2003 Saturn L200

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).

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.

The contact owns a 2003 Saturn L200. The contact stated that while his wife was driving 45 MPH, an abnormal whirling sound was coming from the vehicle and the vehicle stalled without warning. The contact's wife was unable to restart the vehicle and with the assistance of a police officer, she coasted the vehicle off to the shoulder of the roadway. The vehicle was then towed to an independent mechanic where the vehicle was diagnosed with a defective timing chain which resulted in engine failure. The dealer nor the manufacturer had yet to be notified of the failure. The vehicle had yet to be repaired. The failure mileage was unknown.

NHTSA ID

11483230

Incident

Aug 31, 2022

PASSENGER SIDE WIPER BLADE STOPPED WORKING WHILE DRIVING IN RAIN.

NHTSA ID

11289832

Incident

Dec 13, 2019

Mileage

200,000 mi

THE FRONT BUMPER PLASTIC FASTENERS THAT HOLD THE BUMPER TO THE CHASSIS DEGRADE AND BREAK OVER TIME AND THE FRONT BUMPER WILL FALL OFF WITHOUT NOTICE. THIS HAPPENED TO ME AS MY CAR WAS SLOWLY MOVING FORWARD IN A PARKING LOT AND I HAD TO GET OUT AND PICK UP THE BUMPER AND PUT IT IN MY BACK SEAT TO GET IT HOME. WHEN I GOT HOME UPON INSPECTION I NOTICED THE PLASTIC FASTENERS HAD BROKEN AND I WAS NOT ABLE TO PUT THE BUMPER BACK ON. I HAD TO USE WIRE TO ATTACH IT TO THE CHASSIS BECAUSE THE PLASTIC FASTENERS WERE ALL BROKEN AND BRITTLE.

NHTSA ID

11133616

Incident

Jul 6, 2018

Mileage

76,000 mi

BRAKELIGHTS HAVE QUIT WORKING TWICE. ALSO MULTIPLE ELECTRICLE PROBLEMS. ON 1 OCCASION, ABS LIGHT WAS OUT, CAME ON AGAIN WITH RESTART. ANOTHER TIME FUEL GAGUE SHOWED EMPTY, SHOWED FULL ON RESTART. ANOTHER TIME TURNED KEY AND NO ELECRIC AT ALL, UNPLUGGED BATTERY AND ALL WAS WELL.

NHTSA ID

11096896

Incident

May 20, 2018

Mileage

162,000 mi

TL* THE CONTACT OWNS A 2003 SATURN L200. WHILE STARTING THE VEHICLE, THE CHECK ENGINE INDICATOR ILLUMINATED AND AN ABNORMAL NOISE WAS HEARD. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 148,000.

NHTSA ID

10959564

Incident

Aug 16, 2016

Mileage

148,000 mi

WHILE DRIVING WITH TWO KIDS IN THE CAR MY STEARING BECAME ODD. I SLOWED DOWN AND MY CAR STARTED PULLING TO THE LEFT I COULD BARELY KEEP IT IN A STRAIGHT LINE. MY STEARING WHEEL WAS TURNED ALL THE WAY TO THE RIGHT WHEN SUDDENLY IT SOUNDED LIKE I HAD A FLAT TIRE. I STOPPED THE CAR THE WHEEL IT'S SELF LOOKED ODD. I GOT BACK IN AND TRIED TO DRIVE AND MY CAR MADE A AWEFUL NOISE AND I COULD NOT GO ANYWHERE! I WAS SRANDED IN THE DARK ON A HILLSIDE WITH THE KIDS. I HAD MY CAR TOWED HOME TO DISCOVER THE FRAME OF MY CAR HAS SPLIT AT THE A-ARM, THE ENGINE CRADLE HAS CAUSED THIS PROBLEM. MY INSURANCE WONT PAY THIS IS OUR ONLY CAR AND MY KIDS HAVE MEDICAL NEEDS PLEASE HELP !

NHTSA ID

10949533

Incident

Jan 25, 2017

Mileage

150,000 mi

TL* THE CONTACT OWNS A 2003 SATURN L200. WHILE DRIVING 50 MPH, THE STEERING WHEEL CAUGHT FIRE. A POLICE REPORT WAS NOT FILED. THE CONTACT EXTINGUISHED THE FIRE. THERE WERE NO INJURIES. THE MANUFACTURER WAS NOT MADE AWARE OF THE ISSUE. THE FAILURE MILEAGE WAS APPROXIMATELY 160,000.

NHTSA ID

10903758

Incident

Sep 4, 2016

Mileage

160,000 mi

LIGHT FLASHING ON DASH BOARD, CLIMATE CONTROL GOES ON AND OFF ,OIL LIGHT KEEP COMING ON AND OF. EVERYTHING THAT'S ELECTRIC LIKE THE SUN ROOF. AM AFRAID OF GETTING STUCK IN THE MIDDLE OF A HIGH WAY. PLEASE HELP ME. [XXX]. I LIKE TO KNOW IF THIS CAR IS ON RECALL. THANK YOU. WE ARE SECOND OWNER INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10895535

Incident

May 14, 2014

Mileage

179 mi

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection.

Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers.

This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.

This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information.

This Warranty Administration bulletin provides retail and wholesale service personnel with the policies/procedures and the warranty transaction submission procedures that support the Personal Property Damage process.