Engine And Engine Cooling. Review the 200 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Electrical System. Review the 102 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Exterior Lighting. Review the 69 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

12 crash reports12 fire reports5 injury reports

Electrical System complaints

102 reports

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Mileage unknown · May 1, 2023

Electrical SystemExterior Lighting

Rear tail lights will not work. Have checked all fuses relays,and even changed the turn signal switch. My car is currently at the garage. Original appointment was only for inspection. Mechanic has not yet located the issue. Also has no dash lights. Parking lights. Had I known this in advance would have returned car immediately.

NHTSA ODI #11519745

118,000 miles · Apr 3, 2023

Electrical SystemUnknown Or Other

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The contact owns a 2002 Saturn J-Type. The contact stated that while driving at an undisclosed speed, the vehicle's brake lights failed to illuminate. The contact related the failure to NHTSA Campaign Number: 05V245000 (Exterior Lighting), however, the part to do the recall repair is no longer being manufactured. The vehicle was not diagnosed nor repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 118,000.

NHTSA ODI #11515269

130,000 miles · May 26, 2020

Electrical System

MECHANIC FOUND SHORT CIRCUIT IN TAIL LAMP ASSEMBLIES CAUSING BRAKE LIGHTS TO COME ON, AND STAY ON, WHEN HEADLAMPS DO. *TR

NHTSA ODI #11325941

Mileage unknown · Jul 30, 2018

Electrical SystemElectronic Stability Control (esc)Power Train

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TAKATA RECALL VEHICLE IN PARK WHEN STARTED. LIGHTS DIM AN GO BRIGHT ON DASH. FAN GOES ON WHEN MOTOR NOT HOT. WHEN FAN GOES ON AND CAR IS BEING DRIVEN CAR WILL JUMP WHEN CAR SHIFTS GEARS. I ONLY CAN DRIVE ON SIDE ROADS. TO NERVOUS TO GO ON HIGHWAY NOW. ONLY HAPPENS WHEN COOLING FAN IS ON. I HAVE SEEN LOTS OF REPORTS THAT PEOPLE POST OF OTHER CARS LIKE MINE HAVING SAME ISSUES. WAS TOLD THEY REPORTED IT. NOTHING WAS DONE. SERIOUSLY THIS NEEDS TO BE ADDRESSED. SHOULDN'T MATTER WERE THE CAR WAS MADE. PARTS ARE THE SAME. I HAVEN'T BROUGHT IT IN SINCE 2017. I DON'T HAVE MONEY FOR REPAIRS OR FIX IT IF IT'S THE MANUFACTURS FAULTY PARTS. I'VE ALREADY PUT 1400 DOLLARS FOR REPLACEMENT OF FUEL PUMP AN OTHER PARTS. AN THIS PROBLEM STILL EXISTS. PLEASE LET ME KNOW IF AN WHEN YOU CAN LOOK INTO THIS ISSUE.

NHTSA ODI #11114655

Mileage unknown · Dec 26, 2017

Electrical SystemSteering

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

NHTSA ODI #11056381

144,400 miles · Aug 11, 2017

Electrical SystemElectronic Stability Control (esc)Fuel/propulsion SystemFireInjury

FUEL AND COMPUTER FUSE UNDERHOOD 10AMP BLOWING UPON INSERTED

NHTSA ODI #11014679

164,155 miles · Oct 10, 2016

Electrical SystemEnginePower Train

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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.

NHTSA ODI #10915067

110,000 miles · Jul 12, 2016

Electrical SystemEngineFire

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TL* THE CONTACT OWNED A 2002 SATURN L. THE CONTACT STATED THAT THE VEHICLE BEGAN TO SLOW DOWN WITHOUT WARNING. THE CONTACT PULLED THE VEHICLE OVER TO THE SIDE OF THE ROAD AND EXITED THE VEHICLE. THE VEHICLE BEGAN TO EMIT SMOKE FROM THE HOOD AND SUDDENLY CAUGHT FIRE. THE FIRE DEPARTMENT EXTINGUISHED THE FIRE. THE VEHICLE WAS TOTALED. THERE WERE NO INJURIES AND A REPORT WAS NOT FILED. THE VEHICLE WAS NOT DIAGNOSED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 110,000.

