NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
50 reportsClear category filter43,400 miles · Jul 12, 2005
Electrical SystemEquipmentVisibilityFire
PRECEEDING THE TWO ELECTRICAL FIRES IN MY VEHICLE, I HAD INTERMITTENT ISSUES WITH SHORTS IN THE ELECTRICAL SYSTEM (THE LOCKS UNLOCKING/LOCKING AT RANDOM; LIGHTS GOING ON AND OFF AND THE ALARM SYSTEM TRIGGERING EVEN WHEN NOT SET). THERE WAS ALSO LEAKAGE FROM SOMEWHERE IN THE CAR (EITHER THROUGH THE WINDSHIELD OR ELSEWHERE IN THE…
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PRECEEDING THE TWO ELECTRICAL FIRES IN MY VEHICLE, I HAD INTERMITTENT ISSUES WITH SHORTS IN THE ELECTRICAL SYSTEM (THE LOCKS UNLOCKING/LOCKING AT RANDOM; LIGHTS GOING ON AND OFF AND THE ALARM SYSTEM TRIGGERING EVEN WHEN NOT SET). THERE WAS ALSO LEAKAGE FROM SOMEWHERE IN THE CAR (EITHER THROUGH THE WINDSHIELD OR ELSEWHERE IN THE FRONT) THAT WAS QUITE NOTICEABLE DURING A HEAVY STORM. EARLIER THIS YEAR, I WAS EXITING A PARKING GARAGE WHEN I FIRST SAW AND THEN SMELLED SMOKE COMING FROM OUT OF THE DASH. THE ELECTRICAL WIRES SHORTED OUT AND CAUSED A FIRE THAT MELTED A PORTION OF THE WIRING IN THE FRONT OF THE CAR. THE DEALERSHIP COULD NOT REPAIR THE CAR FOR SEVERAL DAYS AND DURING A STORM TWO DAYS LATER, THE ENTIRE SYSTEM SHORTED OUT AGAIN (LIGHTS AND OTHER COMPONENTS WOULD NOT TURN OFF) AND THE BATTERY COMPLETELY DISCHARGED. THE DEALERSHIP DETERMINED THAT THE LEAK WAS DUE TO A FAULTY WINDSHIELD PLACEMENT AND REPLACED THE WINDSHIELD (AND WATER-TESTED IT) ALONG WITH THE AFFECTED WIRING SYSTEMS, THE BATTERY AND THE CARPETING. NOW, JUST TWO DAYS AGO, I HAVE HAD A RECURRENCE OF THE SAME ISSUE. AGAIN, AFTER A HEAVY STORM, I WOKE TO DISCOVER THAT THE WIRING IN THE SAME AREA OF THE CAR HAD SHORTED OUT. THIS TIME, THE RESULTING FIRE MELTED THE PLASTIC HOUSING SURROUNDING THE FUSEBOX, AND THE HOUSING IS NOW A PILE OF MELTED GOO ON THE CARPET IN THE DRIVER'S SIDE OF THE CAR. THE DEALERSHIP HAS YET TO DETERMINE THE CAUSE OF THE SHORT.
