Three problems related to gas recirculation valve (egr valve) have been reported for the 2002 Saturn LS. The most recently reported issues are listed below.
I lost power at highway speeds and at full throttle there was no acceleration. It made a loud boom like a backfire and a large piece of material that looked fiberglass matting and rocks blew out of the exhaust. The car accelerated fine for about 15 miles then started to bog down again. Shut off vehicle and tried to restart unsuccessful, waited a few hours then car restarted with no issues ran vehicle off and on over a three day period, that is when it started malfunctioning again with very rough idle, almost dies, extreme loss of power w/almost no acceleration at full throttle. Contacted mechanic the vehicle resonator was expanded to the point of splitting the seam, he removed the resonator to find all the fiber packing gone and the resonator packed with what looked like rocks. He stated the bits that looked like rocks were part of the catalytic converter packing that had been heated above the limits of the material. The disintegrated material made a blockage in the resonator not allowing the exhaust gasses to flow he checked for TSB's and recall campaigns and found camp # 03v231000 action # 03033 recall # 03-c-06 (electrical system ignition control module) and camp # 07v519000 action # ea06009 recall # 06074. (eng. Timing chain) called gm recall center given case #8-2430110427 per brandy she is getting many calls on this, she shows only the recall 03-c-06 only and she is to deny any additional claims even though they replaced the part with the same part that was recalled to begin with. Investigated recall # 06074 and found that did not include the 2002 Saturn l series however per my mechanic both recalls are contributing factors with the outstanding issues with my vehicle. The car is unsafe to drive. The 2002 Saturn l series should not be on the road and it shouldn't take an accident or a death before you people decide to recall these vehicles.
2002 Saturn l200 suddenly died while I was driving. It was dark out and a lot of traffic. Didn't feel safe waiting in car for tow truck. Had to stand on the side of the road in the dark in 10 degree weather. Timing chain broke, damaged valves. Getting a used engine = $2,000+. Saturn said my VIN # wasn't listed as being a part of the recall on the timing chains. Doesn't make sense that some VIN #s weren't included with the thousands that were recalled.
The contact owns a 2002 Saturn l200. While driving 65 mph, the vehicle suddenly lost power. There were no warning lights present. The contact was able to pull off the road. The vehicle failed to restart and was towed. The weather was clear and approximately 90 degrees. The purchase date was unknown. The current and failure mileages were 67,000.