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 · Mar 23, 2010

Electrical System

2002 SATURN LW300. CONSUMER STATES ELECTRICAL, BODY CONTROL MODULE PROBLEMS WOULD LIKE MORE INFORMATION REGARDING THE PROBLEM. *TGW

NHTSA ODI #10320911

98,000 miles · Jan 22, 2010

Electrical System

MY 2002 SATURN L300 REAR TAILLIGHTS ARE MELTING AND FAILING OFTEN. A RECALL REPAIR WAS PERFORMED 4 YEARS AGO AND IT IS INEFFECTIVE. SATURN IS UNWILLING TO RE-EVALUATE THE MATTER. *TR

NHTSA ODI #10301893

90,000 miles · Jun 27, 2009

Electrical System

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2002 SATURN L 300 6 CYL. SAW SMOKE COMING FROM MY STEERING COLUMN, HAVE REPORTED THIS TO SATURN , AFTER HAVING MY OIL CHANGED. THEY TOLD ME IT WAS DUST BURNING IN THE STEERING COLUMN, AND THAT IT HAPPENS OCCASIONALLY. IT HAS HAPPENED TWICE SINCE THEN, MY CHILD WITNESSED THE SMOKE COMING OUT OF THE TURN SIGNAL LEVER AREA ON THE STEERING COLUMN. MY CAR IS NOW AT A SATURN DEALERSHIP, WITH A BAD BCM ( BODY CONTROL MODULE) THIS IS THE COMPUTER THAT CONTROLS ALL ELECTRICAL DEVICES INSIDE THE CAR. THE LIGHT SWITCH , TURN SIGNAL, WIPERS,INSTRUMENT PANEL, KEYLESS ENTRY, POWER DOORS AND WINDOWS,RADIO, CAR IGNITION, ANTI-THEFT, ETC. WHEN I SPOKE TO THE SERVICE TECH TODAY. HE STATED THE TWO ARE NOT RELATED, AND THAT THERE WILL BE AN EXTRA CHARGE TO HAVE A TECH. LOOK INTO THE STEERING COLUMN. I TOLD HIM I WOULD PAY THE DIFFERENCE BECAUSE SMOKE SHOULD NOT COME OUT OF THE STEERING COLUMN. CORRECT ME IF I'M WRONG, BUT MOST OF THE THINGS THE BCM CONTROLS RUN THROUGH THE STEERING COLUMN. THEY DO NOT WANT TO LOOK AT MY COMPLAINT, THEY ONLY WANT TO PUT IN A 600 DOLLAR PART. IF THE WIRES ARE BURNT THE BCM STILL WON'T WORK. AND THE CAR STILL WON'T WORK OR ELSE IT MAY BURN OUT A NEW BCM. WHY IS SATURN SO HESITANT TO LISTEN TO A CUSTOMERS COMPLAINT ? *TR

NHTSA ODI #10275103

90,000 miles · Jun 26, 2009

Electrical SystemEngine And Engine CoolingSteering

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2002 SATURN L300 . HAVE FOLLOWED ALL MAINT. GUIDELINES. THOUGH IT IS ON IT'S THIRD BATTERY, THIRD SET OF TIRES, POWER STEERING PUMP REPLACED, TIMING BELT REPLACED, ECM REPLACED, TWO CATALYTIC CONVERTERS REPLACED, THE LIST GOES ON AND ON. LESS THAN 90,000 MILES. DROVE THE CAR. GOT OUT, PUSHED THE KEYLESS ALARM ( ORIGINAL FACTORY) GOT DINNER, PUSHED THE KEYLESS ENTRY, GOT INTO THE CAR , TURNED THE KEY..AND THE CAR WAS DEAD. CAR DOES NOT START. LOCKED IN PARK, HAD TO HAVE IT TOWED. TOW TRUCK DRIVER HAD TO USE THE DOLLY LIFTS TO MOVE THE CAR, SO HE COULD POSITION IT TO BE ABLE TO TOW IT. HAD IT TOWED TO A SERVICE GARAGE, THEY FOLLOWED GM'S INSTRUCTIONS ..NO LUCK. THE CAR HAD TO BE TOWED AGAIN , TO A SATURN DEALERSHIP ( THE ONLY ONES WHO HAVE THE CODES) TO RESET THE VEHICLE. THEY TOLD ME THEY COULD NOT RESET IT. TOLD ME IT NEEDS A NEW BCM. STATED ECM AND BCM ARE UNABLE TO COMMUNICATE. SO THAT UNTIL THE MODULE IS REPLACED THE CAR IS INOPERABLE. STATED THEY KNEW THE BCM'S GO BAD, STATED THEY HAVE HAD ALOT OF THESE GO BAD ( ALOT)???. THE SERVICE TECH STATED " THEY ARE LIKE A COMPUTER HARD DRIVE ON STEROIDS" . STATED THEY BURN OUT WITH NO WAY TO CHECK THEM OR FIX THEM. HE SAID THEY SHOULD BE ABLE TOFIX THE CAR. BUT THEY DO NOT KEEP ANY BCM IN STOCK. IT WILL BE A WEEK BEFORE THEY CAN GET THE PART. AFTER REPLACING THE BCM I WAS TOLD THE CARS INFORMATION WILL NOT BE ACCURATE. THEY TOLD ME THE ODOMETER GOES BACK TO ZERO. HOW CAN THAT BE THE DEALER JUST TURN BACK THE ODOMETER ISN'T THAT ILLEGAL? I WAS TOLD THAT SOMETIMES THERE MAYBE SOME OTHER ISSUES ALSO AFTER INSTALLING A NEW BCM?? IF THEY KNOW THAT THE BCM IS A PROBLEM, AND THAT WHEN IT GOES BAD, THE CAR IS COMPLETELY USELESS! WHY ISN'T SOMETHING BEING DONE ! YOU ARE AT THE MERCY OF SATURN / GM BECAUSE NO ONE ELSE IS ALLOWED TO FIX THE CAR. I WILL NOW BE WAITING A WEEK FOR MY VEHICLE TO BE REPAIRED. ONLY TO HOPE IT RUNS CORRECTLY AFTER IT'S REPAIRED. *TR

