Saturn S Series Sedan SL, SL1, and SL2

Swapping a 1997 DOHC into a 2000 SW2

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Old Jan 26, 2024 | 10:19 AM
  #41  
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That looks very interesting. Hybrids will get better and better as battery technology progresses. I will always have range anxiety with pure electric.
 
Old Jan 26, 2024 | 11:58 AM
  #42  
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agree, no pure E for me. Planning a reverse trike with a waste oil fired gen. 2 tandem seats.
 
Old Feb 22, 2024 | 11:48 AM
  #43  
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Getting back on topic after the brief thread hijack
When I did the swap, in the interest of making it quick I kept the fuel system returnless.
I had simply cut off the fuel return line a few inches from the regulator on the 1997 fuel rail and used a rubber plug held in place with a hose clamp to cap it off.
The plan of course was to either make the change to a return type system or replace the temporary plug with something more permanent.
A couple weeks ago I smelled gas and not being anywhere near a gas station I knew what had just happened.
I pulled over and checked and sure enough gas was spraying against the firewall from the burst plug.
I quickly shut it off and scrounged through the few tools and parts I had with me (I was stranded out in the country between cow fields).
Using a broken knife to tighten the hose clamp with a spare ECTS sensor plugged into the line (it fit perfectly) I stopped the leak and drove it the rest of the way home.
I feel lucky to not have a crispy car and haven't driven it since.
I thought I could find some kind of fitting at the local hardware or autoparts store that would be more appropriate but after several searches I could find nothing.
I'm really not in a place to change the fuel system at the moment so I switched to looking online.
It seems that what I need is an adapter and cap that is commonly sold for LS swap EFI setups.
I went ahead and ordered the parts since they cost less than $20 on amazon.
Once I have them in hand and have had a chance to try them I'll get back with the results.
If they work I'll share what I found, if not I'll keep looking but I'm almost certain they'll work.
 
Old Feb 22, 2024 | 12:40 PM
  #44  
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Sorry bout that Chief......lucky you didn't burn er down!
 
Old Feb 23, 2024 | 06:55 AM
  #45  
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No worries Dude!

Very lucky indeed. 5 miles back I had driven by 3 different gas stations and had I smelled it then I would have thought it was coming from one of them, not my car.
I might not have been so quick to stop if it happened then.
 
Old Feb 23, 2024 | 08:20 AM
  #46  
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I'm happy to hear that you and the car are okay, man. I passed a car fire on the interstate a few weeks ago and that sum beech was extremely hot. I was two lanes over from it and still felt the heat as I went by. Fortunately, the driver was not in the car but standing a few hundred feet with his hands on his head and crying. It was a Hyundai Elantra.
 
Old Feb 24, 2024 | 07:53 AM
  #47  
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Keep a small extinguisher in Pri and Goldie just fer that 1 in a million chance........
 
Old Mar 2, 2024 | 12:06 PM
  #48  
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Got it fixed!
After getting the wrong part the first time I got the parts and it works.
No leaks and it's a permanent fix.
If I want to go to a return type system later on it will be easily done with this fitting.
Specifically what I got was a 5/16" quick connect to 6AN flare adapter along with a cap to close it off.
This plugs right into the fuel regulator in place of the fuel return line.
A search of Jegs, Summit and others pointed me in the right direction.
Had to go to Amazon to find it; no local hardware or autoparts store carries this.
I could have got the adapter from Autozone if I placed a special order in person at the store (can't do it online) but I didn't see the cap on their site.
Picture shows it installed (the blue cap)

5/16" male to 6AN fitting and cap
 
Old Mar 2, 2024 | 09:17 PM
  #49  
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Sweet, nice fix!
 
Old Mar 3, 2024 | 10:32 PM
  #50  
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well done!
 



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