2002 Saturn LS Problems

What owners report

Owners of this model year most often describe the engine quitting without warning while driving, with a shop then finding a broken timing chain and valve or cylinder head damage. Other recurring themes in the sampled complaints are a gasoline smell or visible leak at the top of the fuel tank, brake and tail lamps that stop working or stay lit, and electrical faults that knock out the instrument cluster, gauges and security system. Reports are spread across a wide mileage range rather than clustered at one point.

1. 1
   Engine

   Engine quits while driving (broken timing chain)

   • 248 complaints (50%)
   • median 80,000 mi at 7.2 yrs old (231 state mileage)
   • 5 mention a crash, fire or injury
   • owner-quoted repair $2,500 (median of 63 quotes)
   • filed 2002–2021

   Complaints describe the engine cutting out suddenly at road or highway speed with no warning, leaving the car without power assist for steering and brakes and refusing to restart. Shops and dealers quoted in the reports typically found a broken or stretched timing chain, often with bent valves, damaged pistons or a damaged head, and recommended a rebuilt or used engine. Several owners say they were quoted roughly $2,500 to $4,000 and that the manufacturer declined to help because their vehicle fell outside an earlier campaign covering the same engine in the previous model year. Reports are spread from roughly 40,000 to 100,000 miles, many of them while driving at highway speed rather than at start-up.

   What to check: Ask whether the timing chain, tensioner and guides have been replaced and keep oil change records, since some complaints mention the manufacturer pointing to maintenance. Have a mechanic listen for a cold-start rattle and check compression before purchase.

   2 excerpts from owner complaints in NHTSA records

   “The car was running fine. I pulled away from a traffic light and tried to get up to the speed limit of 45 miles per hour. At approximately 40 miles an hour the engine just stopped in the middle of the road. I managed to get it to the side and called the wrecker. Mechanic said timing chain broke and I need a new engine.”

   NHTSA complaint #10597247, filed 2014-06, 129,000 miles

   “As I drove, up hill, while using the speed control feature, the engine began to rev high rpms. It then jerked and began to overheat. I was able to slowly drive it to a safe location and then have it towed to a repair facility. At the repair facility I was told it was a timing chain issue. I began researching the issue and found a recall had been issued for that issue for the 2001 Saturn l200. …”

   NHTSA complaint #10379303, filed 2011-01, 141,000 miles
2. 2
   Fuel system

   Gasoline smell and leak at top of fuel tank

   • 42 complaints (9%)
   • median 77,000 mi at 8.7 yrs old (35 state mileage)
   • owner-quoted repair $576 (median of 11 quotes)
   • filed 2003–2018

   Owners describe a strong gasoline odor, most noticeable after the car is parked or when standing outside it, and in some cases liquid fuel visible on the ground or soaking the top of the tank. Inspections commonly traced it to a cracked plastic fitting or cracked housing on the fuel pump module where the line connects, which in some reports sprayed fuel upward. Owners who took the car in say the fuel pump assembly was replaced, and several noted the service department seemed to recognize the pattern. Reported from roughly 34,000 to about 138,000 miles, usually noticed while parked or just after shutting the engine off.

   What to check: Smell around the rear of the car and under the back seat after a test drive, and look for wet or stained areas on top of the tank. Ask whether the fuel pump module or its fittings have been replaced.

   2 excerpts from owner complaints in NHTSA records

   “Fuel pump leaking fuel from cracked return fitting on module. Gm has already recalled a few models for this problem but only in warmer climates. We had temps in excess of 100 in illinois this year; however my car and state were not on the recall list. I believe the recall should be expanded due to the potential for a fire from gas leaking onto the exhaust.”

   NHTSA complaint #10479416, filed 2012-10, 105,688 miles

   “There were no special events (accidents, unusual road conditions, etc) precipitating this problem. We have a 2002 Saturn l200 with 75.5k mi.s on it. We have been increasingly smelling gasoline odor coming from this car after parking it. I got underneath the car and found that liquid gasoline is coming from on top of the gas tank and soaking the sides of the tank. When I called the dealer, the service dept seemed familiar with the problem. They said it is likely a leaking fitting on the fuel pump; requiring a new fuel pump $400+. …”

   NHTSA complaint #10204236, filed 2007-09, 75,200 miles
3. 3
   Exterior lighting

   Brake lights out or staying on (tail lamp housing)

   • 24 complaints (5%)
   • median 69,950 mi at 6.6 yrs old (20 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2003–2023

   Complaints describe brake lamps that stop lighting, burn out repeatedly, or stay lit together with the headlamps because of a short in the tail lamp assembly. Owners often learned about it from another driver or a traffic stop rather than from any warning. Repairs described include new bulbs, sockets and reinforced socket adapters, and in one case a brake light switch; some owners report the lamps failed again after recall work or that parts were no longer available. Reports range from about 30,000 to 130,000 miles, noticed while driving or when the lamps are inspected with the car parked.

