Hyundai Genesis Forum banner

1 - 20 of 294 Posts

·
I wanna go fast!
Joined
·
469 Posts
Whats going on folks! This will be be my Re-build / Build thread for my GC..... Your probably thinking... " Re-build ? what the hell is he talking about " well let me explain.

So, I purchased my first GC in 2012 - 3.8 Track Acqua Minerale BLue 6 spd - Loved the car ever since I layed eyes on it and couldn't wait to start modding/tweeking/perfecting it... My plan was to eventually get into the F/I side of the house, but that wouldn't be until later on down the road.... Flash forward 1 year later. I moved out to Las Vegas for my job (USAF) and I came across a Red 2012 Rspec / Supercharged that was for sale out in San Diego.... got to talking with the Stealership and got a great deal on the car that i couldn't pass up, especially after around $10K had been dumped into the car... So I drove out to San Diego and traded in my GC for the Red GC... Well I was super stoked to own a S/C GC - pretty much my dream of what I had planned for the future for my car. Well we've all bought used cars before right ? The next day the car over heated, so i began trouble shooting and found that my radiator hose had been sitting on the header and it burnt a hole thru it - so I replaced that. Thought that was the issue, nope she still remained to overheat, so I bought a new thermostat thinking maybe that the oem had taken a dump, but w/ only 12k miles I had high doubt that was the issue, but i still replaced it w/ a mishimoto racing thermostat - car still overheated. I was driving to work one morning and my temp gauge redlined within 5 mins of driving, and when I made it to work I opened the hood and I could hear a drip followed by a "hisssss" - it was coolant leaving the block and dripping on the header..... So this is where the RE-BUILD / BUILD part comes into play....

Before I pulled the motor, I removed the exhaust and stock suspension and installed my Ark Grip V2 & HSD Coilovers :)


This exhaust was SOOOOOOO loud, and it had poor welds, so it was time to go! I ended up giving it to my boy Travis - GenCoupe13 - here on the forum, he had it fixed and re-welded and he threw it on his 13' GC - It sounds amazing now !


Replaced with this beautiful work of art :)


I had these on my other GC and removed them before I traded it in.


Coils & Exhaust being installed.

Now onto the rebuild:

Car was purchased - June 1, 2013 / June 23, 2013 - I pulled the motor out.

After I tore the motor out & down, I came to find that I had Detonation in cyl 4 which caused my head gasket to literally explode and and also damage the top of the cylinder sleeve and Warp my head.... So my awesome purchase of a car was not so awesome after all....

So as of right now the Motor has been at a machine shop having the following done :

- Block Re-surfaced & Honed
- Heads Decked / Straight Edged / Re-Surfaced
- Crank Polished / Re-Balanced
- All Parts Hot Tanked / Degreased / Cleaned
- New Main Bearings
- New Rod Bearings
- New JE Piston Rings
- New Main Bearing Cap Bolts:
- 21117-3C100 P/N - Cap Bolt (8 bolts)
- 21116-3C100 P/N - Cap Bolt (8 bolts)
- 21126-3C100 P/N - Side Bolt (8 bolts)
- New Front Main Seal
- New Rear Main Seal
- New Valve Cover Gaskets
- New Intake Manifold Gasket(s)
- New Plenum Gasket
- Arp Head Stud Kit (16 Bolts)

The motor already had:

- JE Pistons - Size: STD / Bore: 96.0
- Brian Crower Sportsman Connecting Rods w/ ARP 2000 Bolts

So my plan for this Build Thread is to:

1. Keep you all up to date on the process.
2. Upload as many photo's / videos as possible.
3. Post new Mod's / tweek's to the car and motor.

Let the photos Commence!!!!!!!! Most of these pics were taken with my iphone so excuse my crappy resolution... I will try to get a nice camera to take future pics!



Hood Removed


Motor


Motor


Motor


Motor... yet again lol


Up on Jack Stands / Coolant drained


New Toys - Gotta Love Harbor Freight, all that for $185 !


My boy Mike aka Imdubbs here on the forum - Disconnecting the Exhaust


Everything disconnected from the motor


Cherry Picker all hooked up and ready to pull the motor out :p


Another view of the Cherry Picker


Up...


Uupp...


