One problem related to blown head gasket has been reported for the 1996 Saturn SL1. The most recently reported issues are listed below.
For the 4th time, the head gasket is blown and the head is warped. This is the result of a factory design defect in the engine and was repaired the first time without charge by Saturn. However, the repairs do not last and the head blows approximately every 30,000 miles. There is no engine built that should only last 30,000 miles! Saturn refuses to help with these repairs even though the car has been dutifully maintained and serviced at the Saturn dealer. The estimate for repairs is $2,140 with a recommendation of new rods and bearings at this time also. We had new rings, rods and bearings in early 2002. If Saturn admitted to the design defect the first time, and it continues to occur, shouldn't Saturn be held responsible for the repairs?.