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

What owners actually said

493 reports

74,000 miles · Sep 19, 2006

Engine And Engine Cooling

TIMING CHAIN BROKE AT 74,000 MILES ON MY 2002 L SERIES SATURN, SEEMS TO BE A PROBLEM THAT SATURN DOES NOT WANT TO FIX. *JB

NHTSA ODI #10168605

55,125 miles · Aug 30, 2006

Electrical SystemSuspension

Read full complaint

I PURCHASED MY 2002 SATURN L300 BACK ON 9/30/2002. CAR, AT TIME OF PURCHASE, WAS BRAND NEW. SINCE ITS PURCHASE MY VEHICLE HAS BEEN IN THE SHOP MORE TIMES THAN I CAN REMEMBER. RECENTLY I HAD A PROBLEM WHERE VEHICLE WOULDN'T START SO SATURN HAD THE VEHICLE TOWED TO THEIR COLUMBUS, GA LOCATION TO EVALUATE THE PROBLEM. WAS ADVISED BATTERY HAD DIED AND I NEEDED TO REPLACE IT. THE NEW BATTERY REPRESENTS THE 3RD BATTERY THIS VEHICLE HAS HAD SINCE I PURCHASED IT (VEHICLE CURRENTLY HAS JUST OVER 55,000 MILES ON IT). I ASKED, WHILE THEY HAD IT IN THE SHOP, TO LOOK AT THE TIRES AS THEY WERE WEARING UNEVENLY. MY WIFE WENT TO PICK THE CAR UP YESTERDAY 8/29/06 AND WAS ADVISED ALL 4 TIRES NEEDED TO BE REPLACED. THIS WILL BE THE 4TH SET OF TIRES THIS CAR HAS HAD SINCE IT WAS PURCHASED BACK IN LATE 2002. AT TIME OF PURCHASE I ADDED A 5 YEAR 60,000 MILE B-T-B WARRANTY WITH NO DEDUCTIBLE. SATURN, FOLLOWING COMPLAINTS BOTH TO THE SERVICE DEPARTMENT AND THEIR CORP HEADQUARTERS HAS DECIDED THAT THE CAR IN FACT DOES NOT HAVE A PROBLEM AND THAT MY PREGNANT WIFE (WITH 1 YEAR OLD IN BACK SEAT) MUST BE DRIVING IT POORLY. TO DATE, THE VEHICLE'S TIRES HAVE NOT BEEN REPLACED AND THE PROBLEM CAUSING THE TIRES TO WEAR DOWN SO QUICKLY HAS NOT BEEN IDENTIFIED. *NM

NHTSA ODI #10167117

72,000 miles · Aug 28, 2006

Air BagsPower TrainCrash

Read full complaint

DT*: THE CONTACT STATED WHILE DRIVING 60 MPH, THE ENTIRE RIGHT FRONT WHEEL ASSEMBLY DETACHED, CAUSING THE CONTACT TO HAVE TO GUIDE THE VEHICLE DOWN THE RIGHT GUARDRAIL WITH THE BRAKE DEPRESSED TO KEEP THE VEHICLE UNDER CONTROL. ALSO, THE AIR BAGS FAILED TO DEPLOY. THE VEHICLE WAS TAKEN TO A PRIVATE REPAIR SHOP, WHERE THE MECHANIC DETERMINED THAT THE ENTIRE TRANSAXLE ASSEMBLY HAD BEEN SMOOTHLY SHEARED OFF. THERE WERE NO REPAIRS MADE IMMEDIATELY. THERE WAS A POLICE REPORT FILED, AND THE MANUFACTURER WAS ALSO INFORMED.*AK UPDATED 10/25/2006 - *NM