And away!!! :p


Motor out - Crappy pic sorry :\


Motor Out - Better Pic :p


Back of motor - Spec Clutch stage 3 clutch / Ark Headers


Motor / Supercharger Bracket


Valve covers removed - Didn't have bolts to mount the motor on the engine stand lol so 2 - 2x4's will suffice for the time being :p


Heads & Cams


Heads & Cams


Front Cover removed / Wiring Harness Marked & Taped


Front of Cams


Front of Cams


Started to remove the lower intake manifold and snapped my 6mm Hex Bit, I swear the bolts were torqued to 200 ft lbs friggin ridiculous!!!!!!


Hex Bit decapitated :(


Which called for a Beer Break! :p


Quick shot of the garage and how everything was sitting - slightly organized :p


The infamous blown headgasket!


yep, blown to SH*T !


..... grrrrr


...


Head Removed - gasket literally sprung up when I pulled the head off, and you can see the pistons crown of Cyl 4's is nice and shinny from the coolant being sucked in there, thank god she didnt hydro-lock!


heres a better view... steam cleaning at its finest!


Bottom side of the head.... Exhaust valves were soaked as you can see!


Again, exhaust port soaking wet.....


Close Up


Better Close up.... ridiculous.


Heads off / Top Dead Center


Piston crowns


Stupid finger lol


Cleaned the Heads up a lil :p


Thought this was a cool pic :p


Now onto the good stuff.... Cyl 4 side wall damage from the detonation!


Again...


Better angle / up close pic


Headgasket again.... Aye aye aye!


Pretty sweet pic!


And another...


FINALLY!!! got bolts for the block to put on the engine stand lol Thank you Home Depot :p


Organization at its finest!

And thats all for now folks! Stay tuned for more progress and updates!

Update 2
Update 3
Update 4
Update 5
Update 6
Update 7
update 8
Update 9
Update 10
Update 11
Update 11
Update 12
Update 13
Update 14
Update 15
Update 16
Update 17
 

·
, SJ is the man
Joined
·
9 Posts
This seems to be Layzie's car. Bummer that he took a car that had so much bad work done to it, and then sold it to a dealership. I can't believe a dealership would even buy a car like that. Glad you're reviving it, because done properly that should be pretty damn sweet.
 

·
I wanna go fast!
Joined
·
469 Posts
Discussion Starter #4 (Edited)
@ Snoopy - thanks for opening up the thread brotha! There will be way more pictures and way more future progress in the works!

- Stew

@ JT - Yea it was his.... There was a laundry list of things wrong with the build man, but I got the car at a steal, sometimes things really are too good to be true huh ? However, Im taking all of the necessary steps to revive this monster and have everything done right! no cutting corners like the previous attempt of putting this motor together! stay tuned for progress updates!

- Stew
 

·
, SJ is the man
Joined
·
9 Posts
@ Snoopy - thanks for oprning up the thread brotha! There will be way more pictures and way more future progress in the works!

- Stew

@ JT - Yea it was his.... There was a laundry list of things wrong with the build man, but I got the car at a steal, sometimes things really are too good to be true huh ? However, Im taking all of the necessary steps to revive this monster and have everything done right! no cutting corners like the previous attempt of putting this motor together! stay tuned for progress updates!

- Stew
I'm looking forward to keeping up with it! Seriously though, I would triple check anything that you're not personally fixing/replacing. From top to bottom.
 

·
Sleeper!
Joined
·
825 Posts
About damn time Stew haha. Glad to see you finally got around to it though. Call me when your ready to put that beast back together.
 

·
Registered
Joined
·
3,093 Posts
I think I remember the thread this guy was selling the car on. Had all kinds of problems.

Good luck on your resurrection build!! As already stated just triple check everything!! lol. This will be superb once completed!!!
 

·
I wanna go fast!
Joined
·
469 Posts
Discussion Starter #9
About damn time Stew haha. Glad to see you finally got around to it though. Call me when your ready to put that beast back together.
HAHA My man! Yea I was bored lastnight and thought " what would travis do? "....... soooo you're welcome ;) lol
 

·
I wanna go fast!
Joined
·
469 Posts
Discussion Starter #11
I think I remember the thread this guy was selling the car on. Had all kinds of problems.

Good luck on your resurrection build!! As already stated just triple check everything!! lol. This will be superb once completed!!!
Trust me brotha... Myself and my machinist have went thru this motor from top to bottom and side to side with a fine tooth comb to make sure she purr's like a lion in heat :p
 

·
Sleeper!
Joined
·
825 Posts
HAHA My man! Yea I was bored lastnight and thought " what would travis do? "....... soooo you're welcome ;) lol
Haha too funny. You already knew "what would travis do?" haha since I mentioned you needed to make one, right massa? (you had me dying with that too btw). Looks good bud. Keep it up!
 

