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Saturn S-Series repairs by problem area

Engine (50%)

Transmission and Drivetrain (8%)

Brakes and Traction Control (4%)

Suspension and Steering (15%)

Electrical and Air Conditioning (15%)

Paint, Rust, Leaks, Rattles, and Trim (3%)

Other (3%)

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Chart based on 470 repairs.

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Saturn S-Series engine repair cost distribution

$2500+ (0%)

$1000 - $2499 (5%)

$500 - $999 (11%)

$100 - $499 (31%)

< $100 (52%)

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Chart based on 216 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

104000 mi US $120	Radiator cracked,
108000 mi US $77	Belt Tensioner Water pump Failure, Radiator failure. Coolant system flush and fill Thermostat, ECTS Replaced

254000 mi

Timing chain tensioner failure, caused timing chain to wear teeth off cam gear, jumped time bending valves. Engine will be rebuilt but should be considered junked for statistical purposes. sold for scrap in March 2014.

86000 mi US $250	cooling system flush and thermostat replaced-code light came on
112000 mi US $750	Replaced radiator

95800 mi US $20	Replaced Thermostat
120000 mi US $130	Replaced Radiator, Hoses & Coolant

100440 mi C $417	Centre exhaust pipe was broken loose from front pipe. Had shop weld to reconnect. Price of this part of repair trip not included in $267 previously reported...add $150 for this part of repair trip.
115320 mi C $660	Also had them install an exhaust flex pipe which I purchased elsewhere (cost included above).

112000 mi US $185	Idle would drop intermittently. Mechanic replaced spark plug wires.
123000 mi US $28	Oil pan drain plug gasket failed, causing engine to lose oil. Drained out remaining oil, replaced drain plug gasket, and replaced oil. Did not replace oil filter.

132000 mi US $256	Replace water pump.
154000 mi US $20	Replace intake manifold gasket to correct fast idle.
186000 mi	Oil leak

250880 mi C $282	Muffler replaced under warranty, but center pipe not covered by warranty and also required replacement. I believe the labour was also not covered by warranty; just the muffler part itself.
255720 mi C $300	Front "flex" pipe was replaced.
256680 mi C $2486	Clutch pressure plate, disc, and release bearing were replaced...clutch was beginning to occasionally "slip", but I could probably have "nursed it" for awhile longer.
264120 mi C $91	Fuel tank straps replaced after one (of two) broke while refueling.

157000 mi US $500	Radiator had glued seam that leaked, had to replace
162000 mi US $200	Oxygen sensor was bad which triggered check engine light

209000 mi US $12	Crankshaft position sensor replaced, car on ramps. Guided by richpin video on saturnfans forum. Did not need to remove starter but did disconnect battery for safety. Intended as preventive, but afterwards CEL out and runs more smoothly.
242400 mi US $160	Intake gasket replaced,common on these cars,was improperly installed by factory robot,now more responsive,gained 2 mpg and smoother idle from repair,car drove MANY miles with defect before repair..had intermittent check engine before
268200 mi US $60	Misfire,replaced coilpacks
279000 mi US $50	Replaced radiator with one from a junkyard

128500 mi US $750	Engine was missing at idle. Cracked intake manifold gasket. $700 labor for $30 part. Cracked radiator - plastic/metal separating. Will not pay $650 for $100 part - will change out myself.
130000 mi US $150	Replaced Radiator.

83500 mi US $80	The AC was not blowing cold air. Had to evacuate and refill freon.
86000 mi	Replaced belt Tensioner

122300 mi US $50	Exhaust leak that required a small patch.
125000 mi US $50	Exhaust muffler strap broken and replaced. While difficult to find a factory bracket to fit the large factory muffler, a local GM dealer actually had one in stock.

98000 mi	SES light was on due to carbon buildup in EGR valve. Googled code and found you tube video showing how to remove carbon buildup.
98200 mi US $40	Plugs and wires

117000 mi US $100	Replace DOHC cam cover gasket, oil leaking/ usage high. Also replaced the PCV to stop oil usage. Oil use is more than a quart in 1500 miles. Trying to get the usage up to one quart in 3000 miles.
133600 mi US $170	Muffler rusted out. Replaced the whole exhaust system.
143900 mi	Surging at idle. Replaced the throttle position sensor.
146000 mi US $100	Code P0133, O2sensor replaced
148500 mi US $356	New radiator, thermostat, hoses, overflow cap, and flush with new coolant.
163000 mi	The car was running but poorly...had an ignition problem...donated to Rawhide Boy's Ranch.

