My Aztek Engine teardown and build
Welcome to the site! Take a minute to register and join us. It's FREE! (and fun)
The ORIGINAL Aztek Fan Club Welcome, Guest. Please login or register.
Did you miss your activation email?
Always stay logged in

Login with username, password and session length
Home Gallery Help Login Register
Pages: [1]   Go Down
  Print  
Author Topic: My Aztek Engine teardown and build  (Read 987 times)
0 Members and 1 Guest are viewing this topic.
Jaws
Member
*
Offline Offline

Posts: 18


WWW
« on: March 17, 2017, 12:00:00 AM »

Well I'll go ahead and put some progress here and continue to update it. I am making a video about the whole teardown and I'll have that up pretty soon on my channel. So here's the history:

I bought the car last weekend with a known engine issue. I had gone to look at the car, (81k on the odometer) and it was in great shape. It started right up but it had a p0300 code and lots of knocking going on. I did lots of research about these engines before I purchased the car about a month later. So, I went to get a Uhaul and I towed the car back to my shop.

I started with the spark plugs and wires, and that didn't fix the issue. Well then... I decided to change the oil and I did the fuel filter as well.

I decided to tear it apart and do the intake manifold gasket set, thermostat, coolant flush (duh) and and oil change again since I didn't think that one through..

I pulled off the manifolds and to my surprise, the gaskets had been replaced before, so that's a good sign. No signs of failure or leakage, except for some seepage around the outside of the lower intake manifold gaskets. No biggie. Now what I found next was both exciting and disappointing..

I pulled off the rear valve cover at about 2:30 AM. After a few beers and lots of researching as to what could possibly be my issue, I had to find it. I couldn't just guess. Listening to the internet talk about the GM 3400 motor displaying symptoms of broken valve springs, rocker arm bolts backing out of the head, BROKEN CAMSHAFTS?? It was starting to really concern me. However, I have an advantage because it's just my time that I'm spending and maybe 200 bucks at most.. I have the car on a lift in the shop and it's fine to sit there for a while if I want while I fix all the issues it could possibly have.

Sure enough, sitting in the head is a rocker arm, not attached to anything with the aluminum threads still on the bolt. Well, there's the issue! Thankfully it didn't seem to cause any damage to the surrounding areas. Valves are clean and everything looks the way it's supposed to.

So then I ordered all the gaskets and continued to tear down the rest. My goal is to take care of everything I can so I can take the car on roadtrips and not worry about it. I wanted gaskets replaced whether or not they were bad, fluids changed, everything inspected and cleaned.

So far here's what I've done:

EGR gasket
Thermostat
Thermostat gasket
Oil Change
Fuel injector o rings
Threaded time-sert into head to put the rocker arm back in
cleaned head and pushrods
cleaned around all the heads
Fuel Filter
Painted Upper intake manifold and valve covers wrinkle black, cleaned
Cleaned throttle body, new gasket
New AC delco iridium tipped spark plugs and wires
Power steering fluid top off

So.. here's what I plan to do:

New air filter
Replace brake fluid (4% moisture and dark!!)
Replace rear saggy hatch struts
Another oil change... Should have thought of that before I did the intake manifold.
New cabin filters
Full detail inside and out
Hopefully locate new battery tie down... (bungee cords lol)
Transmission fluid and filter change
HID and led upgrades all around.
Various vinyl wrapping projects
I need to buy roof rails so I can put a roof basket on with an LED light bar.
Hopefully upgrade the audio.
Possibly tint the front windows to match
Logged

Instagram: Jawse36
Youtube Channel: Jawsmoker

Current Vehicles:
1996 BMW 328i:
KW V1,UUC System U, Fikse Fm5, Rogue Engineering,
low mileage block, s52 cams, m50 manifold, fan delete, m3 clutch, lightweight flywheel, shark injector stage 3+, fan delete, cat delete, m3 body, luxury package, Full led and hid lighting, suede headliner, 3.38 lsd, UUC camber plates, BMW reinforcement plates, Rogue RSM, Z3m shifter, Rogue WSR+ much more.

2003 Pontiac Aztek Champagne Beige metallic
Jaws
Member
*
Offline Offline

Posts: 18


WWW
« Reply #1 on: March 17, 2017, 01:21:26 AM »

IMG_6869 by andrew johnson, on Flickr
IMG_6870 by andrew johnson, on Flickr
IMG_6871 by andrew johnson, on Flickr
IMG_6873 by andrew johnson, on Flickr
IMG_6874 by andrew johnson, on Flickr
IMG_6876 by andrew johnson, on Flickr
IMG_6877 by andrew johnson, on Flickr
IMG_6878 by andrew johnson, on Flickr
Logged

Instagram: Jawse36
Youtube Channel: Jawsmoker

Current Vehicles:
1996 BMW 328i:
KW V1,UUC System U, Fikse Fm5, Rogue Engineering,
low mileage block, s52 cams, m50 manifold, fan delete, m3 clutch, lightweight flywheel, shark injector stage 3+, fan delete, cat delete, m3 body, luxury package, Full led and hid lighting, suede headliner, 3.38 lsd, UUC camber plates, BMW reinforcement plates, Rogue RSM, Z3m shifter, Rogue WSR+ much more.