·
Registered
Joined
·
3,093 Posts
Trust me brotha... Myself and my machinist have went thru this motor from top to bottom and side to side with a fine tooth comb to make sure she purr's like a lion in heat :p
Oh yeah I don't doubt you for a second man. I honor thee for taking on such a giant task. It will so rewarding though when it starts on the first crank when you're done :D

Either way I am subbed in now for some supercharged goodness!!

Congrats again my man, keep taking lots of pics through the steps, cuz you know we love to see em :D
 

·
Registered
Joined
·
333 Posts
Sub a dub dub
 

·
I wanna go fast!
Joined
·
469 Posts
Discussion Starter #15
Oh yeah I don't doubt you for a second man. I honor thee for taking on such a giant task. It will so rewarding though when it starts on the first crank when you're done :D

Either way I am subbed in now for some supercharged goodness!!

Congrats again my man, keep taking lots of pics through the steps, cuz you know we love to see em :D
Thank you good sir!
 

·
I wanna go fast!
Joined
·
469 Posts
Discussion Starter #16 (Edited)
:::: UPDATE ::::

Just got back from the machine shop today. I had to go drop off my Main Bearing Cap bolts, my machinist spun a bolt and you'll see why you never re-use Oem Hyundai bolts - damn near every bolt on the 3.8 is Torque to Yield - AKA - ONE TIME USE ONLY FOLKS!!!! Anywho, he told me I should have the motor back tomorrow... but im not holding my breath...

Here are some pics of the progress, the motor looks absolutely amazing, these guy did some phenomenal machine work to the Block & Heads:


Beautifully re-surfaced block!


Brings a tear to my eye... :p Fantastic craftsmanship.... Block was knifed .003"


As you can see on the main cap's the furthest one to the right is missing a bolt, because it was spun being put back in! But all is well, it didnt snap - only twisted :p FEWF!


And this is exactly why you never re-use TY bolts folks!


16 New Main Cap Bolts & 8 Side Bolts


Heads w/ Cams... Every piece of this motor was Hot Tanked, Degreased and Cleaned!


Heads w/ Cams


JE Pistons & Brian Crower Connecting Rods.... All have been Hot Tanked, Degreased and Cleaned


Pistons look brand new again :p All new JE Rings installed


Awesomeness :p


Heads were Decked, Straight Edged, Planed, and Re-Surfaced... Again, they look fantastic!


I tried taking a picture of the Cylinder Walls - not the best sorry guys - anyways, they have been honed and lubed.... they look great, extremely smooth!

EDIT:: Also in the last picture, the center cylinder is Cyl 4 where the detonation occured and damaged the top of the cylinder wall.... all fixed - looks like nothing happened! looking great :p

Thats all for now guys... I hope you enjoy seeing the progress as much as I enjoy going thru it :p

- Stew
 

·
I wanna go fast!
Joined
·
469 Posts
Discussion Starter #18
I'm almost crying from happiness! Thanks for saving the honor of the SC gen coupe. lol
Hahahaha you sir are very welcome! I cant wait till i get the motor back and get the car running, shes gonna be bullet proof and one bad SOB :p stay tuned my friend!
 

·
Super Moderator
Joined
·
13,001 Posts
Who told you it would be ok to reuse the factory bolts?

They did an excellent job on that block btw, looks mint. Did you happen to get them to port the exhaust on the heads?
 

·
I wanna go fast!
Joined
·
469 Posts
Discussion Starter #20 (Edited)
Thanks snoopy! they've done a hell of a job re-surfacing the block and the heads... I was blown away today when I seen everything! Trust me I wasn't going to re-use the original bolts... My machinist was re-using them to test fit the new main bearings to check for clearance & fitment just to make sure everything seated well... Half way thru tightening the last bolt it spun on him and luckily enough didnt snap - thank god! and he was able to remove it... I had already purchased the new bolts before hand :p and i'm using ARP head studs for the top end of the motor :)

Also, the reason why it spun in the first place was because the 1st time the motor was torn down by the previous owner's friend who was a "mechanic" he re-used them and torqued them down - big NO-NO. Then the previous owner had the motor torn down a 2nd time at a proper machine shop (due to issues that occured from the 1st tear down/rebuild) that machine shop then re-used and torqued those same bolts again including my head blots.... which blew my mind... because damn near every bolt on the 3.8 including the 2.0 and Torque to yield.
 
1 - 20 of 294 Posts
Top