95700 mi US $16	Cooling System - Bad Radiator Cap
117000 mi US $50	Water pump failure - leaving puddles, no complete loss of coolant. Note that repair cost includes pump, spray gasket maker, 2 gallons coolant, 2 gallons distilled water.

146000 mi US $30	Water pump was leaking and needed to be replaced, so I replaced it with a new one which was purchased at the auto parts store.
146500 mi US $25	The heat shield under the car was loose and vibrating. The used screws to re-attach it to the bottom of the car.
155500 mi US $25	Exhaust was loose and needed to be reattached to the bottom of the car.
168000 mi US $1200	The entire exhaust system, including the catalytic converter and muffler, was replaced.

33680 mi C $500	new mass air sensor, an couple of feet of exhaust pipe, new plugs and associated wires.
34100 mi C $500	Needed new intake manifold gasket
37200 mi C $50	Replace tail pipe

151000 mi	Replaced exhaust flex pipe, catalyst. Replaced O2 sensor when same code activated after replacement of flex and cat.
171000 mi US $47	Emissions - front bank oxygen sensor replaced.

102700 mi US $511	replaced timing cover gasket, crank seal and valve cover gasket to eliminate oil leak replaced EGR valve and air and coolant temperature sensors
104300 mi US $48	Timing chain cover gasket leak and crankcase seal replacement Knock sensor replaced
114000 mi US $35	replaced idle control valve.
117000 mi US $50	replaced Air Intake Temprature Sensor and the Knock Sensor.

87000 mi US $50	Oxygen sensor
92000 mi US $100	Exhaust Pipe replaced
95200 mi US $80	Upper Engine Mount Replaced
96000 mi US $350	clutch Replaced

135000 mi US $60	Replaced intake manifold, crack in the cooling line that runs through it. Problem caused by a bad ECTS preventing the radiator fan from switching on. Replaced ECTS also.
157000 mi	EGR Valve Replacement

110000 mi US $85	CEL traced to gas cap. $70 for diagnostic, $15 to buy cap myself.
112000 mi US $1	CEL light again. Don't remember exact problem.
114000 mi US $3	The gas tank fill neck rusted and caused the "check engine" light to glow. It caused a leak in the evaporative emissions system. I fixed the problem by removing the rust with steel wool.
141200 mi US $150	Replaced thermostat and engine coolant temperature sensor and drained and re-filled the anti-freeze as part of the thermostat and ECTS repair.

105000 mi US $20	Water pump bearings failed, replace water pump. Found a mix of green and Dexcool coolant from previous owner likely accelerating pump bearing wear. Valve cover gasket leaking oil in to #3 and #4 spark plug wells. Replaced valve cover gasket.
109000 mi	Slight stutter during low throttle/low RPM events. Found 1 ignition coil with a loose core and broken ground strap. Ignition coils were cheap aftermarket. Replaced with OEM coils.
109200 mi US $50	Spark knock during low RPM high throttle events. Compression was higher than usual. Pulled spark plugs and noted excessive carbon on the piston tops. Soaked pistons in Seafoam overnight, ran engine, replaced oil/filter and spark plugs. Noted crack in exhaust downpipe at front bracket. Middle exhaust hanger almost rusted through. Replaced exhaust manifold/downpipe, fixed exhaust hanger.
110000 mi	O2 sensor went bad again. Replaced with a spare I had laying around.

148000 mi	Relay for fuel pump didn't work. switched with heater motor relay, both worked. Since than there has been several times no fuel. wiggle relay, and than car starts. Haven't had time to trouble shoot further.
140000 mi	DTC 0404 Cleaned EGR valve and replaced

116000 mi US $200	exhaust repair
120000 mi US $60	turned out to be a different problem with the exhaust, now fixed