NHTSA ODI #10884365

77,000 miles · Dec 4, 2015

Electrical SystemFuel System, Gasoline

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TL* THE CONTACT OWNS A 2002 SATURN L300. THE CONTACT STATED THAT THERE WAS AN ABNORMAL ODOR COMING FROM THE VEHICLE. THE MAINTENANCE AND THE CHECK ENGINE WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE EVAPORATIVE EMISSION CONTROL SYSTEM HAD A LEAK. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 03V231000 (ELECTRICAL SYSTEM). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 77,000. ...UPDATED 07/05/16 *BF THE FUEL PUMP WAS REPLACED. UPDATED 07/15/16

NHTSA ODI #10808426

175,000 miles · Nov 19, 2015

Electrical SystemFire

SMOKE STARTED COMING FROM THE TURN SIGNAL SWITCH IN THE STEERING WHEEL COLUMN IT GOT WORSE AND THEN THE HANDLE MELTED OFF AND THEN IN MINUTES THE FLAMES IGNITED AND THE CAR WAS COMPLETELY INFLAMED. RIGHT BEFORE THIS HAPPENED MY DAUGHTER DROVE THE CAR UP THE STREET TO TAKE MY SON TO THE BUS STOP WHEN SHE BROUGHT IT BACK HOME THE…

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NHTSA ODI #10794792

Official recalls

05V245000 · Exterior Lighting:brake Lights

Jun 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.

05V158000 · Seat Belts

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.

03V231000 · Electrical System:ignition:module

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.

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

PE09028 · Fuel Pump Leaks

Opened May 21, 2009 · Closed Oct 27, 2009

Status: closed (inferred from source dates) · Fuel System, Gasoline:delivery:fuel Pump; Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings

THE OFFICE OF DEFECTS INVESTIGATION OPENED THIS INVESTIGATION BASED ON NINE VEHICLE OWNER QUESTIONNAIRE (VOQ) REPORTS ALLEGING GASOLINE LEAKAGE FROM THE IN-TANK FUEL PUMP ASSEMBLY.SOME COMPLAINANTS REPORTED LEAKS FROM THE FUEL PUMP NIPPLE (I.E., THE FITTING FOR THE FUEL SUPPLY AND/OR RETURN HOSES).OTHERS REPORTED LEAKAGE FROM FUEL PUMP CRACKS, FUEL PUMP LINES, AND FROM THE TOP OF THE FUEL TANK.ODI WAS UNABLE TO VERIFY THAT ALL OF THE LEAKS ORIGINATED FROM THE FUEL PUMP HOSE FITTINGS AND OR NIPPLES.ODI'S ANALYSIS OF THE AVAILABLE COMPLAINT DATA ATTRIBUTED TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES SHOW A LOW OVERALL RATE AND A DECLINING TREND, AS 75% OF THE REPORTS WERE RECEIVED PRIOR TO CALENDAR YEAR 2009.COMPLAINT DATA FOR MODEL YEAR 2001 AND 2003 VEHICLES ALSO DEMONSTRATES A LOW RATE AND SIMILAR DECLINING TREND.A DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

Additional source detail variants (2)

