2000 Saturn LS

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.

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.

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.

I am listing this vehicle identification number to fulfill your request on the safety complaint form, however I believe what I am about to share is an issue that applies to all vehicles on the road today, regardless of their source of motive power, if they have a hydraulic-brake system. I believe the current federal specifications for brake lines are too susceptible to corrosion, and although the materials brake lines are made of on most vehicles, probably meet Federal standards. Federal standards for this and other vehicle parts should evolve more frequently, sensitive to modernization and field experience. Corrosion-resistant brake lines are available and Federal statutes should be upgraded to specify they be constructed of more durable material and also be positioned in vehicles to increase their ease of replacement. Replacement of just the rusted sections of my rear brake lines cost me approximately $3000, and most of that cost was driven by brake line inaccessibility. Brake lines are typically one of the first components installed during vehicle assembly and several layers of components are then placed over them. Given the difficulty of replacement they should be one of the most durable components in the vehicle and calculated to last an appropriate multiple of the vehicle’s service life that is economically feasible.

NHTSA ID

11593168

Incident

Jun 1, 2011

THE WHOLE SUBFRAME ON MY 2000 SATURN LS IS ROTTED SO BAD THAT I CAN'T EVEN DRIVE THE VEHICLE. IT STARTED WITH MY CAR NOT STARTING AND PUTTING IT UP ON A LIFT TO SEE WHAT THE PROBLEM WAS. THAT NOT STARTING PROBLEM IS A BAD RESONATOR, BUT IN THE PROCESS THE SUBFRAME WAS FOUND TO BE SERIOUSLY ROTTED AWAY. *TR

NHTSA ID

11329340

Incident

Jun 11, 2020

Mileage

170,000 mi

CAR LEAKING OIL - NOW ENGINE TROUBLE

NHTSA ID

11072426

Incident

Jan 31, 2018

Mileage

106,000 mi

NOTHING, THANK GOD HAD HAPPENED YET, BUT IT WILL IN A MATTER OF TIME, HOW MUCH TIME I HAVE NO IDEA. THE PROBLEM IS THE MOTOR CRADLE OR FRAME IS RUSTING OUT, THE FRONT WHERE THE MOTOR SETS HAD WHOLES RUSTED IN IT, THE WHOLE THING IS RUSTING AWAY.

NHTSA ID

11019886

Incident

Feb 24, 2016

Mileage

5 mi

WHILE DRIVING DOWN THE INTERSTATE MY TIMING CHAIN SNAPPED. CAR LOST POWER AND PUT ME AND MY FAMILY AT RISK OF AN ACCIDENT.

NHTSA ID

10967286

Incident

Feb 20, 2017

Mileage

180,000 mi

REF: 07V519 I AM FILLING THIS COMPLAINT CONCERNING MY 2000 SATURN LS1 2.2L ENGINE. WHILE DRIVING ON A SOUTHERN CALIFORNIA FREEWAY IN JULY 2008 MY TIMING CHAIN BROKE. THIS CAUSED US TO TRY AND GET TO THE SIDE OF THE FREEWAY FROM THE LEFT SIDE OF THE FREEWAY, A VERY NERVE-RACKING SITUATION. AFTER TALKING TO THE DEALERSHIP AND SEVERAL INDEPENDENT REPAIR SHOPS I ELECTED TO REPLACE THE ENGINE INSTEAD OF FIXING THE TIMING CHAIN AND THE OTHER DAMAGE THAT WAS CAUSED IN THE BROKEN TIMING CHAIN. THE REPAIR WAS COMPLETED BY CLAREMONT AUTO CENTER IN POMONA CA ON 14/JULY/2008. IF NECESSARY I SHOULD BE ABLE TO GET A COPY OF THE REPAIR BILL.

NHTSA ID

10898357

Incident

Jul 14, 2008

Mileage

140,569 mi

TL* THE CONTACT OWNS A 2000 SATURN LS. WHILE DRIVING 70 MPH, THE VEHICLE RANDOMLY STALLED WITHOUT WARNING. THE CONTACT HAD TO COAST THE VEHICLE TO THE SIDE OF THE ROAD. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE. AN INDEPENDENT MECHANIC DIAGNOSED THE VEHICLE AND STATED THAT THAT THERE WAS AN INTERNAL FAILURE WHERE THE TIMING BELT PREMATURELY FRACTURED INTO THE MOTOR AND FRACTURED THE VALVES. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS NOT AVAILABLE.

NHTSA ID

10889243

Incident

Jun 13, 2016

TL* THE CONTACT OWNS A 2000 SATURN LS. WHILE DRIVING AT ANY SPEED, THE TURN SIGNAL DID NOT AUTOMATICALLY DISENGAGE. THE CONTACT HAD TO MANUALLY DISENGAGE THE SIGNAL. THERE WAS NO WARNING INDICATOR. THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC WHO DIAGNOSED THAT THE TURN SIGNAL CANCEL CAM ASSEMBLY NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 7,704.

NHTSA ID

10864012

Incident

Mar 15, 2016

Mileage

7,704 mi

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 technical bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up.

This service bulletin provides service information to technicians on guidelines to replace Oil Cooler, Oil Cooler Lines and Oil Tank if the engine was replaced where large amounts of debris has flowed throughout the oiling system.

This PI bulletin advises the technician on the proper way to install the pistons in an engine.