NHTSA ODI #10128416
11,000 miles · Jun 21, 2004
Electrical System
SEVERE LIGHT DIMMING; ALL LIGHTS DIM SEVERELY (ENOUGH TO CAUSE A TRACTOR TRAILER DRIVER TO THINK I GAVE HIM THE FLASH TO PASS SIGNAL, CAUSING HIM TO MOVE OVER INTO MY LANE) AT RANDOM, SOMETIMES 2 TO 3 TIMES PER MILE DRIVEN. SATURN HAS ISSUED A SERVICE BULLETIN, 04-08-42-001, STATING LIGHT DIMMING IS A CHARACTERISTIC OF THE L-SER…
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SEVERE LIGHT DIMMING; ALL LIGHTS DIM SEVERELY (ENOUGH TO CAUSE A TRACTOR TRAILER DRIVER TO THINK I GAVE HIM THE FLASH TO PASS SIGNAL, CAUSING HIM TO MOVE OVER INTO MY LANE) AT RANDOM, SOMETIMES 2 TO 3 TIMES PER MILE DRIVEN. SATURN HAS ISSUED A SERVICE BULLETIN, 04-08-42-001, STATING LIGHT DIMMING IS A CHARACTERISTIC OF THE L-SERIES, YET THEY HAVE NOT DRIVEN MY CAR ON THE HIGHWAY AT NIGHT TO SEE THE EXTREMITY OF THE DIMMING IN MY VEHICLE. SOMETIMES IT OCCURS RIGHT AWAY, OTHER TIMES IT TAKES A WHILE. SATURDAY NIGHT, 04/24/04 I TOOK THE CAR TO ATLANTA, GA. BETWEEN MOBILE, AND MONTGOMERY, THE LIGHTS DIMMED SEVERELY FOR DOZENS OF MILES. SATURDAY NIGHT, 06/19/04 I TOOK THE CAR ON A TRIP TO BIRMINGHAM, AL TO TRY TO RE-CREATE THE PROBLEM AND DOCUMENT IT. IT DIDN'T OCCUR UNTIL AFTER DRIVING IT 220 MILES. IT THEN DIMMED SEVERELY MANY TIMES FOR AROUND 10 TO 15 MILES (AS MANY AS 2 - 3 TIMES PER MILE). AFTER THAT POINT, IT STOPPED DOING IT. *AK
NHTSA ODI #10078574
17,000 miles · May 26, 2004
Electrical SystemExterior LightingInterior Lighting
THIS IS THE THIRD INCIDENT, SECOND IN SAME DAY, WHERE THE ELECTRICAL SYSTEM FAILED. AUDIBLE CLICKING SOUND UNDER DASH AND LIGHTS REPEATEDLY TURNING ON & OFF, LOCKS ON AND OFF AND HORN SOUNDING. ON 1 PRIOR OCCASIONS, AUDIBLE CLICKING HEARD AND LOCKS REPEATEDLY TURNING ON AND OFF. CLEARLY NOT AN ISOLATED INCIDENT, AS I CAN SEE …
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THIS IS THE THIRD INCIDENT, SECOND IN SAME DAY, WHERE THE ELECTRICAL SYSTEM FAILED. AUDIBLE CLICKING SOUND UNDER DASH AND LIGHTS REPEATEDLY TURNING ON & OFF, LOCKS ON AND OFF AND HORN SOUNDING. ON 1 PRIOR OCCASIONS, AUDIBLE CLICKING HEARD AND LOCKS REPEATEDLY TURNING ON AND OFF. CLEARLY NOT AN ISOLATED INCIDENT, AS I CAN SEE FROM OTHER COMPLAINTS THAT OTHER OWNERS OF THIS MODEL ARE EXPERIENCING THE SAME PROBLEM. CONSEQUENCES OF THE PROBLEM --- NEIGHBORS CALLED POLICE TO COMPLAIN ABOUT NOISE. UNABLE TO KEEP ALARM ON DUE TO CONTINUING PROBLEM, LEADING TO INSECURE CAR. ALSO, SAFETY ISSUE WITH LIGHTS AND LOCKS REPEATEDLY TURNING ON AND OFF WITH THE ELECTRICAL FAILURE. DEALER WILL SERVICE IN TWO DAYS (FIRST AVAILABLE APPT!!) AND WILL UPDATE THEN.