NHTSA ODI #10275029

84,000 miles · Mar 10, 2009

Electrical System

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I'LL KEEP THIS QUICK. NO CRASH, NO DEATHS, JUST FAULTY EQUIPMENT. I'M GOING TO REFERENCE NHTSA CAMPAIGN ID NUMBER: 03V231000 , SATURN RECALL 03-C-06. I HAVE AN 2002 L300 V6 ENGINE THAT IS NOT THE ENGINE IN THIS RECALL, BUT, I KID YOU NOT, WORD FOR WORD SUMMARY YOU WROTE FOR THE ABOVE FITS MY CAR COMPLETELY. I HAVE REPORTED TO SATURN AND THEY'RE SEEING WHAT THEY CAN DO, BUT SINCE MY ENGINE IS NOT INCLUDED IN THIS REPORT, IT'S NOT COVERED IN THE RECALL. I'M NOW FACING UPWARDS 3K BILL TO FIX ALL THE DAMAGE THAT I BELIEVE TO HAVE BEEN CAUSED BY THIS SIMILAR PROBLEM. *TR

NHTSA ODI #10261465

84,650 miles · Aug 18, 2008

Electrical System

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TL*THE CONTACT OWNS A 2002 SATURN L200. EVERY TIME THE SECURITY LIGHTS FLASH, THE VEHICLE WILL TURN OVER, BUT FAIL TO START. THE FAILURE HAS OCCURRED ON THREE OCCASIONS. THE VEHICLE WAS TAKEN TO THE DEALER, BUT THEY COULD NOT DETERMINE THE CAUSE OF THE FAILURE. THE MANUFACTURER STATED THAT THEY HAD NEVER HEARD OF THIS TYPE OF FAILURE. THE CONTACT DOES NOT FEEL SAFE DRIVING THE VEHICLE. THE CURRENT MILEAGE WAS 84,700 AND FAILURE MILEAGE WAS 84,650.UPDATED 09/17/08.*LJ UPDATED 09/25/08. *JB

NHTSA ODI #10238768

46,500 miles · Jul 24, 2008

Electrical System

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MY BATTERY WENT BAD AFTER I TOOK IT INTO THE SHOP TO GET A RECALL COMPLETED ON THE VEHICLE. THE PROBLEM WAS PRESENT AFTER A NEW BATTERY WAS INSTALLED. THE BODY CONTROL MODULE I AM TOLD IS BAD. THERE ARE COMPLAINTS ALL OVER THE INTERNET ABOUT THE CAR HAVING THE SAME PROBLEMS WITH OTHER PEOPLE. MY CAR HAS ONLY 48,000 MILES ON IT. SATURN WILL GIVE ME 10% OFF ON A $1,000.00 REPAIR BILL. THEY SAID BECAUSE I DID NOT HAVE ALL MY SERVICE WORK DONE AT A SATURN DEALERSHIP, THEY WOULD NOT DO ANYTHING BETTER. IT IS A SHAME. MANY PEOPLE ARE HAVING THE SAME COMPLAINT ABOUT THE SAME VEHICLE. *TR

NHTSA ODI #10235676

60,000 miles · Jun 19, 2008

Electrical SystemEngine And Engine Cooling

TL*THE CONTACT OWNS A 2002 SATURN L200. WHILE DRIVING APPROXIMATELY 25 MPH, THE VEHICLE LOST POWER AND THE BATTERY WARNING LIGHT ILLUMINATED ON THE INSTRUMENT CONTROL PANEL. THE VEHICLE WAS INSPECTED BY A LOCAL SERVICE SHOP AND THEY STATED THAT THE TIMING CHAIN FAILED, WHICH CAUSED THE VALVE IN THE ENGINE TO FAIL ALSO. THE D…

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NHTSA ODI #10231610

84,984 miles · May 20, 2008

Electrical System

THE DASHBOARD WARNING LIGHTS ARE ON ALL THE TIME AND NONE OF THE GAUGES ARE WORKING. CAN HEAR CLICKING NOISES IN CONSOLE AND STATIC FROM SPEAKERS. *TR

NHTSA ODI #10228269

500 miles · Apr 14, 2008

Electrical SystemEngine And Engine CoolingExterior Lighting

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TL*THE CONTACT OWNS A 2002 SATURN L300. WHILE DRIVING THE VEHICLE AT VARIOUS SPEEDS, THE EXTERIOR LIGHTS REMAIN ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER AND THEY STATED THAT THE SWITCHES FOR ALL THE LIGHTS ON THE VEHICLE NEEDED TO BE REPLACED. THE CHECK ENGINE LIGHT WAS ILLUMINATED BECAUSE THE ENGINE MODULE COMPUTER NEEDED TO BE REPLACED ALONG WITH OTHER SENSORS. THE CONTACT ALSO STATED THAT THE OIL HOUSING FAILED. WHILE GETTING AN OIL CHANGE AT JIFFY LUBE, THE CONTACT WAS INFORMED THAT THE OIL HOUSING SCREW WAS LOOSE AND THE FILTER COULD NOT BE CHANGED. THE CURRENT MILEAGE WAS 82,564 AND FAILURE MILEAGE WAS 500.

NHTSA ODI #10224428

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