2003 Pontiac Aztek Champagne Beige metallic
Jaws
Member
*
Offline Offline

Posts: 18


WWW
« Reply #2 on: March 17, 2017, 01:23:19 AM »

IMG_6913 by andrew johnson, on Flickr
IMG_6914 by andrew johnson, on Flickr
IMG_6916 by andrew johnson, on Flickr
IMG_6917 by andrew johnson, on Flickr
IMG_6922 by andrew johnson, on Flickr
IMG_6926 by andrew johnson, on Flickr
IMG_6927 by andrew johnson, on Flickr
IMG_6928 by andrew johnson, on Flickr
Logged

Instagram: Jawse36
Youtube Channel: Jawsmoker

Current Vehicles:
1996 BMW 328i:
KW V1,UUC System U, Fikse Fm5, Rogue Engineering,
low mileage block, s52 cams, m50 manifold, fan delete, m3 clutch, lightweight flywheel, shark injector stage 3+, fan delete, cat delete, m3 body, luxury package, Full led and hid lighting, suede headliner, 3.38 lsd, UUC camber plates, BMW reinforcement plates, Rogue RSM, Z3m shifter, Rogue WSR+ much more.

2003 Pontiac Aztek Champagne Beige metallic
Jaws
Member
*
Offline Offline

Posts: 18


WWW
« Reply #3 on: March 17, 2017, 01:26:35 AM »

IMG_6929 by andrew johnson, on Flickr
IMG_6930 by andrew johnson, on Flickr
IMG_6931 by andrew johnson, on Flickr
IMG_6932 by andrew johnson, on Flickr
IMG_6933 by andrew johnson, on Flickr
IMG_6936 by andrew johnson, on Flickr
IMG_6939 by andrew johnson, on Flickr
IMG_6940 by andrew johnson, on Flickr
IMG_6941 by andrew johnson, on Flickr

That's all for tonight!
Logged

Instagram: Jawse36
Youtube Channel: Jawsmoker

Current Vehicles:
1996 BMW 328i:
KW V1,UUC System U, Fikse Fm5, Rogue Engineering,
low mileage block, s52 cams, m50 manifold, fan delete, m3 clutch, lightweight flywheel, shark injector stage 3+, fan delete, cat delete, m3 body, luxury package, Full led and hid lighting, suede headliner, 3.38 lsd, UUC camber plates, BMW reinforcement plates, Rogue RSM, Z3m shifter, Rogue WSR+ much more.

2003 Pontiac Aztek Champagne Beige metallic
Jtaytekker420
Member
*
Offline Offline

Posts: 8


« Reply #4 on: March 17, 2017, 06:08:28 AM »

Wow buddy, ur doin an awesome job!! Congrats on the tek,looks to be in great shape and once u get her back together, I'm sure it's gonna be awesome. I'm totally following your progress...
Logged
Jaws
Member
*
Offline Offline

Posts: 18


WWW
« Reply #5 on: March 19, 2017, 01:34:06 AM »

More progress tonight. My dad wanted to come by and check out the car, so I showed him the features and he held the flashlight while I worked on the car lol

I started putting the rest of the motor back together. For some reason I got tripped up because I was missing an upper intake manifold bolt even though I marked all the separate bolts in ziploc bags to keep track of the different areas that I was assembling. There are certain aluminum bolts that are the same length and thread size, so it gets a little confusing.

I got as far as putting the upper intake manifold back on, valve covers, coolant hoses, coil packs, alternator and pulleys back on as well as the belt, hooked up some of the harnesses and basically what I have left is to put the throttle body back on, hook up the damn egr hose in the back which does not want to go on no matter what angle I position the engine... Then I have to fill the coolant and run it. I bled the brakes too since I had him there to help. I wen to go bleed the back and I didn't notice the little rubber nipple was on and I ended up taking a big stream of brake fluid right into my eye. Dammit.

The brake fluid puddle is just to show the color, and this is after pushing some of the old fluid through the system. It was a greenish brown color.. Nasty. The front bleeder screws hadn't been cracked in so long that they were a little seized. Unacceptable by my standards. I did notice that the cap says to use DOT 3, but I used DOT 4.