Saturn S-Series repairs by problem area

Saturn S-Series engine repair cost distribution

2002 Saturn S-Series 4dr Sedan

2002 Saturn S-Series 4dr Sedan

2002 Saturn S-Series 4dr Sedan

2002 Saturn S-Series 4dr Sedan

2002 Saturn S-Series 4dr Coupe

2002 Saturn S-Series 4dr Coupe

2002 Saturn S-Series 4dr Coupe

2002 Saturn S-Series 4dr Coupe

2002 Saturn S-Series 4-door

2001 Saturn S-Series 4dr Sedan

2001 Saturn S-Series 4dr Sedan

2001 Saturn S-Series 4dr Coupe

2001 Saturn S-Series 4dr Coupe

2001 Saturn S-Series

2000 Saturn S-Series

2000 Saturn S-Series 4dr Wagon

2000 Saturn S-Series 4dr Wagon

2000 Saturn S-Series 4dr Sedan

2000 Saturn S-Series 4dr Sedan

2000 Saturn S-Series 4dr Sedan

2000 Saturn S-Series 4dr Sedan

2000 Saturn S-Series 4dr Coupe

1999 Saturn S-Series

1999 Saturn S-Series 4-door

1999 Saturn S-Series 4-door

1999 Saturn S-Series 2-door

1999 Saturn S-Series

1999 Saturn S-Series

1998 Saturn S-Series

1998 Saturn S-Series 4-door

1998 Saturn S-Series 4-door

1998 Saturn S-Series 2-door

1998 Saturn S-Series 2-door

1997 Saturn S-Series

1997 Saturn S-Series 4-door

1997 Saturn S-Series 4-door

1997 Saturn S-Series 2-door

1997 Saturn S-Series 2-door

1996 Saturn S-Series

1996 Saturn S-Series 4-door

1996 Saturn S-Series 4-door

1995 Saturn S-Series

1995 Saturn S-Series 4-door

1995 Saturn S-Series 4-door

1995 Saturn S-Series 2-door

1995 Saturn S-Series 2-door

Saturn S-Series Engine Problems

130820 mi C $50	Leaky radiator replaced
138760 mi C $300	Replaced radiator
155620 mi C $50	Flex pipe on the exhaust needed to be replaced

209000 mi US $680	Water pump replaced. Previous pump lasted only 34,000 miles.
225000 mi US $140	Crack in Coolant Reservoir. Replaced with OEM.
238300 mi US $341	New radiator. I was planning to go on an 800 mile trip so I had my mechanic do a thorough look-over. He detected a crack.

140000 mi US $7	Bad O2 sensor Bad Engine coolant temperature sensor
199200 mi US $150	Radiator had a crack in it and was replaced. Thermostat was also replaced.

144000 mi US $300	purchased vehicle w/bad water pump. Had to replace pump, T-stat and all temp. sensors to solve issues noticed during purchase inspection.
152000 mi US $250	top motor mount failure resulted in replacing all 4 mounts.

108000 mi US $608	Universal belt tensioner assembly was rattling and worn. Also replaced belt.
132000 mi US $303	Water pump replaced
145000 mi	Engine seized. Car donated to Habitat for Humanity.

126000 mi US $80	Intermittent and frequent failure of radiator fan motor to turn on. Failed radiator fan replaced
131000 mi US $400	Cracked radiator replaced
206000 mi US $200	Radiator fan failure
213000 mi US $700	Oil leaking into cylinder 4 from above. Replaced cam cover gasket. Engine turned over, no spark. Determined to be a bad ignition control module. Replaced ignition control module as well as spark plugs and ignition cables.

41000 mi US $10	Replaced engine temperature control sensor which was cracked causing engine to run rough when cold engine was idling for over half hour and radiator reservoir was empty and steaming - not sure of problem yet as it has not repeated itself.
59000 mi US $38	muffler bracket rusted and broke and was replaced
78000 mi US $4	Throttle plate was sticking causing the gas pedal to do the same.
116000 mi US $30	water pump replaced

183000 mi US $160	Radiator leaked-replaced radiator, thermostat and hoses. (Was original radiator) O2 sensor threw code. Replaced upper sensor Coolant temp sensor replaced
208000 mi US $20	Cam position sensor. Intermittent no start.

72000 mi US $400	Water pump failed, but replaced
91000 mi US $550	Power steering went out; tensioner and belt replaced

108000 mi US $500	Muffler.
138000 mi US $105	motor mounts
165000 mi US $300	Timing chain had become loose and was making noise. Could not trust another week of driving
179200 mi US $750	burnt a lot of oil so I checked the compression and found #3 cylinder was at 60lb. torn down and re-ringed the engine and installed a rebuilt head.