Project: "White Lightning"

[Maxx Mazda]

The truck is named sarcastically of course. There is nothing "lightning" about a 2.2L S-10...



First off, I'll present the truck:


http://imageshack.us/a/img21/6866/img2056jp.jpg


http://imageshack.us/a/img833/3980/img2108ru.jpg


http://imageshack.us/a/img684/9922/img2057yr.jpg


http://imageshack.us/a/img803/8038/img2114z.jpg


It's lightly modded, CAI, Beltech 2" drop spindles, 1" drop leafs, rims, tint, system, clear corners, etc. My favorite mod has to be the white lettered tires. I get more compliments on that than anything else.


I digress... This truck is my winter beater. Yes, some may say it's a nice truck but I have a Mazda that I drive in the summer, and this truck serves as my daily driver, and also hauls my dirtbikes to and from the track.


Anyways, blew the head gasket, so I thought I'd rebuild the entire engine. The truck has about 190,000Km on it right now, I've rebuilt most all of my vehicles, might as well do the S-10 too. An LSx swap was tempting, but with my Mazda putting out close to 400HP, I just need a reliable daily, so I'll be rebuilding the 2.2L, and this will serve as my "rebuild journal". Plans are to replace pistons, all bearings and gaskets, oil pump, water pump, header, etc. A general "freshen up" and replace of all the shit that's been bugging me with this truck since I bought it about a year ago.


And so it begins. The truck wouldnt run under its own power, so I had a few neighbors help get it in the garage, and the teardown began. This is where I got to today. Isn't it disgusting?


http://imageshack.us/a/img11/7633/img3156pj.jpg

[Darkane]

Does the 200hp vortec V6 not bolt right in?

I thought the "Extreme" or whatever model of S-10 had that motor, and it was pretty cool.

[Maxx Mazda]

It does, but it's just my beater. While the 2.2 is gutless as fuck, the fuel economy more than makes up for it.

[Maxx Mazda]

Got this disgusting turd out of the truck. The rear pain has been leaking for a LONG time. Pretty much all the parts below the oil pan looked like this:

http://img824.imageshack.us/img824/196/img3158be.jpg

Each and every nut, bolt, and part went into the varsol tank to get that shit off. Some stuff got a fresh coat of paint. Here is a little bit:

http://img401.imageshack.us/img401/5541/img3162dx.jpg

Look at the oil all over everything:

http://img809.imageshack.us/img809/5954/img3169m.jpg

Gross disgusting engine:

http://img824.imageshack.us/img824/6039/img3170sa.jpg

http://img855.imageshack.us/img855/747/img3171gq.jpg

Some new parts. Picked up some LED front blinkers/parking lights:

http://img9.imageshack.us/img9/4901/img3172gf.jpg

The oil filter on the tutu engine is in the most retarded spot, and even though GM put a nice little "spout" there to catch the oil, it doesnt work. A relocation kit from TransDapt will cure this.

http://img690.imageshack.us/img690/4466/img3173pp.jpg

NGK plug wires:

http://img11.imageshack.us/img11/6134/img3174zf.jpg

New water pump and fuel filter:

http://img812.imageshack.us/img812/5812/img3175vp.jpg

[Maxx Mazda]

It just went up to a hair above 0*C today, so out came the pressure washer, and I did the garage, along with the engine bay, and the engine. The engine bay will get a spray bomb touch up once it's dry, and the engine of course was just getting most of the sludge off so I can tear it down.

http://imageshack.us/a/img689/6890/img3178dk.jpg

Got probably 90% of the gunk off the engine with 3200psi of gas powered goodness!

http://imageshack.us/a/img24/1336/img3180hk.jpg

[Cody D]

Aren't you worried about damaging something with that pressure washer in the engine bay and on the engine? I just see nothing but possible problems arising from that.

[Maxx Mazda]

Fuck no. All open lines and hoses were capped, and the engine is being rebuilt.

[Cody D]

Originally posted by Maxx Mazda
Fuck no. All open lines and hoses were capped, and the engine is being rebuilt.

Sounds good, just curious, I've hand scrubbed engine bays before and this looks like a much better solution. Good luck with your rebuild.