NHTSA ODI #10073181
50 miles · Feb 19, 2004
Electrical System
THE DRIVER HAS TO APPLY EXCESSIVE EFFORT TO ACTIVATE THE HORN AND ONCE IT WAS PRESSED THERE WAS A 4 TO 5 SECOND DELAY. THE VEHICLE WAS TAKEN TO THE DEALER WHO INDICATED THAT THE VEHICLE WAS OPERATING AS DESIGNED. *NM
NHTSA ODI #10059321
15,758 miles · Dec 3, 2003
Electrical SystemEngine And Engine CoolingExterior Lighting
PROBLEMS WITH VEHICLE'S POWER STEERING SYSTEM.*MR CONSUMER NOTICED THE FAILURE WHEN DRIVING OFF THE LOT BUT THOUGHT I WAS DUE TO COLD WEATHER. LATER SHE LEARNED THE RACK AND PINION NEEDED TO BE REPLACED DUE TO FLUID LEAKING. AFTER THE REPAIR, CONSUMER STARTED HEARING GRINDING NOISE WHEN TURNING. ON 10/08/03, THE CON…
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PROBLEMS WITH VEHICLE'S POWER STEERING SYSTEM.*MR CONSUMER NOTICED THE FAILURE WHEN DRIVING OFF THE LOT BUT THOUGHT I WAS DUE TO COLD WEATHER. LATER SHE LEARNED THE RACK AND PINION NEEDED TO BE REPLACED DUE TO FLUID LEAKING. AFTER THE REPAIR, CONSUMER STARTED HEARING GRINDING NOISE WHEN TURNING. ON 10/08/03, THE CONSUMER LEARNED THE STEERING PUMP HAD TO BE REPLACED. AFTER PICKING UP THE VEHICLE ON THIS DATE, CONSUMER HEARD MORE NOISES. THIS TIME IT WAS A AIR POCKET IN THE STEERING FLUID. IN ADDITION, THE AUTOMATIC CLIMATE CONTROL SYSTEM FAILS TO WORK AS DESIGNED. IT'S PROGRAMMED AT 87 DEGREES WHEN ITS COLD OUTSIDE. INSTEAD OF HEAT, IT WOULD BLOW WARM THEN COLD AIR. THE COMPUTER WAS REPROGRAMMED AND THE PROBLEM BECAME WORST THAN AT FIRST. THERE WERE COUNTLESS OTHER PROBLEMS WITH THIS VEHICLE. *PH
NHTSA ODI #10050082
500 miles · Oct 30, 2003
Electrical SystemExterior LightingVehicle Speed Control
CONSTANT ELECTRICAL FAILURE WITH 2003 SATURN L SERIES SEDAN..LIGHTS DON T WORK PROPERLY(DAYTIME RUNNING REGULAR LIGHTS)..CONSTANT SHORTING ..HORN BLASTS..CRUISE CONTRLL GOES ON.. MAP LIGHT.. ALARM ACTIVATES WHILE DRIVING..SENDING UNIT FAILURE..HEATER CORE FAILURE..*AK
NHTSA ODI #10045054
2,300 miles · Oct 13, 2003
Electrical System
*SATURN BUYERS BEWARE* I PURCHASED A BRAND NEW L200 IN MARCH 03. TO DATE I HAVE HAD THE FOLLOWING PROBLEMS: -CAR DOES NOT START ALL THE TIME -TEMPERATURE CONTROLS DOES NOT WORK -REMOTE ENTRY SYSTEM DOES NOT WORK PROPERLY I HAVE TAKEN MY CAR INTO SATURN 4 TIMES, BUT TO NO AVAIL. THEY CLAIMED THAT THEY CAN'T FIND ANY PR…
