Last post on Jan 23, 2010 at 8:59 AM
You are in the Saturn S-Series
What is this discussion about?
Saturn S-Series, Engine, Sedan
#19 of 81 Re: I keep getting code p0101 [booboo6]
Nov 27, 2007 (10:51 am)
I think I'm having the same problem on the same car...faulty intake manifold gasket on a 2002 Saturn SL1. The car is idling high, and a recent diagnostic test revealed a misfire of the #1 cylinder. I replaced the plugs and wires, hoping for a quick, easy and cheap fix, but with no results. I checked out the EGR and IAC valves and they seem to be clean and functioning fine. I haven't looked at the throttle body, but then again that would not explain the misfire.
So, I'm concluding that I will have to replace the intake manifold gasket. I'm going to spray carb cleaner around the gasket to determine if this is really the problem before I go at it. I plan to pick up a Haynes manual to attempt to do this on my own. This is the first larger project I've undertaken on this car, but I really would rather spend the $300 a shop wants for labor on tools and learning how to do it myself. Is replacing this gasket something that someone with good diy skills can tackle with a repair manual, a will and a weekend, or should it be left to a mechanic? Any tips?
#20 of 81 Re: I keep getting code p0101 [dillomite]
Nov 27, 2007 (11:17 am)
You almost certainly have the same problem and it is chronic. You likely have code 0507 showing PCM inability to control the fast idle. Your '02 Saturn (like mine), does not actually have an EGR. '02 and possibly '01 eliminated EGR. That valve you identified as EGR is nothing but a control valve that opens to let the DC blower inject air into exhaust manifold for fast catalyst heat up. When the PCM calls for shutdown of the fan, PCM will close that valve at same time to prevent exhaust from baking the fan.
It is not a major job at all. Don't take apart all the things mentioned in the Haynes manual, which is for outright manifold removal from car. Only remove what you have to and slide the very lightweight assembled intake manifold straight back and off the studs. No scraper needed as with other cars. This gasket will come right off. I'm in NYC on travel. Can send you my checklist and whatever else and pics when I get back home in Boston, including my gasket's leak point, etc. If I do it again, can do in 2 hours. Don't take to Saturn dealer, which will put in another same gasket with possible reoccurance. The plastic gasket just doesn't adhere to the clamped surfaces and gasket probably expands/contracts too much with each engine heat up. The gasket just flows and distorts, creasing and whatever, letting in air. Car will run like new with gasket work!
#21 of 81 Re: I keep getting code p0101 [booboo6]
Feb 22, 2008 (6:33 am)
I also have the same problem. I'm in Canada if that makes any of the work harder or easier. I was told by the local Saturn dealer that my off warranty 2001 Saturn SL1 would require the same gasket to fix the problem. They tried selling me a OEM gasket set for over $100, and then said that it would take 7 to 10 hours work to get it in and would more then likely cost me $900 for work. I know for a fact it won't take more then 3 hours, but you know dealers, they wanna stick it to you in labour. So I decided to check the Haynes guide and it said to remove some front end parts for clearance, but that is way over my head. Could you send me your checklist of how to do this without all the unnecessary removal of parts for "clearance" I picked up the felpro gasket to fit, and just need to find a way to do this easily considering that I have already spent over $700 (arms-length list of replaced, and probably unneeded parts) to find this problem and don't want to spend any more then I need to at this point.
#22 of 81 Re: I keep getting code p0101 [darkfyre07]
Feb 22, 2008 (7:00 am)
Your Saturn dealer is strange. Mine wanted 5 hours and that task is well known and booked. It is really a 2 hour job for them, and the gasket is worthless. Makes no sense to put the a new plastic gasket in there again. Haynes manual is my reference guide too, and its procedures are for outright removal of the intake manifold from the car. This is not necessary for gasket change only. The work is much less than prescribed. There's enough clearance to do the job pretty easily. Best to do this yourself if you're comfortable under the hood. This job is pretty straightforward. I should be able to look you up on the forum and get the repair material to you. I feel sorry for your situation. They probably replaced your fast idle solenoid, maybe injectors, maybe more. It's outrageous of course.
#23 of 81 Re: I keep getting code p0101 [booboo6]
Feb 22, 2008 (7:12 am)
User Darkfyre07: click on my forum user name and use that E-mail to send me yours. Your profile lists your E-mail as private.
#24 of 81 Re: I keep getting code p0101 [booboo6]
Feb 22, 2008 (2:21 am)
yeah the list of parts I have replaced so far:
coolant temp sensor, 4 injectors, idle air controller, air filter, spark plugs, plug wires, ignition coils, ignition module, and many more that I can't remember. Also have had to do 4 oil changes because of fouling in the engine oil. I've only had the car for a month now, and I have to get an emmisions test done to get the car plated and on the road, but without this fix, it's not road legal.
#25 of 81 Re: I keep getting code p0101 [booboo6]
Feb 22, 2008 (7:31 am)
ok, my email should be visible now... if not then it's darkfyre07hotmail.com
#26 of 81 Re: I keep getting code p0101 [darkfyre07]
Feb 22, 2008 (7:40 am)
I've your E-mail. OMG on the above work done. Your gasket leak must be in bad shape, to include the cyl-4 end of the block. Your gasket must be letting coolant into the manifold and some of this getting into the oil via cyl-4 or so. You probably have been smelling coolant burned with the exhaust for a while. Here in Massachusetts, the emissions test is failed if the OBD-II computer shows a fault. The SL is fundamentally a well designed car.
#27 of 81 Re: I keep getting code p0101 [booboo6]
Feb 22, 2008 (7:52 am)
it's funny, it's not that bad. I just can't get it to stop. I'm following what I was told to follow, and now I have just said screw it and started looking for alternatives. I noticed the manifold leak when I was trying to clean some leaves from the cowl, I saw some fluid dripping from the cylinder 4 end of the manifold after it had been run, it was dripping onto the hot block and making a sizzling sound, so I took a rag and swiped it, and noticed it was smelling of gas and sugar, telling me that it was leaking a little bit of coolant, but not that much. The car sat outside from last July until late november without being run for more then a few minutes to move it, and the gasket looks like it just came apart from lack of use. It's not plastic, it looks more like cheap tin covered cardboard, so I know it's been done once. I just got it basically and have had nothing but trouble diagnosing what was wrong. I had a 1990 toyota camry before this car and the transmission broke going like 80km/h and literally stopped the front wheels and made the car skid into a ditch and rolled over 3 times. I did all my own work on it for the 2 years I had it, and never had a problem like this...
#28 of 81 Re: I keep getting code p0101 [darkfyre07]
Feb 22, 2008 (8:06 am)
Your gasket sounds like it has been deteriorating for quite a while. The material is fiberglass. It flows and deforms over time from the heat and general lack of grip with the clamping surfaces. It doesn't expand in manner needed to match the aluminum head and manifold. Misdiagnosing has always been costly, and even the shops are like this to some extent. But the car will run like new after the gasket change. A flaw here and there is fixable, but a general bad design is not. The SL is not a bad car. Lots of good solid thinking went into it as I could tell studying it. Too bad you didn't visit this forum earlier on. Folks would've saved you a lot of aggravation. Be sure to have a deep socket 13mm, I think that was the only tool I took from the seldom-used tools supply. An extra person helps a lot, but not necessary.