[Maxx Mazda]

Head off and in the Varsol tank:

http://imageshack.us/a/img580/6222/img3182s.jpg

Gave the pistons a quick wipe down, we can see that 2 and 3 had the blown head gasket and were burning coolant. The pistons have been "steam cleaned" so to speak.

http://imageshack.us/a/img26/5070/img3184v.jpg

Rocker arms, pushrods, and lifters all removed and layed out in order.

http://imageshack.us/a/img69/7646/img3185cf.jpg

Timing cover off. Ran out of time, the lady had supper ready so had to call it a night. Tomorrow should have the engine completely apart.

http://imageshack.us/a/img707/8238/img3186lh.jpg

I'll probably send the head to my friends at Precise Engine Rebuilders for them to do their recondition on it and throw some new valve seals in if I don't just do it myself. I'll do the block myself since it's only getting a hone and fresh bearings.

[Maxx Mazda]

Did a bit more work today on getting the engine apart, nothing special.

Took a rattle can to the engine bay and made it look new again. Also the area behind the grille:

http://imageshack.us/a/img69/3796/img3189rj.jpg

http://imageshack.us/a/img23/585/img3190b.jpg

[Maxx Mazda]

Sorry its been awhile since an update, work has been progressing steadily but I've just neglected the thread.

Block stripped down:

http://imageshack.us/a/img651/9789/img3201j.jpg

Used my 12 ton press to press the wrist pins out:

http://imageshack.us/a/img132/5346/img3203ge.jpg

The water neck is just pressed into the thermostat housing. A shitty move by GM. This leaks all the time. So I used aluminum brazing rod and brazed the two pieces together. Might not look like much, but it is strong and air tight.

http://imageshack.us/a/img515/669/img3204c.jpg

http://imageshack.us/a/img526/5223/img3205n.jpg

Painted up:

http://imageshack.us/a/img266/3582/img3207q.jpg

Painted other misc. engine pieces. All parts were painted with Dupli-Color engine enamel and then baked for an hour. Paint cures rock hard.

http://imageshack.us/a/img5/4319/img3206w.jpg

http://imageshack.us/a/img515/6688/img3212q.jpg

My new header arrived:

http://imageshack.us/a/img521/7828/img3214c.jpg

[Maxx Mazda]

My friends at Precise engine rebuilders did the block and head for me. The block was hot tanked, and had the cam bearings installed. I honed the cylinders myself.

The clean block:

http://imageshack.us/a/img829/7230/img3234xx.jpg

They milled the head flat for me, I had to change the valve seals so out came the spring compressor, and the old junk seals were toast:

http://imageshack.us/a/img856/8612/img3238n.jpg

New seals installed:

http://imageshack.us/a/img842/3936/img3240g.jpg

A tip: when installing the valves again, put grease on the shaft to help hold the keepers in place:

http://imageshack.us/a/img28/2500/img3244l.jpg

http://imageshack.us/a/img838/151/img3242s.jpg

Completed head:

http://imageshack.us/a/img521/9549/img3246c.jpg

I honed the cylinders, then took the block outside and cleaned it thuroughly with simple green and water. After an extremely thurough rinse, the block was blown dry with compressed air, then masked and painted:

http://imageshack.us/a/img687/1379/img3247m.jpg

http://imageshack.us/a/img801/3143/img3248cg.jpg

My hone job on the cylinders:

http://imageshack.us/a/img694/4791/img3249cf.jpg

[firebane]

Nice clean up on everything!

Where did you get than trans dapt relocator kit?

[Maxx Mazda]

Mopac

[tobypaddock]

lookin good, god you do nice work - i HATE S10's but i keep checking back into this thread just to see what youve done to it, cant wait to see it finished!:thumbsup:

[Maxx Mazda]

Re-honed the cylinders to get a better cross hatch. It's hard to see on camera, but it's a legit 45* pattern. After honing, the block was again thuroughly cleaned with soap and water. The cylinders and cam bearings were wiped clean with mineral spirits, and the block was blown dry with compressed air.

http://imageshack.us/a/img210/4408/img3252o.jpg

http://imageshack.us/a/img849/3166/img3253p.jpg

Gapped the rings. Spec is 0.020"-0.010" so I went on the tighter side, and
settled on 0.013".

http://imageshack.us/a/img803/9634/img3255s.jpg

Next up, I went to press the wristpins into the pistons. I froze the
wristpins overnight and heated the conn rods with a MAPP torch as reccomended. Needless to say, even with that and a 12 ton press, I shat the bed bigtime.

http://imageshack.us/a/img685/1084/img3256wm.jpg

I don't think I've ever been so mad... Oh well, what can you do? I've ordered a new set, hope they get here by Friday.

