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Old 01-04-2006, 03:12 PM   #1
Brazos Bob
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Default True confessions: "extra" part and missing part

Greetings, all.
First time posting to this forum, which I wish I'd found earlier. To make a long story longer, I have a 95 SL2 that I really like. I'm not into performance, because my bar is generally set at "utility". I bought the car used several years ago, and when it recently lost compression on #3 cylinder my mechanic said to junk it (200k+ miles). Other than that, it was running just fine, and I hated to junk a perfectly good car just because its book value made a "paid" repair unrealistic.
So, I decided to make it a do-it-yourself project, a decision made easier when my son said I could drive his car while repairing my own.
Background: My high school did not have auto shop. My father was not mechanically inclined. Most of my mechanical experience was obtained from watching The Chief (retired Navy Chief Wessel) who was my next door neighbor for several years; Chief, if you'd not moved away I'd be driving this Saturn by now! I have had to pick up things the hard way, but I usually figure that I can do what someone else can do, as long as I do some homework and I'm not in a hurry. I draw the line at brain surgery and transmission repair. In the case of my SL2, I had a car that was one tow away from the junkyard, so how much damage could I do?
Personal philosophy re. repairs: Bob's Rule of Do-it-yourself repair - 1) buy needed parts and any required tools, 2) fix it, 3) determine what it would have cost to have someone else do it, 4) spend half the "saved money" on tools or other toys. You're still ahead of the game, and you're better prepared for the next job.
This job's #1 nuisance: After reworking the head and putting everything back together, I have a bracket and bold that I can't figure out. I had labeled it "behind/below intake manifold" but I'm drawing a blank. The bracket is about 5 inches long, not quite straight, and it's tapped at one end, presumably to screw onto a stud or to have a bolt threaded into it. The other end has a hole in it, presumably to bolt this end onto something. My inclination is to screw the bracket onto the stud that sticks out of the intake manifold and see what comes close to the other end. I looked through lots of interesting pictures of engine rebuilds, etc., but eventually I decided that a public display of my ineptitude would be good for my soul and might solve the problem sooner. Thatís assuming one of you can tell me where this part goes. I did read a thread about priming an oil pump with Vaseline, so I donít need any rectal references.
This job's #2 nuisance: In removing the fuel rail, I lost one of the ceramic spacers (?) from a fuel injector. Saturn will sell me a fuel injector, complete with the ceramic spacer, but doesnít carry the missing part itself. Iím inclined to visit my local ďpick-a-partĒ junkyard and find a Saturn that will donate one of two of these, unless someone can suggest another source.
Thanks for your patience. Comments and suggestions are invited.
Bob

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Old 01-04-2006, 03:39 PM   #2
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Default Re: True confessions: "extra" part and missing part

You could always go to one of the actual mechanics.. "hey dude I lost this injector o-ring do you have one laying around?"

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Old 01-04-2006, 03:46 PM   #3
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Default Re: True confessions: "extra" part and missing part

That bracket should be the fuel line brace. It goes between the intake manifold and throttle body. There should be a clamp or something in the middle that holds the two fuel lines. It takes a special bolt on the throttle body, the kind that has the nut in the middle (hard to explain). Hope this helps.

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Old 01-04-2006, 03:51 PM   #4
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Default Re: True confessions: "extra" part and missing part

Pictures will always help to describe whatever it is.

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Old 01-04-2006, 05:17 PM   #5
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Default Re: True confessions: "extra" part and missing part

If/when you visit the boneyard, take a look at one of the engines, should give you a good idea of where that part belongs & might supply you with any small parts you may need to reinstall it.

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Old 01-04-2006, 05:33 PM   #6
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Default Re: True confessions: "extra" part and missing part

Got a photo of it?

Hey, don't feel bad. Just after I bought my waggin, the TPS failed. Still on warranty. They overtorqued the replacement and warped the TB. When they replaced the TB, they left off a bracket that goes from (IIRC) the EGR to the TB. I found it laying in my cam cover, with one of the nuts.

