The oddity about the rust you mentioned is that the Saturn, and Pontiac variants were more prone to rust than the Buick and Chevy Counterparts. The Saturn and Pontiac had plastic cladding on the lower doors, and rockers, which retained water, dirt, debris, salt, etc. The Buicks and Chevys didnt have that.
Anyways..
2 weeks ago, I got the emissions done, and it passed with extreme flying colors. I was a bit shocked, as the plugs are still OEM, and at that point, I still had not done the oil change or transmission filter. The emissions certifier didnt believe the numbers either, and crawled under the van to make sure no modifications were done. He was surprised when he saw a completely stock exhaust, fuel system, and emissions system.
1 week ago, I did the oil and filter, transmission oil and filter. No noticeable difference in the way it drives. I am going to drive it for 2-3 years, and let the dealer do the plugs and wires.
Got the rebuilt from salvage inspection done this morning. Passed with flying colors. The Colorado State Patrolman was a bit miffed that the drivers front door still had the VIN from the donor junkyard van. Not much I can really do about it, and nothing he could do, or say, about it either.
Went to the DMV to get a new title, and plates.
She is officially road worthy, and legal, although I have been driving it the past month, and about 1400 miles. She drives wonderfully, although a bit under powered. My Aztek with the 3400 engine has the same drivetrain, but has FR9 3.29 gears, where the Saturn has a 3500 engine, and FR3 3.69 gears. The Aztek has more pep in its step.. The Saturn, not so much. She does get better gas mileage, 18 mpg.
I cant say I enjoy driving it thou, I also dont enjoy driving the Aztek. But they arent for me, they are for the wife.
She will start driving it full time tomorrow, and I get my Envoy back..
I also get to start trying to fix the Aztek. I am hoping the fuel filter is clogged. But I am thinking a have a bad injector or fuel pump.
And if that wasnt bad enough, I still have to figure out the high speed vibration on the Envoy. I think the rear driveshaft needs to be balanced, or the rear end needs to be rebuilt... Leaning towards the rear end rebuild. Which means sending it to a shop. I have no way to check thrust, or drive in or out the pinion bushing.
I also need to take the Saturn to the body shop tomorrow to get the estimate from the tire shop damage.