Had the crank polished:

http://imageshack.us/a/img715/386/img3257y.jpg

New main bearings installed, and the crank was plastigauged. Took the caps off again, and when all clearances were confirmed, the crank went for a final clean, then it was dropped into place with lots of assembly lube.

http://imageshack.us/a/img703/2585/img3258u.jpg

Cam was polished also. It was lubed liberally and installed into the
block.

http://imageshack.us/a/img339/8431/img3261b.jpg

New timing gears, chain, and tensioner installed. Engine was timed, all bolts torqued.

http://imageshack.us/a/img96/9139/img3263q.jpg

Because I couldn't install the pistons, I decided to bolt on whatever else I could. Oil filter adapter plate, CMP and CKP sensors, freeze plugs, block heater, etc.

http://imageshack.us/a/img338/9496/img3264f.jpg

http://imageshack.us/a/img547/8453/img3265f.jpg

Installed a new water pump, and installed the timing cover with a new gasket.
(All gaskets are new.) Pressed on the crank pulley adapter as well, and thats
where it sits tonight.

http://imageshack.us/a/img203/2743/img3266b.jpg

[Maxx Mazda]

Still waiting on pistons, so tied up a few loose ends today. Changed the fuel filter, and fixed the transmission cooler lines.

The stock lines are known to leak at the flexible connector. Mine were. I decided that rather than replace the lines (none available for weeks here) or add my own -6AN softline, I would eliminate the softline all together. There is enough tubing to reach the radiator when the softline is eliminated if you do some creative bending.

Used a tubing cutter and cut the leaky shits out of there:

http://imageshack.us/a/img20/5295/img3268f.jpg

Used a pipe flaring tool and flared it, and put some compression fittings to use:

http://imageshack.us/a/img580/4567/img3267z.jpg

http://imageshack.us/a/img703/1935/img3270n.jpg

[03ozwhip]

Dang, i wish you would come to my house and do this to my 68 mustang lol good work man.

[Maxx Mazda]

Originally posted by 03ozwhip
Dang, i wish you would come to my house and do this to my 68 mustang lol good work man.

At least this truck won't classify as "Hella Flush"

[03ozwhip]

Lol i sure hope not. I should do hella flush on my mustang! Good thinking lol but really though, come to my house and do this to my engine. Please. :)

[Maxx Mazda]

Got lots done today. The engine is complete. Pressed the wristpins into the connecting rods.

http://imageshack.us/a/img217/6515/img3279ejn.jpg

With lots of assembly lube, the pistons were installed, along with a new oil pump and of course all new bearings.

http://imageshack.us/a/img543/2666/img3282ku.jpg

Used plenty of Permatex "Right Stuff" black, along with new gaspets where required and installed the oil pan.

http://imageshack.us/a/img705/5016/img3283s.jpg

http://imageshack.us/a/img818/515/img3284ei.jpg

Top view showing pistons installed, lifters and lifter guides installed as well.

http://imageshack.us/a/img502/3165/img3285rl.jpg

A new head gasket was installed:

http://imageshack.us/a/img526/8879/img3287ab.jpg

The head was installed, and torqued in three steps.

http://imageshack.us/a/img832/32/img3289pm.jpg

Pushrods and rocker arms lubed and installed.

http://imageshack.us/a/img515/8066/img3291f.jpg

With a new valve cover gasket in place, I could get to work bolting up all the accessories.

http://imageshack.us/a/img834/1148/img3292az.jpg

http://imageshack.us/a/img171/3443/img3294l.jpg

http://imageshack.us/a/img685/5478/img3295zc.jpg

That's all for now, should have it into the truck tomorrow and hopefully running on Thursday!