Boosted 4-Cylinder Saturn Ion Redline Gets Big Cams & New Transmission: Hellkitten Build

Transmission Replacement and Road Trip Mishap

• 🚗 The project begins with a Saturn Ion Redline, chosen for its manual transmission, suicide doors, and supercharger.
• ⚙️ A major hurdle is a broken transmission with a stuck intermediate shaft, requiring a replacement.
• 💥 During a trip to pick up a used transmission, the trailer is rear-ended, leading to a roadside tire change for the other driver.
• 🤝 The situation is resolved amicably, with the focus shifting back to acquiring the necessary replacement transmission.

Engine and Drivetrain Upgrades

• 🛠️ The rear main seal is replaced as a preventative measure during the transmission swap.
• 💡 A new aluminum flywheel from ZZP is installed, along with a six-puck clutch.
• ⚙️ A custom 3D-printed bushing is fabricated to properly center the clutch alignment tool due to the engine's lack of a pilot bearing.
• 🔩 A newer, factory limited-slip transmission is sourced and installed, requiring modifications for compatibility.

Camshaft and Valvetrain Overhaul

• 🚀 Big camshafts are installed to increase horsepower by allowing more air in and out.
• ⚙️ Upgraded valve springs and titanium retainers are fitted to handle the higher lift and allow for higher engine revs.
• 🛠️ The process involves airing up the cylinders to keep valves seated while replacing springs and retainers, using specialized tools and techniques.
• 💡 New ZZP camshafts are installed, with measurements showing a significant increase in lobe lift compared to stock.

Reassembly and Tuning

• 🔧 The front timing cover and oil pump are removed and reinstalled with a new gasket and seal.
• ⚙️ The timing chain and guides are replaced, with careful attention to aligning the timing marks.
• 🚗 The supercharger pulley is swapped for a smaller one to increase boost, though a slight modification to the supercharger snout is needed.
• 💻 The engine is reassembled, fluids are topped off, and an E85 tune is uploaded via HP Tuners to optimize performance for the new modifications.

Performance and Dyno Results

• 🔥 The car is fired up with the new cams, producing a distinct **