Joint near catalytic converter glowing red hot

[NickNnator]

Our vue has been having trouble starting lately. I replaced the battery, but no luck. I did get it running today, it's running rough, shutters when idling (low rpms). Took it to the car parts dealer, it drove sluggishly. They ran a quick code check, but it came up "pass". No codes given. The service engine soon light is on consistenly (starts to blink when I drive it). I let it run in the driveway for awhile, then noticed the joint after the catalytic converter was glowing red hot. I immediately shut it off. Any suggestions as to what is going on here?

[Bill Murray]

Sounds like you've got a major misfire (aka lack of spark at one or more cylinders) causing it to run badly - and overheat the catalyst.
You need to get somewhere competent with an OBD2 code reader, my guess is the parts store person didn't do the job properly - a blinking service light is a "hard" or "active" code and there will be something wrong that triggers it and will most likely lead you to the root cause.

[harsha]

For some reason, if it turns out to be a bad catalytic converter...it has 8yr/80000 miles warranty as per federal emmissions law. So if you are not more than 80,000 miles it should be covered under warranty even though factory warranty(3yr/36,000 miles) has expired.

Somebody correct me if I'm wrong.

[IMkenNY]

The flashing aspect of the service engine light indicates that you have a misfire condition thats is allowing unburned fuel to be burned in the converter, continued operation will (if not already) cause permanent converter damage.

Saturn has a TSB out concerning a failure of the coil pack on the ecotec 2.2

[mellissam]

The flashing aspect of the service engine light indicates that you have a misfire condition thats is allowing unburned fuel to be burned in the converter, continued operation will (if not already) cause permanent converter damage.

Saturn has a TSB out concerning a failure of the coil pack on the ecotec 2.2

Ken, does the TSB give a range of years for the 2.2l, or is it all of them? thx.

[IMkenNY]

Ken, does the TSB give a range of years for the 2.2l, or is it all of them? thx.


Subject: SES Light and Severe Engine Misfire on Cylinder 1 and 4 or Cylinders 2 and 3 Due to a Repeat Ignition Module Concern - keywords ICM miss no P0300 P0301 P0302 P0303 P0304 plug spark #PIP3433B - (10/20/2005)



Models:
2003-2006 Saturn Ion

2004-2005 Saturn L Series

2002-2006 Saturn Vue

with 2.2L Engine (VIN D or F - RPO L61)

--------------------------------------------------------------------------------

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:
Some customers may comment on a severe engine misfire and a SES Light. Upon inspection, DTCs P0300 - P0304 may be found due to misfires on cylinders 1 and 4 or cylinders 2 and 3.

Recommendation/Instructions:
If ICM (ignition control module) replacement temporarily corrected the above issue only to have the same concern return again, perform the SI diagnostics. If the SI diagnostics lead to ICM replacement again, something may have damaged the ICM causing the vehicle to return with the same concern again. If it appears that something has damaged the ICM, replace the ICM as directed by SI, ensure that the ICM ground is clean and tight, and replace all of the spark plugs to possibly prevent ICM damage again.

If the SI diagnostics do not isolate a cause for the above concern due to the intermittent nature, inspect circuits 406 (IC Control for 2/3 Coil) and 423 (IC Control for 1/4 Coil) for an intermittent short to ground. Depending on the model, this may occur on the AC lines near the AC compressor, on the transmission mount, or on the transmission lines where they enter the transmission. If no shorts are found, inspect the ignition control module ground to ensure that it is clean and tight.

[runerx]

Plugged convertor or raw fuel into the exhaust (misfire etc.) most likely. Be sure that you are very careful about where you park, heat like that could easily start a fire.... You really don't want to continue to drive it like that, if it is an engine related condition, and you burn up the convertor, they are VERY expensive IIRC. I'd be willing to bet that the floor was getting hot also, might be too far forward to feel it though.

I bet polymer stinks when it burns...:no:

Dave

[ssicarman]

Welcome to the Board.

First thing to do is to find a place that is better at reading codes. If the SES light is on or has been on then there are codes.

Second do not drive the car if the SES light is flashing. As mentioned already you will murder the converter this way.

Third--the expensive part. Replace the ignition module. To be safe than sorry replace the plugs as well. Get the code erased.

Finally if the converter has been damaged the SES light will be back on in a week or two. It will give you a P0420 code, poor converter efficiency.


By the way the plugs are to prevent a possible reoccurance of the ignition module going bad. Have seen a document for repeat failure of the ignition module with the more common cause being the plugs.

[greyhound bus]

By the way the plugs are to prevent a possible reoccurance of the ignition module going bad. Have seen a document for repeat failure of the ignition module with the more common cause being the plugs.

Not realy applicable to this case, but this is a good reason NOT to see how many extra miles you can squeeze out of a set of spark plugs. Even if the vehicle still runs good, worn spark plugs (and plug wires, caps and rotors where used) put excessive load on the ignition system and contribute to burnt up modules and failed coils. Back in the late 70's and 80's when nearly everybody was having trouble with ignition modules in GM HEI igntion systems, the cars I maintained NEVER had any failures because we kept the tune-up parts fresh. Late model platinum plugs are a little pricey, but I would still change them on the safe side of the service interval. There is no way I will let the plugs in my Vue go 100,000 miles. Remember, the damage done to your car today may show up the day after your warrenty runs out.

[NickNnator]

Thanks for all the advice, gives me a good idea what to do. I have an ICM ordered and will pick up some new plugs. Any suggestions as to which platinum plugs are best?