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*SATURN BUYERS BEWARE* I PURCHASED A BRAND NEW L200 IN MARCH 03. TO DATE I HAVE HAD THE FOLLOWING PROBLEMS: -CAR DOES NOT START ALL THE TIME -TEMPERATURE CONTROLS DOES NOT WORK -REMOTE ENTRY SYSTEM DOES NOT WORK PROPERLY I HAVE TAKEN MY CAR INTO SATURN 4 TIMES, BUT TO NO AVAIL. THEY CLAIMED THAT THEY CAN'T FIND ANY PROBLEMS WITH THE CAR. SATURN CUSTOMER SERVICE IS TERRIBLE AS WELL. *LA
NHTSA ODI #10041731
70 miles · Oct 8, 2003
Electrical SystemExterior LightingInjury
A TRACTOR TRAILER WAS PASSING ME ON THE INTERSTATE. JUST AS HIS TRAILER WAS APPROXIMATELY 2/3 PAST ME, MY LIGHTS DIMMED OUT ON MY CAR BY THEMSELVES. THE DRIVER OF THE TRACTOR TRAILER THOUGHT I HAD FLASHED MY HEADLIGHTS AT HIM, TO LET HIM KNOW HE HAD CLEARED MY CAR AND WAS SAFE TO COME INTO MY LANE, WHICH WAS NOT THE CASE. THIS…
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A TRACTOR TRAILER WAS PASSING ME ON THE INTERSTATE. JUST AS HIS TRAILER WAS APPROXIMATELY 2/3 PAST ME, MY LIGHTS DIMMED OUT ON MY CAR BY THEMSELVES. THE DRIVER OF THE TRACTOR TRAILER THOUGHT I HAD FLASHED MY HEADLIGHTS AT HIM, TO LET HIM KNOW HE HAD CLEARED MY CAR AND WAS SAFE TO COME INTO MY LANE, WHICH WAS NOT THE CASE. THIS MADE THE DRIVERS BEHIND ME AND THE TRACTOR TRAILER IN ALL 3 LANES, TO SLAM ON THEIR BRAKES. THE TRUCK DRIVER ALMOST LOST CONTROL OF HIS RIG TRYING TO KEEP FROM HITTING ME WHEN HE REALIZED THAT HE DID NOT HAVE CLEARANCE AS MY LIGHTS "SUGGESTED" TO HIM THAT HE HAD. ALL OF US WERE FORTUNATE AT THIS TIME NOT TO HAVE WRECKED. (YET I RECEIVED A LOT OF JERKING OF MY NECK AND HEAD WHEN BRAKING AND STEERING TO GET OUT OF THE WAY). NEXT TIME MY LIGHTS DO THIS IT COULD MAKE ANOTHER TRUCKER OR PERSON PULLING AN RV OR A SCHOOL BUS FULL OF KIDS OR TOUR BUS FULL OF TOURISTS THINK I HAVE GIVEN THE "CLEARANCE" TO MOVE INTO MY LANE; WHEN I HAVE NOT. SOMEONE IS GOING TO GET KILLED IF THIS ISSUE WON?T FORCE TO BE REPAIRED BY GM/SATURN. I REPORTED TO SATURN, WHAT CAUSED THIS SEVERE POWER DRAIN ON MY CAR. WHEN THE AUXILIARY COOLING FAN NEAR THE COMPRESSOR KICKS IN, IT PUTS A SEVERE POWER DRAIN ON THE CARS LIGHTS, WHICH WAS USING THE HEAT OR A/C THAT COULD BE DOZENS OF TIMES IN A MATTER OF MINUTES IF IT APPEARS THAT I AM FLASHING MY HEADLIGHTS TO THOSE IN FRONT OF ME AND TAPPING MY BRAKES TO THOSE BEHIND ME. LAST WEEK, MY LOCAL DEALERSHIP WAS TRYING TO FIX MY CAR. ON THE 2ND DAY OF WORKING ON MY CAR THE SERVICE DEPT. CALLED SATURN INCORPORATED FOR HELP. MY DEALERSHIP WAS FORCED BY SATURN CORPORATION TO STOP WORKING ON MY CAR. THEY WERE TOLD NOT TO FIX MY CAR CLAIMING ALL SATURNS ARE DESIGNED THIS WAY. THEY SAID IT IS NOT A SAFETY OR WARRANTY ISSUE BECAUSE MY LIGHTS DON'T GO ALL THE WAY OFF. MY LIGHTS MIGHT NOT GO ALL THE WAY OUT BUT THEY GO OUT TOO MUCH TO BE CONSIDERED SAFE. NOTE:(THE 2004 L-300 LOANER THEY HAD SUPPLIED ME DOES IT TOO) *LA
