1995 Saturn SL2 Build Thread

[cgg17]

Decided to start a build thread for my 95 Sl2, I've owned it since 2018 and have been doing some bolt-ons as well as grabbing accessories for it. Ill start from the beginning and once I catch up I will update it accordingly.

Below is the day I picked up the car. It had 152k on it with a failing automatic transmission but a suprisingly strong engine. The body was in great shape which was my major deciding factor in purchasing it. It needed a front subframe and transmission work, so naturally it was only $400. It made it an hour or so home and then the work began from there.

[cgg17]

I did some general matinenece at first like lubricating the window regulators and replacing the rusted out rear drivers vent window. It was a strange place to rust, I have no clue why, but the rear drivers seat belt retractor also rusted too.

[cgg17]

Next task was addressing the transmission issue. I had planned to swap in my old powertrain from the 1994 Sl2 that I rolled over the previous winter. It only had 56k miles on it (verified with paperwork) and was a fully loaded manual car. So, I had the basics for a manual swap and grabbed everything else I needed from the local yard. I also replaced the subframe (which came home on the roof rack on our 1999 Sl2) and the lower control arms to get it ready for inspection. I also threw on my old sawtooth rims for a finishing touch.

[cgg17]

I planned on attending the 2018 Boston extinct car day show, so I detailed the interior and exterior of my 95. I threw on a warm air intake as well just for fun. Also, I wanted a spoiler and I found a member from saturnfans that met me at the Boston extinct car day, and I installed it on the spot. I was very thankful for the spoiler, as it completed the look of the car in my opinion.

[cgg17]

I installed cruise control, oem fogs, black badges, and kept up with cleaning the car for a while.

[cgg17]

I made a short throw shifter for it (true short throw), but later went back to a chop top shifter. I got tired of the floppy boot. I also put on a thermal r&d catback, one of my first bolt-ons.

[cgg17]

A little later I found an OEM Saturn (made by Saris) roof rack, which I just had to get. So, now I can bring my bike and kayak around without needing a truck. I also put on gen 3 hubcaps and steelies, as my sawtooth alloys became corroded.

[cgg17]

I planned on making a trip to the upper peninsula of Michigan, so I went through the entire car and refreshed things. All new suspension poly bushings and moog struts, fluids, entire cooling system, a/c condenser and refridgerant, 5th gear swap, and tires. I also got rid of power steering by swapping in a manual rack. To retain A/C without shaving castings off of the timing cover I used a 70mm pulley (advanced auto # 89052) and a stock sohc belt with AC without power steering. I have over 20k miles on that set up with zero issues so far. I also threw a 4-2-1 header/downpipe set up on, getting rid of the cat. The entire exhaust was now 2.25" into the 2.25" thermal r&d catback.

[cgg17]

My brother and I drove my 95 up to the upper peninsula of Michigan from eastern Pennsylvania, about 1000 miles each direction. The car ran great and had no issues. Upon our return I got washed and waxed the car as well as detailed the interior.

[cgg17]

I found an AEM cold air intake for 91-99 S-Series on facebook marketplace for $10. I didnt have change so I paid $20, but it was still a great deal. It was new in box and never used. I had to cut the fender liner and make a splash gaurd but I am pleased with how it came out.

[cgg17]

My dogbone mounts were shot so I got poly inserts for them and the difference was quite nice. No more wheel hop on hard acceleration in low gears, and it seemed to keep the engine from rocking back and forth too much. Well worth the money.

[cgg17]

Next on my agenda was some more matinence, but also a small twist. I decided to replace the entire timing system as the engine had about 170k on it. I did the timing kit, as well as an oil pump and crank seal. While I was there I did the twin intake cam mod, and went 2 teeth retarded on the cam gear. I kept the engine in the car and was very careful with shaving the nub off of the head.

[cgg17]

Next thing I wanted to tackle was doing an upgraded diff pin. I did it on two mp3 transmissions, one for my brother's 1997 Sl2 for peace of mind, and one for my 95. I haven't installed mine yet but I will soon enough. I also was suprised to find that both factory pins were in good shape. I also put in all new gaskets and seals (besides the NLA quill seal).

[cgg17]

I finally got around to addressing the rear trailing arm mount rust that my 95 had. I was able to get a donor floor pan from a facebook forum member, and it was a real life saver. I had a bodyshop cut it out and install the new piece as well as paint it to keep the rust at bay. Next thing they need to do are my door sills but they can wait for a while.

[cgg17]

I found a GEO storm TB and threw it on, it seemed to increase throttle response nicely. Another thing I wanted to do was take away some fuel for more power. Essentially I wanted a quick way to tune it, as it is going to remain N/A for now. I grabbed an old 5 knob Apexi SAFC, as well as an AEM wideband 02 kit. I installed the SAFC in the empty cup holder and ran the wires under the center console.