99 2.4L DOHC Rebuild. - Performance Forum

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99 2.4L DOHC Rebuild.
Sunday, July 18, 2010 8:32 AM
Hey all, thanks for taking a look.

So a couple weeks ago I pulled the engine out of my 1999 Malibu. I matted the throttle and got it above 6K and it didn't govern/shift for some reason. The engine (unbeknown to me) was about 1/2qt. below the hash marks and responded to this abuse with a few ticks, and I let off on the skinny peddle. Less than a 1/4mi. latter I reached my destination, and the engine was noticeably knocking on deceleration, leading me to believe the oil pump was cavitating. I've run into this, the car burns oil, so I added a quart. Well on the way home it got awefull, and lost almost all power, and knocked always. Now with 178,000mi. I feel it's premature but I had been thinking of freshening up the engine for the fun of it, so now I'd just have a reason. End result was three spun connecting rod bearings, 2, 3, & 4 if I recall correctly. All other bearings show signs of severe wear. Weather they were all severely oil starved, or if one was and the bits from that started wearing the others, but the crank is gone so I need to procure a new one, or get this one welded and reground.

My few questions are this;

Why wouldn't the car have shifted? Or governed the RPM's since they were in the precautionary range? I'd think it can only sustain that for several seconds right?

I've read that the wrist pins often have trouble. Mine show signs of some scratches/galling. If I really had to, I could use them again, but I don't plan on it. My real question is, is how are they lubricated? I don't see any direct means of oil supply? How did GM miss this? Are there any mods to fix this? Does GM really expect the cooling oil shot onto the piston to lubricate these bearing surfaces?

I'm not looking to make gobs of power. Indeed with how tired the engine was, stock will seem great. I remember this car being very peppy at 20,000mi when I got it. However if there are any after-market parts of comparable price to stock, I would be interested since I have it completely torn down. A good example seems to be the "secret cams".

Parts list so far is;
I need to replace/recondition the crank
Replace the connecting rods (the one that didn't spin still has that wrist pin damage).
Wrist pins (galled)
Possibly one of the camshafts. IIRC the exhaust has very small blue marks on the edge of the lobes, not in the center where I would expect it though? Is this common? It still honestly looks serviceable the center contact area of the lobes are still smooth.
Are over-sized cams available? The very last bearing surface shows the slightest pitting in a very localized area. Very tempted to just run it.

I've dye-penned the head and the block with a very long dwell time, they seem fine.
I have pics if anyone is interested.

Basically looking for recommendations, or tips during my reconditioning. Oil supply, tricks, etc. Anything others have learned in order to get more than 178,000mi out of this engine this time around.

Thanks for looking!

- Hawkeye

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