96 SL2 Random Shuts Down

Discussion in 'Saturn S-series' started by Rapadash, Nov 15, 2025.

  1. Rapadash

    Rapadash

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    Saturn s series randomly shuts down randomly for approximately an hour after check engine light comes on for catalytic converter. Car doesn't overheat. Usually would run fine after car cools off below operating temperature. Fuel and crankshaft sensor tests good. No other codes than the po420. Any ideas??
     
    Rapadash, Nov 15, 2025
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  2. Rapadash

    Derf Moderator

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    Sorry I typed this last night but didn't post it



    How quickly does the CEL turn on after you begin driving, both in time and in mileage?

    If you do not clear the code and let it cool down an hour and then start it and drive, does the CEL ever go out before the next time it stops running?
     
    Derf, Nov 16, 2025
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  3. Rapadash

    Rapadash

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    Approx 15 miles, 15 minutes at 62 miles an hour. Sitting on side of road now. This time no PO420 cause I disconnected the O2 sensors so got a PO134 instead for the O2 sensors. Just replaced the ignition module yesterday. Again fuel pump tests good. New crankshaft sensor. New coolant temperature sensor. Honeycomb in catalytic converter in tact. Don't know about the light after breakdown because I keep clearing it. Thanks
     
    Rapadash, Dec 4, 2025 at 7:09 PM
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  4. Rapadash

    Derf Moderator

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    When you disconnect the front O2, you remove the computer's ability to adjust the air fuel mix in real time.
    I'm sure there is some default mix that it reverts to in order to keep the engine running until the front of O2 is replaced.

    The question is what is that mix?

    Also, did you buy an ACDelco ignition module or a cheapie? Many of the cheap ones don't even function to get the vehicle started, so at least yours was running. Interested to know the brand.

    Not sure what you mean about codes being read after the shutdown. Usually you have to cycle the ignition as part of the clearing process. Were you pulling over and doing this along the way? And what codes besides those for the oxygen sensor where you seeing if any?

    What is the status of the vehicle now? No crank no start, crank no start? Etc.
     
    Derf, Dec 4, 2025 at 7:59 PM
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  5. Rapadash

    Derf Moderator

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    I believe that default mix is extremely rich and has the potential to dump raw fuel into your cat con which is a good way to wreck it. Highway driving under these conditions can be especially damaging.
     
    Derf, Dec 4, 2025 at 8:03 PM
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  6. Rapadash

    Derf Moderator

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    Kindly answer my question just prior to your most recent post.
     
    Derf, Dec 4, 2025 at 8:05 PM
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  7. Rapadash

    Rapadash

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    Since last post, car would only travel a couple of blocks before shutting off. Decided today to put back original module. Noticed that replacement part was broken off on top. Also part of the other tab was also broken. Had car running in drive till operating temperature without shutdown. My original one could be partially broken as well. Do these parts become extremely brittle after 29 years?? Car is actually a 97. NO CEL!! 106200e2-6382-4b4c-b1a0-49bfedaff079.jpg
     
    Rapadash, Dec 7, 2025 at 10:04 PM
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  8. Rapadash

    Derf Moderator

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    Clean the corrosion off of the bolts that go through the coil packs through the ICM into the bell housing. The coils are grounded by the copper rings around those mounting holes, through the bolts, to the bell housing. I wonder if you are losing the ground when things heat up and expand..... Do not crank down on these bolts when putting back together trying to get a better ground. You will snap them off and you did not want to have to try to drill one of these out and rethread the hole
     
    Derf, Dec 8, 2025 at 5:40 AM
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  9. Rapadash

    Rapadash

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    The bolts all look good and with a similar car would get a PO340 but, that car never shutdown (only leaked all over the place). Noticed that these ignition module getting hot and then losing spark for an hour is a common problem for these cars. Having the module and coils looked at after New Years. No more questions. Thanks
     
    Rapadash, Dec 8, 2025 at 11:23 PM
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  10. Rapadash

    Derf Moderator

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    You never answered if you used an AC Delco.
    I have 500K mi on two ign modules that have never done that. They're expensive but they work

    A car with a p0340 I would argue has a different issue.

    The point of checking the bolts is to check the services you cannot see while they are attached......
     
    Last edited: Dec 9, 2025 at 12:51 AM
    Derf, Dec 9, 2025 at 12:44 AM
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