Fuel System, Gasoline:delivery:fuel Pump

Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings

PE08061 · Timing Chain Breaks, Engine Stall

Opened Oct 16, 2008 · Closed Apr 8, 2009

Status: closed (inferred from source dates) · Engine And Engine Cooling

ON MAY 22, 2008, THEOFFICE OF DEFECTS INVESTIGATION (ODI) WAS PETITIONED BY THE NORTH CAROLINA CONSUMERS COUNCIL (NCCC) TO BROADEN THE SCOPE OF SAFETY RECALL 07V-519, WHICH WAS CONDUCTED BY GENERAL MOTORS CORPORATION (GM) FOR MODEL YEAR (MY) 2001 SATURN L-SERIES VEHICLES EQUIPPED WITH THE L61 2.2L ENGINE AND BUILT DURING A 4-MONTH PERIOD FROM NOVEMBER 2000 THROUGH FEBRUARY 2001 (DP08-002). ON OCTOBER 16, 2008, ODI GRANTED DP08-002 AND OPENED PE08-061 TO INVESTIGATE TIMING CHAIN FAILURES RESULTING IN ENGINE STALL WHILE DRIVING (SWD) IN THE SATURN L-SERIES VEHICLES EQUIPPED WITH L61 ENGINES AND THAT USED THE SAME DESIGN TIMING CHAIN AND TIMING CHAIN LUBRICATION SYSTEM AS THE RECALLED VEHICLES.A REDESIGNED TIMING CHAIN AND LUBRICATION SYSTEM WERE IMPLEMENTED LATE IN MY 2002 PRODUCTION (MAY 1, 2002).HENCE, THE SUBJECT VEHICLES FOR THIS INVESTIGATION ARE ALL MY 2000 THROUGH 2002 SATURN L-SERIES VEHICLES EQUIPPED WITH 2.2L L61 ENGINES AND BUILT PRIOR TO MAY 2002 THAT WERE NOT INCLUDED IN RECALL 07V-519. IN THIS INVESTIGATION, ODI ANALYZED UPDATED COMPLAINT AND WARRANTY CLAIMS DATA FOR TIMING CHAIN FAILURES RESULTING IN INCIDENTS OF ENGINE STALL WHILE DRIVING, WHICH COMPRISE SLIGHTLY OVER HALF OF ALL TIMING CHAIN FAILURES OCCURRING IN THE SUBJECT VEHICLE POPULATION.ODI'S ANALYSIS OF COMPLAINT AND WARRANTY DATA SHOWS THAT VEHICLES PRODUCED WITH THE SUBJECT TIMING CHAIN AND LUBRICATION SYSTEM EXPERIENCED ELEVATED FAILURE RATES WHEN COMPARED WITH THE MY 2002 THROUGH 2003 VEHICLES USING THE REVISED COMPONENTS.HOWEVER, THE ANALYSIS ALSO SHOWED THAT THE MY 2001 SATURN L-SERIES VEHICLES RECALLED IN 07V-518 EXPERIENCED A SIGNIFICANTLY HIGHER RATE OF TIMING CHAIN FAILURES THAN THE SUBJECT VEHICLES.THE COMPLAINT RATE FOR TIMING CHAIN FAILURES RESULTING IN SWD WAS APPROXIMATELY 5 TIMES HIGHER FOR THE RECALLED VEHICLES,19.2 INCIDENTS PER THOUSAND VEHICLES (IPTV), THAN FOR THE SUBJECT VEHICLES, 3.7 IPTV.THE WARRANTY CLAIMS RATE FOR CHAIN FAILURES RESULTING IN SWD WAS OVER 3 TIMES HIGHER FOR THE RECALLED VEHICLES, 2.4 PERCENT, THAN FOR THE SUBJECT VEHICLES, 0.7 PERCENT.THE COMPLAINT AND WARRANTY RATES FOR THE SUBJECT VEHICLES WERE SIMILAR TO RATES RECORDED IN OTHER RECENTLY CLOSED INVESTIGATIONS FOR CONDITIONS THAT COULD RESULT IN SWD WITH NO ENGINE RE-START, EA07-015 AND EA07-018.ANALYSIS OF ALL COMPLAINTS, FIELD REPORTS AND WARRANTY CLAIMS FOUND NO ALLEGATIONS OF CRASHES OR INJURIES ASSOCIATED WITH THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AFTER APPROXIMATELY 7 TO 9 YEARS IN SERVICE. ODI'S ANALYSIS OF THE STALLING INCIDENTS THAT HAVE RESULTED FROM TIMING CHAIN FAILURES IN THE SUBJECT VEHICLES FOUND THAT THEY CAN OCCUR AT ANY SPEED AND ALMOST ALWAYS RESULT IN A NO RESTART CONDITION.THESE ARE GENERALLY CONSIDERED TO BE FACTORS THAT INCREASE THE SEVERITY OF STALLING INCIDENTS.HOWEVER, ANALYSIS OF SWD FAILURE RATES IN THE SUBJECT VEHICLES SHOW THAT THEY HAVE OCCURRED AT MUCH LOWER RATES THAN WERE OBSERVED IN THE RECALLED POPULATION.IN ADDITION, THE SWD COMPLAINT AND WARRANTY RATES FOR THE SUBJECT VEHICLES ARE SIMILAR TO RATES OBSERVED IN PRIOR INVESTIGATIONS INVOLVING SIMILAR CATEGORIES OF ENGINE STALL CONSEQUENCES THAT WERE CLOSED WITH NO ACTION.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IF WARRANTED.

