2002 Saturn SL Service and Repair Manual

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Factory-Grade Data

2002 Saturn SL service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Built for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and use wiring diagrams and system sections to diagnose problems faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical coverage with wiring diagrams
  • Coverage across key systems: engine, transmission, brakes, steering, suspension, HVAC, and more

Trims covered

  • Base Sedan 4-Door

Engines covered

  • 1.9L 116Cu. In. l4 GAS SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2002 Saturn SL Recalls & Complaints

NHTSA #09E01200007/04/2009Component: EXTERIOR LIGHTING

SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONF

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE S

TSB #11020816

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

TSB #11006621

Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected mo

TSB #11004557

This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.

TSB #11002312

This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information.

TSB #10252735

This bulletin provides information for electrical ground repairs using new General Motors replacement fasteners with conductive finish.

TSB #10251890

This technical bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels shou

TSB #10250775

This service bulletin provides service information to technicians on guidelines to replace Oil Cooler, Oil Cooler Lines and Oil Tank if the engine was replaced where large amounts of debris has flowed throughout the oiling system.

TSB #10249579

This PI bulletin advises the technician on the proper way to install the pistons in an engine.

Showing the 8 most recent of 244 technical service bulletins on file with NHTSA.

20040726Component: AIR BAGS:FRONTALCrash reportedFire reported1 injured

AFTER A CRASH IN A SATURN AND THE AIR BAGS EXPLODED. THE PASSENGER SIDE OF THE DASHBOARD AREA STARTED SMOLDERING. THE FIRE DEPARTMENT ARRIVED AND PUT THE FIRE OUT BEFORE IT DID A LOT OF DAMAGE.*AK

20060720Component: SEATS:FRONT ASSEMBLY:RECLINERCrash reported2 injured

DT*: THE CONTACT STATED THE TWO FRONT SEATS FAILED WHEN THE VEHICLE WAS IN AN ACCIDENT, AND BOTH THE DRIVER AND THE PASSENGER RECLINED. THE VEHICLE WAS DEEMED TOTALED AND THE INSURANCE COMPANY DETERM

20230704Component: AIR BAGSCrash reported1 injured

A car hit me it the front passenger side the hood of my car bent up the passenger side of my windshield cracked and my car went spinning not one air bag came out

20180831Component: SEATSCrash reported1 injured

THE VEHICLE WAS STOPPED, WAS INVOLVED IN A 3 CAR COLLISION. THE VEHICLE WAS HIT FROM BEHIND BY A 1985 CADILLAC FLEETWOOD TRAVELING AT AT LEAST A MODERATE RATE OF SPEED. THE VEHICLE WAS PUSHED INTO A

20170110Component: AIR BAGSCrash reported1 injured

DRIVING ON HIGHWAY RT. 80, WHEN A CAR SWERVED INTO RIGHT LANE IN FRONT OF ME FROM ENTRANCE RAMP. I WAS TRAVELING AT APPROX. 45 MILES AN HOUR. AIRBAGS FAILED TO DEPLOY IN A FRONT END COLLISION, CAUSIN

Showing the 5 most serious of 154 complaints filed with NHTSA.

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