Replaced coolant tank pressure cap at 40000 miles as it leaked.
Idler pulley developed noisy operation in 2004 at about 42000 miles which I replaced with a junkyard replacement off a new model Saturn and so far works great. Cost $5.00.
An engine miss developed at 42500 which I traced to number #3 ignition cable being corroded at the ignition coil. Not sure whether a body man had disturbed the wire when it went in for front end collision damage repair. I surmise the ignition coil got splash from rain water as it is mounted very low on the engine. Replaced the entire set and cleaned the ignition coil terminal.
Dash rattles. Removed the entire upper dash and had to replace all the weird GM Velcro that holds the corners down. Used EXTREME Velcro brand in 4 spots Broke a clip that holds the curved section of the dash over the instrument cluster as the plastic that holds the clip is very thin and after 11 years had become brittle. This occurred at about 49000 miles.
ABS brake fluid is very difficult to replace without the fancy computer required to turn on the ABS pump.
Worn ignition key caused the check engine light to come on and made the windows, interior fan, rear defog, locks and more to be inoperative as the key wasn't pulling in the tumblers all the way making it hang so it wouldn't return to the run position sometimes after startup. Replaced key, problem solved. Occured for at least a few years until my girlfriend showed me the problem while I was in the car. Diag code showed 12 which meant the computer didn't see the problem. Took original key and had a copy made and stored the original in a safe place.
Replaced one brake lite so far in the life of the car.
Muffler has a tiny hole developing in it, but not a big deal after 11 years.
Glove box latch needed adjustment recently by simply bending the bar the latch grabs on to.
Clutch pedal squeaks even though it has been disassembled and greased. The repair lasted about 1 year. Before that, and I am talking 10 years no problem.
I'm 6ft tall so it's a squeeze to enter the drivers seat even with the steering wheel in the upper position.
Other than that I like the body design and the acceleration and performance is rated as acceptable.
Saturns are excellent cars, but it really sounds as if yours has had more than the usual share of problems. My God son bought a new Saturn SL-2 in 1996 and in 100,000 miles never had a single problem with it. I admire your ability to do your own servicing and repairs. I do all my own repairs also, and it boggles my mind what some people will pay a shop to repair their cars!! I can't fathom paying $400 for a brake job when the total parts cost is under $30!! My best friend, who doesn't know which end of his car the engine is in, paid a shop $280 to replace a TAIL LIGHT BULB!!!