NHTSA ODI #10041433
70 miles · Oct 8, 2003
Electrical SystemInjury
A TRACTOR TRAILER WAS PASSING ME ON THE INTERSTATE. JUST AS HIS TRAILER WAS APPROXIMATELY 2/3 PAST ME, MY LIGHTS DIMMED OUT ON MY CAR BY THEMSELVES. THE DRIVER OF THE TRACTOR TRAILER THOUGHT I HAD FLASHED MY HEADLIGHTS AT HIM, TO LET HIM KNOW HE HAD CLEARED MY CAR AND WAS SAFE TO COME INTO MY LANE, WHICH WAS NOT THE CASE. THIS…
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A TRACTOR TRAILER WAS PASSING ME ON THE INTERSTATE. JUST AS HIS TRAILER WAS APPROXIMATELY 2/3 PAST ME, MY LIGHTS DIMMED OUT ON MY CAR BY THEMSELVES. THE DRIVER OF THE TRACTOR TRAILER THOUGHT I HAD FLASHED MY HEADLIGHTS AT HIM, TO LET HIM KNOW HE HAD CLEARED MY CAR AND WAS SAFE TO COME INTO MY LANE, WHICH WAS NOT THE CASE. THIS MADE THE DRIVERS BEHIND ME AND THE TRACTOR TRAILER IN ALL 3 LANES, TO SLAM ON THEIR BRAKES. THE TRUCK DRIVER ALMOST LOST CONTROL OF HIS RIG TRYING TO KEEP FROM HITTING ME WHEN HE REALIZED THAT HE DID NOT HAVE CLEARANCE AS MY LIGHTS "SUGGESTED" TO HIM THAT HE HAD. ALL OF US WERE FORTUNATE AT THIS TIME NOT TO HAVE WRECKED. (YET I RECEIVED A LOT OF JERKING OF MY NECK AND HEAD WHEN BRAKING AND STEERING TO GET OUT OF THE WAY). NEXT TIME MY LIGHTS DO THIS IT COULD MAKE ANOTHER TRUCKER OR PERSON PULLING AN RV OR A SCHOOL BUS FULL OF KIDS OR TOUR BUS FULL OF TOURISTS THINK I HAVE GIVEN THE "CLEARANCE" TO MOVE INTO MY LANE; WHEN I HAVE NOT. SOMEONE IS GOING TO GET KILLED IF THIS ISSUE WON?T FORCE TO BE REPAIRED BY GM/SATURN. I REPORTED TO SATURN, WHAT CAUSED THIS SEVERE POWER DRAIN ON MY CAR. WHEN THE AUXILIARY COOLING FAN NEAR THE COMPRESSOR KICKS IN, IT PUTS A SEVERE POWER DRAIN ON THE CARS LIGHTS, WHICH WAS USING THE HEAT OR A/C THAT COULD BE DOZENS OF TIMES IN A MATTER OF MINUTES IF IT APPEARS THAT I AM FLASHING MY HEADLIGHTS TO THOSE IN FRONT OF ME AND TAPPING MY BRAKES TO THOSE BEHIND ME. LAST WEEK, MY LOCAL DEALERSHIP WAS TRYING TO FIX MY CAR. ON THE 2ND DAY OF WORKING ON MY CAR THE SERVICE DEPT. CALLED SATURN INC FOR HELP. MY DEALERSHIP WAS FORCED BY SATURN CORPORATION TO STOP WORKING ON MY CAR. THEY WERE TOLD NOT TO FIX MY CAR CLAIMING ALL SATURNS ARE DESIGNED THIS WAY. THEY SAID IT IS NOT A SAFETY OR WARRANTY ISSUE BECAUSE MY LIGHTS DON'T GO ALL THE WAY OFF. MY LIGHTS MIGHT NOT GO ALL THE WAY OUT BUT THEY GO OUT TOO MUCH TO BE CONSIDERED SAFE. NOTE:(THE 2004 L-300 LOANER THEY HAD SUPPLIED ME DOES IT TOO) *LA
