper was snapped off. It looks like he had a little fender bender which caused this. This would also explain the broken bracket for the turn signal.... Luckily no other major damage is done. How much is a new bumper gonna run me?

Note: Am I missing something here or can you only upload 1 image at a time. Its very time consuming and annoying

...
1996 SC1
1995 SC2

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Old 09-27-2005, 12:31 AM   #3
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Default Re: So it begins: Rebuilding a 1995 SC2

A new front bumper from saturn is $300+ ! I'm gonna see if i can repair this one. The mounting piece is a plastic part that snapped off and I have the piece.

What would someone recommend as a permanent, strong way to join two pieces of plastic?

...
1996 SC1
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Old 09-27-2005, 02:17 AM   #4
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Default Re: So it begins: Rebuilding a 1995 SC2

Quote:
Originally Posted by RalliArt16
A new front bumper from saturn is $300+ ! I'm gonna see if i can repair this one. The mounting piece is a plastic part that snapped off and I have the piece.

What would someone recommend as a permanent, strong way to join two pieces of plastic?

Take the bumper to a business that specialises in bumper repair and reconditioning. They can weld plastic. No adhesive I have ever found works worth a hoot at holding the tab to the rest of the fascia at the spot right by the corner of the corner lamps. I had the same kind of damge on my car, and I wasted six months and too much money trying to glue it together with $60 adhesive kits, etc.

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Old 09-27-2005, 11:57 AM   #5
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Default Re: So it begins: Rebuilding a 1995 SC2

jjbumpers.com had reconditioned bumpers at pretty decent prices.

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Old 09-27-2005, 03:01 PM   #6
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Default Re: So it begins: Rebuilding a 1995 SC2

After inspecting it closer and referring to saturnpart.net, it seems the broken part is actually removable and replaceable. Its #10 is this image,

http://www.trademotion.com/schematic.../I/IA91910.gif

the "lower support fascia". And its "only" $45

...
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Old 09-28-2005, 02:10 AM   #7
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Default Re: So it begins: Rebuilding a 1995 SC2

Ok, so i've done a little more removal of parts. Now planning to attack the A/C. I plan on totally stripping the car of A/C (even tho I do live in Florida..). Obviously I can't get the car to a professional A/C shop. With that in mind, what is the next best thing to remove the refrigerant from the a/c system? Is there an alternative to purchasing a vacuum pump?

I'm open to suggestions, even if it involves ghetto rigging something. Anything is better than simply letting it all into the atmosphere.

...
1996 SC1
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Old 09-28-2005, 08:03 AM   #8
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Default Re: So it begins: Rebuilding a 1995 SC2

A home or appliance A/C repairman can remove the refrigerant for you. Try calling your city hall, to find out what they do with old refrigerators and A/C units.

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Old 09-28-2005, 09:50 AM   #9
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Default Re: So it begins: Rebuilding a 1995 SC2

pssssssssssssssssssss...

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Old 09-28-2005, 11:45 AM   #10
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Default Re: So it begins: Rebuilding a 1995 SC2

If it makes you feel better the 134A in your year is ozone friendlier...

Still illegal to vent it but it was designed from the ground up to be nice to the air.

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Old 09-28-2005, 04:22 PM   #11
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Default Re: So it begins: Rebuilding a 1995 SC2

Quote:
Originally Posted by dixonba
pssssssssssssssssssss...
LOL.... it is only 1.5 lbs after all... Dunno have to think about it. Just think though, at work (advance auto) we sell ridiculous amounts of R134a to DIYers.. just imagine how much they are dumping because of leaks in their systems, and simply keep refilling it instead of getting it repaired.

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Old 09-28-2005, 04:29 PM   #12
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Default Re: So it begins: Rebuilding a 1995 SC2

Heh i just went out and started unbolting the A/C lines.. and nothing came out! Guess the system was bone dry already due to a leak somewhere.

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Old 09-28-2005, 06:35 PM   #13
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Default Re: So it begins: Rebuilding a 1995 SC2

Update as of today:




Got the a/c compressor out, coolant / wiper fluid reservoir out, and a few other misc things.

Came across the nice suprise that the passenger's side CV joint is totally mangled. The driver's side joint looks identical...


...
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Old 09-29-2005, 12:52 PM   #14
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Default Re: So it begins: Rebuilding a 1995 SC2

i'm thinking about picking up an SC2 and rebuilding too. are there any years i should stay away from?

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Old 09-29-2005, 01:31 PM   #15
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Default Re: So it begins: Rebuilding a 1995 SC2

curious why you are removing everything? if you need a weight reduction guide go here:

http://www.evilplastic.com/p92-wgt1.htm

...
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94 SL2
95 SC2

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Old 09-29-2005, 03:05 PM   #16
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Default Re: So it begins: Rebuilding a 1995 SC2

Why am I removing everything you ask? It is going to get a new paint job. At the moment I am an amateur painter however. I purchased a few books on automobile painting and will invest in a very good compressor + painting tools. Plus the great part about saturns is that every panel comes off except the roof.. which will make painting them immeasurably easier.

Not to mention taking everything off makes access to things a lot easier, plus it pisses my parents off more

...
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Old 09-29-2005, 03:08 PM   #17
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Default Re: So it begins: Rebuilding a 1995 SC2

By the way, I will attempt the crank pulley today. Going to pick up some impact sockets + some piping to use as a cheater bar. However, what is the best way to keep the crank pulley from rotating as i undo the bolt?

I would think you just put it in gear, however.. the tranny is shot so it won't engage into gear... I guess i'm gonna have to try to wedge something in between the pulley to hold it steady. Any other ideas?

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Old 09-29-2005, 03:42 PM   #18
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Default Re: So it begins: Rebuilding a 1995 SC2

I'm rebuilding a 91 SC. Pics in my gallery.

I noticed from the 91 to my 94 that some of the bolts they decided to use are different. For example...the interior bolts to remove the front right fender on my 91 were the Torx-T-27 bolts. On my 94 SC1 they are either 10MM or 13MM bolts.

I guess that goes to show you how they change things from the beginning.....

I need to get back to working on my car....I haven't devoted any time to it recently. I've kind of been involved in work and spending free time with my wife and our dog....

Maybe I'll do some work on it this weekend.....

...
Bryan

94SL2 HCE, "Pearl"

99 SL

94SL2 260K Miles
1/15

97SW2 266K Miles
2/15

Always
94SC1 340,501 Miles
Org. Engine/Auto Trans
2/97-10/08
Gone 3/12

92SL1
05VUE
91SC

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Old 09-29-2005, 04:04 PM   #19
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Default Re: So it begins: Rebuilding a 1995 SC2



That was my first attempt. Just replace tire iron with impact wrench...

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Old 09-29-2005, 05:02 PM   #20
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Default Re: So it begins: Rebuilding a 1995 SC2

Quote:
Originally Posted by dixonba


That was my first attempt. Just replace tire iron with impact wrench...
Heh i'll have to rig something similar. Taking off the crank pulley has been put on hold for a while however. I have large craftsman sockets but they're 12pt.. (after contacting craftsman, they dont have 6pt sockets in 20mm and above.. because the "12mm sets sell better" ). I dont have an impact wrench at the moment, but i can purchasing them because 1) they're 6 pt and 2) i will buy an impact wrench in the future. I just ordered a set of metric impact sockets online from sears.com. They dont have large sets at my local sears store and its $10 per socket... so i opted to just order a set.

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