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Old 01-04-2006, 06:53 PM   #7
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Default Re: True confessions: "extra" part and missing part

Brazos,
It may be the bracket that attaches to the egr stud and then to the TB. Which is a support bracket for the TB.

There is also a small one for the power steering pump/

look in my gallery under ( bracket) It won't show the one for the egr/tb but will show the PS ONE.

Sorry I havent figured out how to insert them here.

Greg

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Old 01-05-2006, 12:03 PM   #8
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Default Re: True confessions: "extra" part and missing part

I seem to recall when I did my rebuild that there is a support bracket that attaches to a stud on the bottom of the intake manifold on one end. The other end attaches to the bottom of the block on the backside. Could it be this one?

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Old 01-05-2006, 01:28 PM   #9
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Default Re: True confessions: "extra" part and missing part

Quote:
Originally Posted by romzek
That bracket should be the fuel line brace. It goes between the intake manifold and throttle body. There should be a clamp or something in the middle that holds the two fuel lines. It takes a special bolt on the throttle body, the kind that has the nut in the middle (hard to explain). Hope this helps.
there is also a support bracket that's under the intake that i had to partially remove when i did my gearbox removal. i'll check my tech manual and let you know. that part DOES sound very familiar, tho...


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Old 01-05-2006, 04:15 PM   #10
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Default Re: True confessions: "extra" part and missing part

Look here:

http://www.saturnfans.com/forums/att...2&d=1125961184

Should see it somewhere in this thread if not this particular photo!

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Old 01-05-2006, 09:47 PM   #11
Brazos Bob
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Default Re: True confessions: "extra" part and missing part

Quote:
Originally Posted by blackeagle1
I seem to recall when I did my rebuild that there is a support bracket that attaches to a stud on the bottom of the intake manifold on one end. The other end attaches to the bottom of the block on the backside. Could it be this one?
No. I have that one already in place. I thought it might screw onto the same intake manifold bolt... Thanks.

Bob

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Old 01-05-2006, 09:53 PM   #12
Brazos Bob
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Default Re: True confessions: "extra" part and missing part

Quote:
Originally Posted by Earl43P
Look here:

http://www.saturnfans.com/forums/att...2&d=1125961184

Should see it somewhere in this thread if not this particular photo!
Earl:
Another opportunity to confess ignorance on my part. How do I determine which thread this attachment showed up in? Thanks.
Bob

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Old 01-06-2006, 11:22 AM   #13
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Default Re: True confessions: "extra" part and missing part

Begging 1,000 pardons....

http://www.saturnfans.com/forums/showthread.php?t=60814

From the How-to library, cleaning the EGR valve with pictures.

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Old 01-07-2006, 06:22 PM   #14
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Default Re: True confessions: "extra" part and missing part

Quote:
Originally Posted by Brazos Bob
After reworking the head and putting everything back together, I have a bracket and bold that I can't figure out. I had labeled it "behind/below intake manifold" but I'm drawing a blank. The bracket is about 5 inches long, not quite straight, and it's tapped at one end, presumably to screw onto a stud or to have a bolt threaded into it. The other end has a hole in it, presumably to bolt this end onto something. My inclination is to screw the bracket onto the stud that sticks out of the intake manifold and see what comes close to the other end. I looked through lots of interesting pictures of engine rebuilds, etc., but eventually I decided that a public display of my ineptitude would be good for my soul and might solve the problem sooner. That’s assuming one of you can tell me where this part goes.
There are two brackets that attach to the bottom of the intake manifold on the front (passenger's) side of the engine. One runs down to the block, and the other runs over to the power steering pump. If I recall correctly, neither bracket has an end that is threaded, although they both slip over the stud threaded into the bottom of the intake manifold.

Does it look like either of these?


Last edited by Razorbak; 01-07-2006 at 06:33 PM..