NHTSA ODI #10041432
44,000 miles · Aug 18, 2003
Electrical System
SUDDEN ELECTRICAL FAILURE RELATED (ACCORDING TO DEALER) TO FAILURE OF BCM (COMPUTER MODULE. RESULTED IN LOSS OF GAGES IN DASHBOARD, LOSS OF HEADLIGHTS, LOSS OF WINDSHIELD WIPERS, ELECTRIC DOORLOCKS FAILING, CAR COULD NOT BE TAKEN OUT OF GEAR (PARK) WHEN STOPPED.*AK
NHTSA ODI #10033054
Official recalls
4Jun 2, 2005
ON CERTAIN SEDANS AND WAGONS, THE PLASTIC HOUSING IN THE REAR TAIL LAMP ASSEMBLY CAN BECOME DISTORTED IF THE BRAKE LAMPS REMAIN ON FOR AN EXTENDED TIME.
Consequence & remedy
Consequence: THIS CAN CAUSE (1) AN INTERMITTENTLY INOPERATIVE BRAKE/TAIL LAMP BULB OR (2) A SHORT CIRCUIT THAT OPENS A FUSE CAUSING INOPERATIVE BRAKE LAMPS (INCLUDING THE CENTER HIGH-MOUNTED STOP LAMP) OR TAIL LAMPS. A FOLLOWING DRIVER MAY NOT KNOW WHEN THE BRAKES HAVE BEEN APPLIED, AND A REAR-END CRASH COULD OCCUR WITHOUT PRIOR WARNING.
Remedy: DEALERS WILL INSTALL TWO NEW TAIL LAMP REINFORCING SOCKET ADAPTERS AND SOCKETS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 17, 2005. OWNERS MAY CONTACT SATURN AT 1-800-972-8876.
Apr 20, 2005
CERTAIN WAGONS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 210, "SEAT BELT ASSEMBLY ANCHORAGES." THE SEAT BELT ANCHOR MAY SEPARATE FROM THE FLOOR OF THE VEHICLE BEFORE HOLDING THE REQUIRED TEST LOAD FOR THE REQUIRED TIME.
Consequence & remedy
Consequence: IF A SEPARATION OCCURRED IN CRASH, THE RIGHT AND CENTER REAR SEAT OCCUPANTS MAY NOT BE PROPERLY RESTRAINED, INCREASING THE RISK OF PERSONAL INJURY.
Remedy: DEALERS WILL INSTALL A REAR SEAT CENTER BELT ANCHOR REINFORCEMENT PLATE TO THE FLOOR PAN OF THE VEHICLE FREE OF CHARGE. THE RECALL BEGAN ON APRIL 25, 2005. OWNERS MAY CONTACT SATURN AT 1-800-972-8876.
Jun 23, 2003
ON CERTAIN PASSENGER VEHICLES EQUIPPED WITH 2.2L L4 (L61) ENGINES, A FAILURE OF THE IGNITION CONTROL MODULE MAY CAUSE DETERIORATION IN IDLE QUALITY, REDUCTION IN OVERALL ENGINE POWER, AND THE VEHICLE MAY BE HARD TO START. CONTINUED OPERATION OF THE VEHICLE AFTER SUCH AN IGNITION MODULE FAILURE WILL RESULT IN THE "SERVICE ENGINE SOON" LIGHT FLASHING, AND MAY LEAD TO SECONDARY FAILURES OF THE CATALYTIC CONVERTER, OXYGEN SENSOR, AND EXHAUST RESONATOR.