Untitled by andrew johnson, on Flickr
Untitled by andrew johnson, on Flickr
Untitled by andrew johnson, on Flickr
Untitled by andrew johnson, on Flickr

Rolling the engine forward with an engine mount and hooking it to the (car's left side) crossmember. It works great! I can relieve the tension whenever I need to and tighten it right back up when I need to re position the motor. It seems obvious, but based on the videos I've seen on youtube with people strapping the other end of the cable to questionable stationary objects... I decided this route was safer.
Untitled by andrew johnson, on Flickr

Untitled by andrew johnson, on Flickr
« Last Edit: March 19, 2017, 01:46:34 AM by Jaws » Logged

Instagram: Jawse36
Youtube Channel: Jawsmoker

Current Vehicles:
1996 BMW 328i:
KW V1,UUC System U, Fikse Fm5, Rogue Engineering,
low mileage block, s52 cams, m50 manifold, fan delete, m3 clutch, lightweight flywheel, shark injector stage 3+, fan delete, cat delete, m3 body, luxury package, Full led and hid lighting, suede headliner, 3.38 lsd, UUC camber plates, BMW reinforcement plates, Rogue RSM, Z3m shifter, Rogue WSR+ much more.

2003 Pontiac Aztek Champagne Beige metallic
geosheets
Noob
*
Offline Offline

Posts: 1


« Reply #6 on: March 19, 2017, 09:13:17 AM »

Looking good... that's a common problem with these aluminum heads. The threaded holes get oil down inside them and people don't clean the oil out. When you tighten the rocker arm down with oil in the hole it liquid locks and ends up pulling the threads out. I have an 03 tek with 70k miles that had the same issue... someone replaced the intake gaskets and a few thousand miles later the threads let go on one of the rockers. They always seem to let go a few thousand miles after the fact.
Logged
Jaws
Member
*
Offline Offline

Posts: 18


WWW
« Reply #7 on: March 19, 2017, 12:20:37 PM »

Looking good... that's a common problem with these aluminum heads. The threaded holes get oil down inside them and people don't clean the oil out. When you tighten the rocker arm down with oil in the hole it liquid locks and ends up pulling the threads out. I have an 03 tek with 70k miles that had the same issue... someone replaced the intake gaskets and a few thousand miles later the threads let go on one of the rockers. They always seem to let go a few thousand miles after the fact.

Interesting, I didn't know about that. When I pulled the bolts out they were all clean, so that's a good sign. The bolts all torqued down properly after I put the time-sert into the head. I hope that I can go a few years without having another rocker arm back out, but at least I know how to take it apart now. It's disappointing that the Aztek didn't run a few years longer, I'm sure they would have come up with a better engine to put in there.
Logged

Instagram: Jawse36
Youtube Channel: Jawsmoker

Current Vehicles:
1996 BMW 328i:
KW V1,UUC System U, Fikse Fm5, Rogue Engineering,
low mileage block, s52 cams, m50 manifold, fan delete, m3 clutch, lightweight flywheel, shark injector stage 3+, fan delete, cat delete, m3 body, luxury package, Full led and hid lighting, suede headliner, 3.38 lsd, UUC camber plates, BMW reinforcement plates, Rogue RSM, Z3m shifter, Rogue WSR+ much more.

2003 Pontiac Aztek Champagne Beige metallic
Jaws
Member
*
Offline Offline

Posts: 18


WWW
« Reply #8 on: March 20, 2017, 10:51:00 PM »

I put the Tek on my insurance and transferred the title today, so that was really nice! I wanted to get this thing on the road after being down for a whole week.. I don't mind driving my BMW at all, but I was excited to see how this thing drove.. (It feels weird saying that.)

Well, I went to go put coolant back into the car and I found a leak. I had a feeling I knew exactly where the leak was coming from.

Later on after I had assembled everything, I found the correct O rings that were included in the kit.. I had used an O ring that appeared to be the right size from the shop's O ring kit, which has every size imaginable. However, it wasn't the right size. I had to go back and take apart the throttle body and everything else just to get to the tube on the back side of the thermostat.

I put the correct o ring on, and I pressure tested it and filled the system with coolant. Good to go! I finished buttoning it up and while I was there, I tinted my fog lights yellow with some Oracal 8300 brimstone film I had from other projects. I can't leave anything stock. More light mods will come soon.. Now I just need to find a tent and some other stuff and I'm good to go! Thanks for checking out the tear down thread.

IMG_6966 by andrew johnson, on Flickr
IMG_6965 by andrew johnson, on Flickr
IMG_6964 by andrew johnson, on Flickr
IMG_6963 by andrew johnson, on Flickr


Logged

Instagram: Jawse36
Youtube Channel: Jawsmoker

Current Vehicles:
1996 BMW 328i:
KW V1,UUC System U, Fikse Fm5, Rogue Engineering,
low mileage block, s52 cams, m50 manifold, fan delete, m3 clutch, lightweight flywheel, shark injector stage 3+, fan delete, cat delete, m3 body, luxury package, Full led and hid lighting, suede headliner, 3.38 lsd, UUC camber plates, BMW reinforcement plates, Rogue RSM, Z3m shifter, Rogue WSR+ much more.

2003 Pontiac Aztek Champagne Beige metallic
Pages: [1]   Go Up
  Print  
 
Jump to:  

Powered by SMF 1.1.20 | SMF © 2013, Simple Machines
Theme Underground Yellow