NHTSA ODI #10166722

71,000 miles · Aug 25, 2006

Electrical System

Read full complaint

I OWN A 2002 SATURN L100. ABOUT A MONTH AGO THE AUTOMOBILE EXPERIENCED DIFFICULTY IN STARTING. IT TURNS OUT, AFTER TAKING THE VEHICLE TO SATURN THE PROBLEM WAS DETERMINED TO BE THE BODY CONTROL MODULE(BCM). REPLACEMENT COST APPROX. $550.00. I HAVE TWO ISSUES. 1. BECAUSE THE CAR WOULD START AFTER MAKING A NUMBER OF ATTEMPTS, IT WAS DRIVABLE. UNFORTUNATELY, THE AIRBAG SENSOR WAS TRIPPED WHICH COULD CAUSE THE AIRBAGS TO DEPLOY(ACCORDING TO THE OWNER'S MANUAL) CAUSING AN EXTREMELY DANGEROUS SITUATION. 2. MY RESEARCH ON VARIOUS ON-LINE SITES SEEMS TO INDICATE THAT A VAST NUMBER OF SATURN CUSTOMERS HAVE HAD THIS SAME PROBLEM,I.E. BCM FAILURE. CONSEQUENTLY, I BELIEVE THAT THIS BCM HAS BEEN POORLY MANUFACTURED AND SHOULD BE RECALLED AND REPLACED AT NO CHARGE TO THE CONSUMER. *JB

NHTSA ODI #10166508

Mileage unknown · Aug 18, 2006

Engine And Engine Cooling

Read full complaint

I WAS RESPONDING TO AN EMERGENCY CALL WITH MY LOCAL FIRE DEPT WHEN MY 2002 SATURN L SERIES MOTOR QUIT RUNNING ON THE MAIN HIGHWAY. IT TURNED OUT THAT I AM ONE OF MANY THAT HAD THE TIMING BELT BREAK WITHOUT ANY WARNING SIGNS. NO ROUGH IDLE OR HESITATIONS, PIFF IT WAS DEAD. THE MOTOR HAS ONLY 75000 MILES. I CAN NOT AFFORD TO HAVE SATURN FIX IT NOR WANT TO GIVE THEM THE FUNDS SO I AM HAVING ANOTHER MECHANIC FIX IT WITH STILL SOME HIGH EXPENDITURES. LUCKILY I WAS NOT LIKE SOME WHO HAD TO REPLACE VALVES AND SUCH. THE CHAIN FELL TO THE LOWER AREA. THE WHOLE ASSEMBLY NEEDED TO BE REPLACED. LOOKS AS IF ENGINEERING OR QUALITY MATERIALS ARE AN ISSUE, NOT OIL CHANGES AS IT APPEARS SATURN IS USING AS AN EXCUSE TO AVOID THE ISSUE. *JB

NHTSA ODI #10165948

78,000 miles · Aug 14, 2006

Engine And Engine Cooling

Read full complaint

DRIVING AT 30 MILES PER HOUR MY 2002 SATURN L200 LOST ALL POWER. I WAS IN TRAFFIC AND FORTUNATELY HAD ENOUGH STRENGTH TO TURN THE STEERING WHEEL,WHICH HAD NO POWER, TO WHERE I COULD SAFELY PULL OFF THE ROAD. I HAD 3 CHILDREN IN THE CAR AT THE TIME. HAD THE CAR TOWED TO A SATURN DEALERSHIP AND FOUND IT WAS THE TIMING CHAIN THAT BROKE CAUSING VALVE DAMAGE. THE COST TO REPAIR IS $3019.I WOULD LIKE TO ADD MY COMPLAINT TO THE MANY ON FILE AND HOPE SATURN WILL RECALL AS THIS COULD HAVE BEEN A DANGEROUS SITUATION. SATURN HAS OFFERED ME 2 YEARS OF FREE OIL CHANGES IF I REPAIR IT,HARDLEY SEEMS TO WARRANT WHAT COULD CAUSE DEATH. *NM

NHTSA ODI #10165466

62,619 miles · Aug 10, 2006

Engine And Engine Cooling

Read full complaint

WHILE DRIVING AT 50 MPH, MY 2002 SATURN L100 LOCKED UP AND QUIT WORKING. AFTER GETTING IT TOWED TO THE SATURN DEALERSHIP, I WAS INFORMED THAT THE TIMING CHAIN HAD BROKEN AND THE HEAD WOULD NEED TO BE REPLACED, RESULTING IN A COST OF APPROXIMATELY $2,150, PLUS $190 IN TOWING CHARGES. ALTHOUGH THIS CAR IS 4 YEARS OLD AND OUT OF WARRANTY, I FEEL THIS IS STILL A NEW ENOUGH CAR THAT A COSTLY REPAIR AS THIS SHOULD NOT HAPPEN. AFTER DOING SOME RESEARCH I FOUND THAT THERE IS A PATTERN OF TIMING CHAINS BREAKING ON THE L SERIES CARS. *NM