Consequence & remedy
Consequence: FAILURE OF THE RESONATOR WILL CAUSE INCREASED EXHAUST NOISE. PROLONGED OPERATION OF THE VEHICLE FOLLOWING A RESONATOR FAILURE MAY LEAD TO A FIRE.
Remedy: DEALERS WILL (1) REPLACE THE IGNITION CONTROL MODULE, (2) REPLACE THE IGNITION CONTROL MODULE AND SPARK PLUGS, OR (3) REPLACE THE IGNITION CONTROL MODULE, SPARK PLUGS, AND UPDATE THE POWERTRAIN CONTROL MODULE CALIBRATION. OWNER NOTIFICATION BEGAN ON AUGUST 4, 2003. OWNERS SHOULD CONTACT SATURN AT 1-800-553-6000, PROMPT 3.
Oct 29, 2002
CERTAIN SPORT UTILITY AND PASSENGER VEHICLES EXHIBIT A CONDITION IN WHICH THE WINDSHIELD WIPER MOTOR COULD FAIL DURING USE BECAUSE OF IMPROPER MANUFACTURE.
Consequence & remedy
Consequence: IF THIS WERE TO OCCUR IN SEVERE WEATHER, DRIVER VISIBILITY COULD BE REDUCED, WHICH COULD RESULT IN A VEHICLE CRASH.
Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE WIPER MOTOR ASSEMBLY. OWNER NOTIFICATION BEGAN NOVEMBER 6, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT SATURN AT 1-800-553-6000, PROMPT #3 OR HUMMER AT 1-866-486-6376.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
2PE06006 · Timing Chain Failure
Opened Jan 24, 2006 · Closed Jun 6, 2006
Status: closed (inferred from source dates) · Engine And Engine Cooling
ON DECEMBER 12, 2005, ODI RECEIVED A DEFECT PETITION (DP05-008) REQUESTING THE INVESTIGATION OF TIMING CHAIN FAILURES THAT COULD CAUSE STALLING IN SATURN VEHICLES EQUIPPED WITH THE 2.2L (L61) ENGINE. ODI OPENED PE06-006 ON JANUARY 24, 2006, WITH 24 VEHICLE OWNER COMPLAINTS THAT ALLEGED A BROKEN TIMING CHAIN CAUSED THE VEHICLE TO STOP OPERATING.ON APRIL 12, 2006, ODI RECEIVED INFORMATION FROM GENERAL MOTORS (GM) CONCERNING TIMING CHAIN FAILURES IN APPROXIMATELY 412,000 MODEL YEAR (MY) 2000 THROUGH 2003 SATURN L-SERIES AND ION VEHICLES WITH 2.2L ENGINES. GM'S RESPONSE INCLUDED 1,020 OWNER COMPLAINTS AND FIELD REPORTS CONCERNING TIMING CHAIN FAILURE, INCLUDING 228 THAT ALLEGED THE FAILURE CAUSED THE VEHICLE TO STALL WHILE DRIVING.GM ALSO PROVIDED WARRANTY CLAIM DATA THAT SHOWED 1,902 SUBJECT VEHICLES RECEIVING TIMING CHAIN REPAIRS, INCLUDING 261 WHICH INDICATED THAT A STALL WHILE DRIVING RESULTED FROM THE FAILURE.THE GM COMPLAINTS, FIELD REPORTS AND WARRANTY CLAIMS THAT DID NOT CONTAIN SUFFICIENT INFORMATION TO DETERMINE THAT A STALL WHILE DRIVING OCCURRED WERE PROVIDED IN THE CATEGORY OTHER.GM STATED THAT THE MAJORITY OF THESE INCIDENTS PROBABLY OCCURRED WHILE THE VEHICLES WERE PARKED SINCE THE TIMING CHAIN IS MORE LIKELY TO BREAK DURING