Field Fixes

TBI Gasket Inspection.:

SOHC (LKO) TBI UNIT GASKET REPLACEMENT AND INTAKE VALVE INSPECTION FOR SOHC (LKO) ENGINES

If the SOHC (LKO) engine starts and then stalls or stumbles after approximately one minute. complete the following repair procedures:

NOTICE: Always replace the SOHC (LKO) TBI unit gasket with the revised gasket PIN 21006914, if the TBI unit or intake manifold are removed.

1. Remove the SOHC (LKO) TBI assembly. Refer to Throttle Body Injection (TBI) Unit Removal procedures.

2. Inspect the intake valves for carbon build-up on the valves.

a. If heavy carbon build-up is found, the engine valves should be cleaned of build up.


b. Valves with minimal carbon build-up can be sprayed with carburetor/combustion chamber cleaner, Saturn P/N 21007129 or heavily brushed with liquid, Saturn P/N 21007128 or equivalent.


3. Install the TBI unit, wiring and vacuum harnesses, making sure all electrical connections and vacuum harnesses are properly routed and attached. Refer to Throttle Body Injection (TBI) unit replacement procedures.

Torques:

TBI Unit Bolts: 33 Nm (24 lbs ft)

Fuel Feed/Return Lines: 25 Nm (19 lbs ft)

IMPORTANT: After the TBI unit has been completely installed and the bolts torqued to specification open the throttle blade and inspect the throttle body bore to make sure that none of the gasket is protruding into the throttle bore. If the edge of the gasket does protrude into the throttle bore, it must be replaced.


IMPORTANT: Make sure that the throttle position sensor wiring harness is routed over the EGR solenoid inlet vacuum line. If the harness is not routed properly, the vacuum line can become disconnected from the EGR solenoid.