DP08002 · Timing Chain FAILURE-STALL

Opened Jun 18, 2008 · Closed Oct 16, 2008

Status: closed (inferred from source dates) · Engine And Engine Cooling

ON JUNE 6, 2006, ODI OPENED AN INVESTIGATION OF TIMING CHAIN FAILURE RESULTING IN ENGINE STALL WHILE DRIVING WITH NO RESTART IN APPROXIMATELY 20,514 MODEL YEAR (MY) 2001 SATURN L-SERIES VEHICLES EQUIPPED WITH 2.2L ENGINES (L61) BUILT FROM NOVEMBER 2000 THROUGH FEBRUARY 2001 (EA06-009).THE VEHICLES BUILT DURING THOSE MONTHS EXHIBITED HIGHER FAILURE RATES THAN SIMILARLY EQUIPPED VEHICLES BUILT BEFORE AND AFTER.GM INTRODUCED A NEW TIMING CHAIN DESIGN IN PRODUCTION IN MAY 2002.ODI CLOSED ITS INVESTIGATION AFTER GM INITIATED A SAFETY RECALL ON NOVEMBER 7, 2007 (RECALL 07V-519). ON MAY 22, 2008, THE NORTH CAROLINA CONSUMERS COUNCIL (NCCC) SUBMITTED A DEFECT PETITION TO ODI REQUESTING THE EXPANSION OF RECALL 07V-519 TO INCLUDE ALL MY 1999 THROUGH 2003 SATURN L-SERIES VEHICLES WITH 2.2L ENGINES USING THE SAME TIMING CHAIN DESIGN AS THE RECALLED POPULATION.THE PETITION STATES THAT THE NCCC CONTINUES TO RECEIVE COMPLAINTS FROM CONSUMERS THAT HAVE HAD A TIMING CHAIN FAIL IN VEHICLES BUILT OUTSIDE THE PRODUCTION RANGE COVERED BY THE RECALL.THE PETITION ALSO NOTES THAT ODI HAS CONTINUED TO RECEIVE COMPLAINTS.SINCE THE CLOSING OF EA06-009 ODI HAS RECEIVED 80 NEW COMPLAINTS FROM CONSUMERS WHO HAD A TIMING CHAIN FAIL IN A MY 2000 THROUGH 2002 SATURN L-SERIES WITH THE 2.2L ENGINE THAT WERE NOT COVERED BY RECALL 07V-519 AND WERE BUILT PRIOR TO THE TIMING BELT CHANGE IN MAY 2002.THE COMPLAINTS DESCRIBE THE SAME FAILURE MODE AS THE RECALLED POPULATION WHERE THE TIMING CHAIN CAN BREAK SUDDENLY AND WITHOUT WARNING, RESULTING IN ENGINE DAMAGE AND LOSS OF MOTIVE POWER.THE DEFECT PETITION HAS BEEN GRANTED. A PRELIMINARY EVALUATION (PE08-061) HAS BEEN OPENED.

PE06006 · 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.

PE05010 · Inoperative Tail Lamps

Opened Feb 15, 2005 · Closed Jun 3, 2005

Status: closed (inferred from source dates) · Electrical System; Exterior Lighting; Exterior Lighting:brake Lights; Exterior Lighting:tail Lights

GENERAL MOTORS HAS DECIDED THAT A SAFETY RELATED DEFECT EXISTS ON CERTAIN MODEL SATURN 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.THIS CAN CAUSE (1) AN INTERMITTENTLY INOPERATIVE BRAKE/TAIL LAMP BULB OR (2) A SHORT CIRCUIT THAT OPENS A FUSE CAUSING INOPERATIVE BRAKE OR TAIL LAMPS (INCLUDING THE CENTER HIGH-MOUNTED STOP LAMP).GM WILL CONDUCT A SAFETY RECALL ON AN EXPANDED SCOPE OF SATURN VEHICLES TO INSTALL A REINFORCING SOCKET ADAPTER (AND CORRESPONDING NW SOCKET) TO THE BACK OF THE EXISTING LAMP ASSEMBLY.GENERAL MOTORS WILL RECALL 291,652 MY 2000-2002 SATURN LS SEDANS AND MY 2000-2004 SATURN LW WAGONS.THE RECALL IS IDENTIFIED BY NHTSA NUMBER 05V-245.