HIGH CHAIN LOAD SITUATIONS, SUCH AS ENGINE STARTUP.GM'S DATA SHOWED ELEVATED FAILURE RATES IN APPROXIMATELY 20,500 MY 2001 L-SERIES VEHICLES PRODUCED DURING A FOUR MONTH PERIOD FROM NOVEMBER 2000 THROUGH FEBRUARY 2001.OVER ONE-THIRD OF GM'S TOTAL COMPLAINTS AND FIELD REPORTS (34.3%) AND WARRANTY CLAIMS (38.2%) INVOLVED L-SERIES VEHICLES BUILT DURING THE 4-MONTH PERIOD, WHICH ARE ONLY ABOUT 5% OF SUBJECT VEHICLE PRODUCTION.THE TIMING CHAIN FAILURE RATE IN THE VEHICLES BUILT DURING THIS RANGE IS OVER 10 TIMES GREATER THAN THE REMAINING SUBJECT VEHICLE POPULATION. FOR THE MY 2001 L-SERIES VEHICLES BUILT DURING THE 4-MONTH PERIOD, THE 36-MONTH FAILURE RATE FOR REPAIRS INVOLVING STALL WHILE DRIVING IS SLIGHTLY UNDER ONE PERCENT.HOWEVER, IF THE INCIDENTS CODED AS OTHER ARE ADDED, THE 36-MONTH FAILURE RATE RISES TO NEARLY FIVE PERCENT FOR THOSE VEHICLES.ODI AND GM ARE CONTINUING TO ASSESS THE NUMBER OF COMPLAINTS AND WARRANTY CLAIMS CODED BY GM AS OTHER THAT INVOLVE INCIDENTS OF STALL WHILE DRIVING.GM'S STATISTICAL MODELING OF THE FAILURE DATA INITIALLY CONCLUDED THAT THE FAILURE RATES WERE DECLINING WITH AGE AND MILEAGE FOR ANY SET OF WARRANTY DATA ANALYZED (E.G., STALL WHILE DRIVING, OTHER OR COMBINED).HOWEVER, SUBSEQUENT ANALYSIS SHOWED THAT THE FAILURE RATES ARE INCREASING. BASED ON THE HIGH COMPLAINT AND WARRANTY RATES FOR TIMING CHAIN FAILURE IN THE 4-MONTH PRODUCTION PERIOD FOR THE MY 2001 L-SERIES VEHICLES, THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS TO FURTHER ASSESS THE FREQUENCY OF STALL INCIDENTS DUE TO TIMING CHAIN FAILURES IN THOSE VEHICLES (EA06-009).
DP05008 · Timing Chain Failure
Opened Dec 20, 2005 · Closed Feb 6, 2006
Status: closed (inferred from source dates) · Engine And Engine Cooling
ANALYSIS UNDERTAKEN IN RESPONSE TO THE PETITION IDENTIFIED 26 COMPLAINTS ALLEGING TIMING CHAIN FAILURES IN MY 2000-2003 SATURN L-SERIES VEHICLE EQUIPPED WITH THE 2.2L L4 ENGINE.MOST COMPLAINTS OF TIMING CHAIN FAILURE REPORTEDLY RESULTED IN A SUDDEN LOSS OF ENGINE POWER AND STALLING.ODI ALSO NOTED THAT CERTAIN MY 2002-2003 SATURN VUE AND MY 2003 SATURN ION MODEL VEHICLES WITH THE 2.2L ENGINE VEHICLESCOVERED BY A TECHNICAL SERVICE BULLETIN (03-06-01-017) THAT ADDRESSED TIMING CHAIN DESIGN AND SERVICE PROCEDURE CHANGES, EXHIBITED NO COMPLAINTS OF TIMING CHAIN FAILURE.ODI WILL GRANT THE PETITION AND OPEN A PRELIMINARY EVALUATION TO ASSESS THE FREQUENCY, TREND, SCOPE AND SAFETY CONSEQUENCES ASSOCIATED WITH THE ALLEGED DEFECT IN THE SUBJECT VEHICLES.REFER TO PE06-006.