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Old 01-07-2006, 06:41 PM   #15
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Default Re: True confessions: "extra" part and missing part

Quote:
Originally Posted by Razorbak
If I recall correctly, neither bracket has an end that is threaded...
Actually, now that I think about it a bit, the above statement is wrong. The power steering support bracket IS threaded on one end... the end that the power steering bolt threads into longitudinally. I bet it's the power steering support bracket.

On the DOHC engine, torque the bolt from the power steering pump to the support bracket first, and then torque the bolt (or stud & nut) connecting the support bracket to the intake manifold.

Last edited by Razorbak; 01-07-2006 at 06:47 PM..

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Old 01-08-2006, 11:58 AM   #16
Brazos Bob
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Default Re: True confessions: "extra" part and missing part

Quote:
Originally Posted by Razorbak
Actually, now that I think about it a bit, the above statement is wrong. The power steering support bracket IS threaded on one end... the end that the power steering bolt threads into longitudinally. I bet it's the power steering support bracket.

On the DOHC engine, torque the bolt from the power steering pump to the support bracket first, and then torque the bolt (or stud & nut) connecting the support bracket to the intake manifold.
Thanks, Razorbak - I'll bet that's the one. I have to get the PS pump out of the way anyway, in order to get better access for torquing down the nuts on the intake manifold bolts, so I'll make sure my "bonus piece" gets on that stud.

As a matter of trivia, I spent an entertaining few hours at a local Pick-a-Part junkyard yesterday, locating parts for my Saturn and another vehicle. I crawled under 6-8 Saturns and was surprised at the variety in terms of braces, or lack thereof. Also, anyone who wonders about wear and tear on the upper motor mount should see those cars. Almost every one had the motor mount already scavenged.

Bob

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Old 01-08-2006, 06:01 PM   #17
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Default Re: True confessions: "extra" part and missing part

Quote:
Originally Posted by Brazos Bob
Thanks, Razorbak - I'll bet that's the one. I have to get the PS pump out of the way anyway, in order to get better access for torquing down the nuts on the intake manifold bolts, so I'll make sure my "bonus piece" gets on that stud.
Good luck. Please confirm, when you get the thing back on, whether or not it actually was the PS support bracket.

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Old 01-08-2006, 06:28 PM   #18
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Default Re: True confessions: "extra" part and missing part

Quote:
Originally Posted by Razorbak
Good luck. Please confirm, when you get the thing back on, whether or not it actually was the PS support bracket.
Yep. That's where it went. I wondered why I had an "extra" bolt in my bag labeled "PS pump". I took a closer look at the PS section that bolts to the head, and found a fourth hole. The extra bolt went through there and screwed into the tapped end of that brace. Thanks for the lead on that location. It must be an easy part to leave off, because I don't think any of the Saturns on my junkyard adventure had the bracket.
Bob

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Old 01-08-2006, 06:41 PM   #19
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Default Re: True confessions: "extra" part and missing part

Much thanks to everyone who offered suggestions and ideas on solving my problem. As they say down here in Texas, I'm back in the (Saturn) saddle again. Razorbak keyed me into the home for my "extra" bracket - connecting the intake manifold and the power steering pump. reisjunk alerted me to a potential vacuum leak on plastic tubing running from the intake manifold to a solenoid unit (?) on the head, below the intake manifold. My tubing was OK, but it turned out that the rubber vaccum hose running from that unit to a metal line on the firewall was totally shot.
It's all back together now and it sounds good. Miller time!
Thanks again.
Bob

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Old 01-08-2006, 10:03 PM   #20
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Default Re: True confessions: "extra" part and missing part

Quote:
Originally Posted by Brazos Bob
Yep. That's where it went. I wondered why I had an "extra" bolt in my bag labeled "PS pump". I took a closer look at the PS section that bolts to the head, and found a fourth hole. The extra bolt went through there and screwed into the tapped end of that brace. Thanks for the lead on that location.
Cool! Congratulations. Glad I could help. It was kinda fun trying to solve the puzzle.

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