Additional source detail variants (4)

Electrical System

Exterior Lighting:brake Lights

Exterior Lighting

Exterior Lighting:tail Lights

DP05001 · Inoperative Tail Lamps

Opened Feb 10, 2005 · Closed Feb 22, 2005

Status: closed (inferred from source dates) · Electrical System; Exterior Lighting:brake Lights; Exterior Lighting:brake Lights:switch; Exterior Lighting:tail Lights; Exterior Lighting:tail Lights:switch

ON JANUARY 25, 2005, A SAFETY DEFECT PETITION WAS RECEIVED BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), REQUESTING AN INVESTIGATION OF INOPERATIVE TAIL LAMPS ON MY 2000-2002 SATURN L-SERIES VEHICLES.THE PETITIONER ALLEGES A DEFECT IN THE DESIGN AND ASSEMBLY OF THE TAIL LAMP ASSEMBLY CIRCUIT BOARD AND LIGHT SOCKET CONTACT.THE PETITIONER IDENTIFIED 47 VEHICLE OWNER QUESTIONNAIRE'S (VOQ'S) ASSOCIATED WITH THE ALLEGED DEFECT, AND ODI CONCURS THAT 40 OF THOSE VOQ'S SATISFY THE SCOPE OF THIS INVESTIGATION.ODI HAS FOUND AN ADDITIONAL 10 VOQ'S RELATED TO THE ALLEGATION.ODI HAS GRANTED THE PETITION AND OPENED A PRELIMINARY EVALUATION (PE05-010).

Additional source detail variants (5)

Electrical System

Exterior Lighting:brake Lights

Exterior Lighting:brake Lights:switch

Exterior Lighting:tail Lights

Exterior Lighting:tail Lights:switch

PE03017 · Headlamps Flicker Off And On

Opened Apr 17, 2003 · Closed Aug 25, 2003

Status: closed (inferred from source dates) · Exterior Lighting; Exterior Lighting:headlights; Exterior Lighting:headlights:concealment Devices; Exterior Lighting:headlights:high/low Beam Dimmer Switch; Exterior Lighting:headlights:switch; Exterior Lighting:tail Lights:switch; Exterior Lighting:turn Signal; Exterior Lighting:turn Signal:switch

THIS PE WAS OPENED BASED ON SIX ODI COMPLAINTS THAT HEADLAMPS FLICKER OFF AND ON, AND TWO ODI COMPLAINTS THAT THE SWITCH IS HOT TO THE TOUCH.THE INVESTIGATION HAS FOUND NO OCCURRENCES OF HEADLAMPS GOING OUT.THE COMPLAINTS ARE DUE TO SPORADIC DIMMING (FLICKERING) OF THE HEADLAMPS AS A RESULT OF VARIATION OF THE VOLTAGE TO THE HEADLAMPS.GM HAS SHOWN THAT A 1.5 -2.0 VOLTAGE DROP OCCURS WHEN OTHER ELECTRICAL DEVICES ARE ACTIVATED, HOWEVER AT NO TIME DO THE HEADLAMPS TURN COMPLETELY OFF.WITH RESPECT TO ALLEGATIONS THAT THE HEADLAMP SWITCH IS HOT TO THE TOUCH, GM REPORTS THAT THE AMBIENT TEMPERATURE OF THE SWITCH IS 35 DEGREES C WHICH IS NOT HOT ENOUGH TO BURN A FINGER OR HAND.IN MAY 2001, GM MODIFIED THE HEADLAMP SWITCH CRIMPING OPERATION TO ELIMINATE THE OCCURRENCE OF HOT SWITCHES.ODI EVALUATED THE COMPLAINTS AND WARRANTY RETURNS AND FOUND NO EVIDENCE OF MELTING OR BURNING. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

Additional source detail variants (8)

Exterior Lighting

Exterior Lighting:headlights:concealment Devices

Exterior Lighting:headlights

Exterior Lighting:headlights:high/low Beam Dimmer Switch

Exterior Lighting:headlights:switch

Exterior Lighting:tail Lights:switch

Exterior Lighting:turn Signal

Exterior Lighting:turn Signal:switch