19bonestock88's 2004 Saturn "Ion Green Line" build...

[19bonestock88]

A replacement engine is in the plans, just not a stock one. No sense not upgrading while I’m in there

[cRiPpLe_rOoStEr]

I know it might sound like a downgrade, but have you never considered experiencing with a 122 engine out of a late-model S10?

[19bonestock88]

Originally Posted by cRiPpLe_rOoStEr

I know it might sound like a downgrade, but have you never considered experiencing with a 122 engine out of a late-model S10?

I don’t particularly want an LN2, and it wouldn’t bolt directly to my existing transaxle, I’d need the variant from the Cavalier

[cRiPpLe_rOoStEr]

Originally Posted by 19bonestock88

I don’t particularly want an LN2, and it wouldn’t bolt directly to my existing transaxle, I’d need the variant from the Cavalier

Odd enough, the local equivalent of the Cavalier in my country and the regional versions of the S10 shared an Opel-designed engine, interchangeably between both the transverse-engined FWD models and the longitudinally-engined RWD ones.

[19bonestock88]

The US market Cavalier and S-10 for the longest time shared a common engine, the GM LN2, which was a 2.2 liter pushrod four cylinder making (I think) right around 100hp. The “spicier” L61 that I’m building should make in the ballpark of 175-185bhp and still give amazing mileage on the highway.

[Ecky]

How are the internals on these engines?

I recently learned that even the 67hp 3 cylinder economy engine in the Insight has forged pistons, forged rods, and a nitride coated forged crank. Since you lost a rod through the block, I'm guessing at least the rods aren't forged from the factory, and probably something you'd want to change.

[19bonestock88]

The L61 has cast pistons and rods, generally known to normally be safe to around 250whp if you do nothing other than add the air/fuel mass to support that. While I’d *love* to do an all forged bottom end for this car, considering I’m not planning to really try for big power I don’t see the reason to spend the extra money on the parts and block machining. It also makes engine replacement as easy as finding another short block for the worked head to go onto. Ya know, “ah **** I blew it up, let’s grab another from the salvage yard and try again”

[19bonestock88]

So while I wait for engine parts I’ve been working on my Ion a little. Since getting it home I’ve stripped off the bumpers and have been working on revising my aero/cutting weight. I’ve so far deleted the spare tire well and replaced my damaged trunk lid with a new and slightly lighter one with a new, bigger, (hopefully) better spoiler, and have begun work on smoothing the aero on the front bumper similar to GM’s land speed record Ion

[19bonestock88]

More progress, I replaced the broken and faded headlights on my Ion with new ones and instead of halogen bulbs I went with Morimoto 2Stroke 3.0 LED bulbs. They’re rated 28W instead of 55W for the bi-xenon setup I had before, and also use the stock harness instead of requiring a relay and control harness and projector, so I’ve likely also cut a small amount of weight. I also finished smoothing out the front bumper cover, made new faschenfeld edges for my rear bumper (to match the new longer spoiler) and marked for vents to be cut into the bumper similar to what I have on the front fenders.

All the while, I’m waiting on the UPS guy to bring me parts so that I can prepare the next engine for install…

[19bonestock88]

Done some more aero work to the car while waiting for engine related stuff. Made some holes underneath my faschenfeld edges to allow low pressure to pull air out from behind the bumper cover. Also installed vents in the bumper cover that mimic what I had initially installed on the front fenders and made/attached new wheel skirts of a similar design to before with the added evolution of having a steel rod run through one flute which allows the piece of coroplast to be bent slightly and hold the curve