   Recall 05V245000

   What to check: With the engine running, have someone watch the rear lamps while you press the brake, and check whether the brake lamps glow whenever the headlamps are on. Ask whether the tail lamp recall work was completed and whether the sockets or housings were replaced afterward.

   2 excerpts from owner complaints in NHTSA records

   “I purchased my '02 Saturn l300 from a highly recommended local used car dealership here in florida mid may '05. It was close to closing time when the final papers were drawn so the salesman and I walked around the car and I noticed then that the left rear brake lamp was out. He told me that the parts dept was closed so to come back the next business day. I came back that monday and they fixed it no problem. Well a month or so later, on my way to work, I was pulled over by a state trooper and was told my left rear brake light was out. …”

   NHTSA complaint #10131768, filed 2005-08, 32,995 miles

   “The contact owns a 2002 Saturn l200. The contact stated that the rear lights were continuously burning out and the bolt was cracking. The vehicle was not taken to the dealer. The manufacturer was made aware of the failure who did not offer any assistance since the vehicle was already repaired under NHTSA campaign number: 05v245000 (exterior lighting). The vehicle was not repaired. The failure mileage was 60,000 and the current mileage was 88,000.”

   NHTSA complaint #10607530, filed 2014-07, 60,000 miles
4. 4
   Electrical system

   Instrument cluster, security and gauge failures

   • 54 complaints (11%)
   • median 76,000 mi at 6.7 yrs old (43 state mileage)
   • 3 mention a crash, fire or injury
   • owner-quoted repair $700 (median of 9 quotes)
   • filed 2003–2017

   Owners describe the security light flashing while driving, followed by loss of headlamps, dash lighting and gauge readings, and sometimes an odometer that reset itself or a car that would not shift into gear until it sat for a while. Several reports point to a failed body control module or control computer that took out the alarm, key fob, radio and transmission interlock at once. One owner reported smoke and then fire from the turn signal switch in the steering column, and another described the ignition not recognizing that the key had been removed, setting off the alarm. Spread from about 37,000 miles to well past 150,000 miles, with several reports arriving shortly after the warranty period ended.

   What to check: Check that all gauges, interior lamps, the key fob and the alarm behave normally, and watch for a flickering security light on the test drive. Ask whether the body control module has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “Electronic controle computer shorted out working sortly after warenty expierd. Alarm did not work, key fob did not work, transmision inter lock would not disegage, fule gage did not work, temp gage did not work, radio did not work, no instrument lights.”

   NHTSA complaint #10127100, filed 2005-06, 37,000 miles

   “Security system is failing. While driving, security light will flash on and off. When this happens, lose headlights, dash lights. Also causes fuel gauge and temperature gauge to fail. Had auto part store access on board computer. No errors found. Problem happened again. Was unable to car into gear. Had to let car sit for awhile. Tried to disable alarm system per handbook. No success. Another result of this is my odometer reset to 000000 miles and now loses miles when it does work.”

   NHTSA complaint #10129285, filed 2005-07, 46,787 miles
5. 5
   Suspension

   Front subframe rust at the lower control arm

   Mentioned in 4 of 60 sampled complaints

   Owners describe a vibration or a steering wheel that has to be held off-center to keep the car straight, which a mechanic then traced to rust-through of the front subframe where the lower control arm attaches. In the reports the rusted mount was severe enough to damage the inner CV joint and axle, and the subframe had to be replaced. Reported around 49,000 to 112,500 miles, in cars driven where road salt is used.

   What to check: Look underneath at the front subframe where the lower control arms bolt up, especially on cars from snowy states, and probe for flaking or soft metal before buying.

   2 excerpts from owner complaints in NHTSA records

   “This car has been nothing but trouble. I have had to have the drive shaft replaced, the motor mounts replaced, the tail light assembly replaced, the steering assembly replaced and I too have a problem with the dash lights dimming. The technicians at the local Saturn dealership are nothing but rude. They dont fix the problems you bring the car in for and you end up having to take it back the next day or even sometimes that same evening for a repair that wasnt done properly. …”

   NHTSA complaint #10126779, filed 2005-06, 26,000 miles

   “2002 Saturn l-100 sedan. Front subframe assembly rusted to the point of total failure on the right hand side where lower control arm connects. Failure happened in parking lot so there was no personal injury or crash. Failure took out right inner cv joint and drive shaft. Wheel well liner and fender also damaged. Front subframe assembly had to be replaced with new part. New cv joint and drive shaft installed.”

   NHTSA complaint #10262933, filed 2009-03, 49,000 miles

Buying note. Have a candidate inspected for timing chain condition, fuel leaks at the top of the tank and front subframe rust before purchase, and ask for records showing whether the tail lamp recall work and any timing chain repairs were completed.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.