I just bought a bare bones 1999 Saturn SL1 (EFI/OHC) with manual transmission. It has 140k miles and seems to be in good shape. Although it is noisier and rides rougher than I'd consider normal for a Saturn SL. I'd like to refurbish it mechanically and thought that the owners manual would state what elements were addressed with any given scheduled maintenance but no such luck. What are your recommendations for refurbishing this age/millage Saturn?

 

It probably needs struts if it is riding rough. I would also check the motor mounts. The muffler strap is a common issue which lets the exhaust fall down against the cross member and then it clanks annoyingly, so that could be a source of noise.

Keep an eye on the oil, and with no more miles than it has it should be good for another 140K easily. Around 275k they seem to develop bad valves, based on my two. That's a big job but doable.

 

I found most of what I was looking for in "Haynes Saturn Automotive Repair Manual". Section one contains a list of scheduled maintenance items for 3k, 6k, 15k and 30k and says which section of the manual the where inspection/repair is described. The Maintenance schedule is cumulative and the maintenance at 80k would repeat the 3k through 30k.

There's, also, a site where "check engine light" codes are explained.

More general scheduled maintenance can be found at this site.

The Saturn Forum has a thread for a 2000 SL1 and 100k maintenance. Although it's antidotal, it's still worth the read.

Haynes S-series 1991-1999

Factory Service Repair manual 1997-2002

 

Change your oil at 5000 mi with synthetic, 3000 with Dino oil. No I'm not kidding. It keeps the oil consumption from kicking in. I've driven s cars since '92. Although they were all DOHCs which have a much bigger problem with oil consumption.

Use kyb struts and mounting hardware, stock plugs. If your service engine light comes on, post the codes here and we'll help you sort it out.

If you have an automatic transmission, it will die eventually. Many issues, many solutions which stave off the death certificate.

Lower control arms and/or bushings and/or ball joints are all on the same piece. You can replace the bushing where front stabilizer bar goes without disconnecting things I do believe although I've never tried it and I would expect most of the rubber of the GM left over parts was used for manufacture at least 10 years ago and is probably dried out and stiff / useless. Upper torque axis mount is consumable on these vehicles about every 70,000 miles. The OEM stock is long gone and the aftermarket ones are crap.

Use Moog sway bar end links in the back and be sure to grease them and put the covers back on. If they've been on there sufficiently long, it's easier and quicker to use a saws all to cut each of the two bolts to get it off.

There's a replacement plastic wheel to bring your odometer back to life. Do you have to disassemble it but no effort no gain. Rebulbing the dash is pretty straightforward as long as you don't damage the connector at the edge of the circuit board trying to get it off. Take your freaking time.

Don't replace the muffler with a fart can.
I will personally ban you from the forum
​​​​​​No straight pipe either.

The few remaining Saturns on the road need to represent. And that does not mean represent riced out rides that were popular 20 years ago.

Sure it's your car.
Just hope I don't find out.

All joking aside, welcome