NHTSA ODI #10165194

67,100 miles · Jul 31, 2006

Service Brakes, Hydraulic

DT*: THE CONTACT STATED, WHILE DRIVING 60 MPH., THE BRAKE PEDAL DEPRESSED ALL THE WAY TO THE FLOOR AND, FAILED TO SLOW THE VEHICLE. AFTER PUMPING THE BRAKE PEDAL MANY TIMES, THE BRAKES RESPONDED AND SLOWED THE VEHICLE. THIS PROBLEM HAS HAPPENED 5 TIMES. THE SERVICE DEALER WAS UNABLE TO DUPLICATE THE PROBLEM. THE MANUFACTURER H…

Read full complaint

NHTSA ODI #10163971

40,000 miles · Jul 25, 2006

Suspension

Read full complaint

DT: THE CONTACT STATED WHILE DRIVING AT VARIOUS SPEEDS THE CONTACT HEARD A HIGH PITCHED SQUEAL COMING FROM THE FRONT OF THE VEHICLE. THE DEALERSHIP DETERMINED THE FRONT WHEEL BEARING NEEDED TO BE REPLACED. THE DEALERSHIP REFUSED TO REPAIR THE BEARING. THE CONTACT TOOK THE VEHICLE TO AN INDEPENDENT MECHANIC WHO DETERMINED THE BEARING OVERHEATED CAUSING THE SQUEAL. THE MECHANIC INFORMED THE CONTACT THE BEARING SHOULD HAVE LASTED THE LIFE OF THE VEHICLE. THE BEARING WAS REPLACED BY THE INDEPENDENT MECHANIC. *AK

NHTSA ODI #10163390

90,000 miles · Jul 17, 2006

Exterior Lighting

Read full complaint

MY HUSBAND AND I OWN A 2002 SATURN L300, OF WHICH I AM THE PRIMARY DRIVER. A FEW WEEKS AGO, I NOTICED THAT THE "BRIGHT" INDICATOR WOULD APPEAR SOMETIMES WHEN THE DAYTIME RUNNING LIGHTS WERE ON. THEN THE DAYTIME RUNNING LIGHTS WOULD STAY ON SOMETIMES FOR A FEW MINUTES AFTER THE MOTOR WAS STOPPED. THE LIGHTS ALWAYS WENT OUT, AND WE THOUGHT IT WOULD BE OK TO WAIT UNTIL OUR NEXT MAINTENANCE VISIT TO THE DEALER TO ASK ABOUT THE PROBLEM. LAST WEEK THE LIGHTS WOULDN'T GO OFF, SO WE MADE AN APPOINTMENT. WE ALSO DISCOVERED THAT IF WE PUSHED THE LIGHT STICK (THE LONG SWITCH THAT PROJECTS OUT FROM THE STEERING COLUMN) SLIGHTLY TOWARD THE DASHBOARD, THE LIGHTS WOULD GO OUT. WE THOUGHT USING THIS DISCOVERY AND PROPPING THE LIGHT SWITCH TOWARD THE DASHBOARD WOULD HOLD US UNTIL OUR APPOINTMENT. HOWEVER, THE DAY BEFORE THE APPOINTMENT, THE LIGHTS BECAME MORE STUBBORN AND THE STEERING COLUMN BECAME FIERY HOT NEXT TO THE SWITCH. THERE WAS ALSO THE ODOR OF SOMETHING BURNING. I PARKED THE CAR AND STAYED HOME. THE NEXT DAY AT THE APPOINTMENT, MY HUSBAND WAS TOLD THAT THE SERVICE PEOPLE SEE A SHORTING OUT OF THE LIGHT STICK ALL THE TIME WITH SATURNS. AS A MATTER OF FACT, THERE WAS ANOTHER CAR IN THE SHOP AT THAT MOMENT HAVING THE SAME REPAIR WORK DONE. I AM NOT AN EXPERT AND DON'T KNOW IF THIS PROBLEM IS DANGEROUS. ANY TIME THERE IS A SHORT IN A CAR, I JUST ASSUME THERE IS AN ASSOCIATED FIRE DANGER. HOWEVER, I DO KNOW THAT IF THIS PROBLEM IS AS COMMON AS THE DEALERS SERVICE PERSONNEL SAY, THEN THE PUBLIC NEEDS TO BE NOTIFIED. I DIDN'T RECOGNIZE THE PROBLEM WHEN IT BEGAN, AND NOW BELIEVE THAT WE AVOIDED A FIRE FROM THE SHORT CIRCUIT. *JB

NHTSA ODI #10162556

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