
You can weld in a replacement flex or replace the entire pipe.

The bolt holding the clamp rusts out and will eventually abrade a hole in the 400 stainless downpipe. Also to replace the input shaft nut (it’s TTY, can’t just be retightened) if necessary. The permanent fix is to replace the valve body with one rebuilt using the Sonnax update, which fixes and prevents the problem with the bores becoming worn. Fortunately it’s easy to get at the valve body in these transmissions. If left for a while, it will knock the input shaft nut loose, further worsening the condition of the shifts. It will eventually destroy the line pressure solenoid, which will make for very hard upshifts. This causes the car to “slam” into reverse and/or harsh upshifts, depending on which is worn. Worn pressure regulator valve and reverse boost valve in the auto trans valve body: There is a stainless steel replacement here: The gear shift will be loose and/or fail to shift completely. It’s made of plastic and eventually breaks. It’s possible to re-spring the connector, or just replace the entire IPJB.īroken Shifter cable bushing (manual trans): You will probably know about it when the fuel pump stops working. The radio, chime module, dome light, 12v socket, and fuel pump are on this circuit. There will be melted plastic around the fuse. This is caused mainly by overdrawing from the 12v socket, or high power aftermarket accessories drawing from the same circuit. F6 (gen 1), F5 (gen 2), F2 (gen 3) IPJB fuse block segment overheating: OE junkyard replacements from a gen-1 or gen-2 car are your best bet. If you’re doing struts, replace the springs. Broken coil springs in 3rd generation (00-02) cars. There’s a product specifically for fixing this problem: There will be a fairly slow but significant leak around where the coolant hose runs into the manifold near cylinder #4. Crack in the coolant stem running into the intake manifold (00-02 DOHC only). Spray carb cleaner around the intake, specifically the #1 runner, if idle changes, problem is verified. The symptom is sporadic or consistently high idle, p0300, p0301, or p0302. Something went wrong at the factory here. Intake manifold gasket leak in 3rd generation (00-02) SOHC (Sx1) cars: The aftermarket replacements seem to work. You’ll be driving along, and suddenly the engine dies, and won’t restart until it cools. They usually fail when the engine is hot. Not hugely common, but still a recurring failure. The aftermarket replacements have a quality problem best bet is to find a low mileage junkyard replacement or order the OE part (~$70). If shutting off the car then restarting it causes the idle to drop back down, and the ECTS is good, it’s almost definitely the TPS. These have a higher than normal failure rate. NGK BKR5ESA-11 (DOHC) and BKR4ESA-11 (SOHC). The easiest thing to do here is just use the OE spark plugs, they’re inexpensive and just work.

Narrow fine wire electrodes almost always cause problems, usually a p0300 and running like the car needs new plugs. Without getting into too much detail, the basic requirement is the diameter of the electrode should be roughly the width of the ground. The S-Series has an early version of a distributerless ignition system, it’s fairly particular about what spark plugs to use. If there is any sign of corrosion on the connector it needs to be replaced. When they fail coolant tends to leak through the sensor and damage the connector as well.

This sensor has at least something to do with almost everything the computer does. Symptoms include hard starting, rough idle, temperature gauge not working, awful fuel economy, poor performance, and stumbling, among many other things. ALL of them failed, if you still own one of these cars and it hasn’t been replaced, it has failed. Saturn experimented with making these out of plastic, it was a huge failure. This one is universal, and the single biggest cause of problems with these cars. Failed Engine Coolant Temperature Sensor and/or connector: These are from my personal experience and experiences of others on various forums: Here are a lot of these car’s pattern failures that people have picked up on over the years.
