Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||||
| 3135 | 01/01/2004 | 10010045 | Pop noise from engine area during heavy throttle input. *tc | 11/03/2004 | |
| 3116 | 01/01/2004 | 10009971 | Ses illuminated engine miss/misfire feel or rough idle. *sc | 11/02/2004 | |
| 040604008 | 10/01/2004 | 040604008A | 10006167 | Service engine soon (ses) lamp illuminated with dtc p0135 ho2s heater circuit performance bank 1 sensor 1 and/or dtc p0155 ho2s heater performance bank 2 sensor 1. *mr this bulletin replaces previous 04-06-04-008. *eh | 04/23/2004 |
| 030602002 | 03/01/2003 | 10001193 | Insufficient heat, service engine soon (malfunction indicator lamp) telltale on, diagnostic trouble code p0128 set. *tt | 04/22/2003 | |
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| PIP-4495C | 03/01/2011 | 10038510 | Ready | 06/16/2011 | |
| PIP-4495C | 03/01/2011 | 10038510 | Gm: there may be noise coming from the cylinder head, because of low oil pressure which is caused by debris. *rm | 06/16/2011 | |
| 0804 | 08/01/2004 | 10014346 | Oil life system reset procedures - cars. *nm | 04/29/2005 | |
| 040604085 | 12/01/2004 | 10011533 | Service engine soon (ses) and/or reduced power lamp illuminating following cold engine start up in subfreezing temperatures, diagnostic trouble codes (dtc) p0638, p1510 and/or p1516 stored in engine control module (ecm). *tt | 01/26/2005 | |
| 010604016 | 12/01/2004 | 010604016A | 10011039 | Service engine soon (ses) telltale illuminated with diagnostic trouble codes (dtcs) p0171, p0172, p0174 and/or p0175. *tt | 12/27/2004 |
| 040601011 | 05/01/2004 | 10006979 | Service manual update for engine block clearance, cylinder head clearance and fastener torque specifications. *tt | 05/20/2004 | |
| 040601009 | 04/01/2004 | 10006739 | Oil leak from front cover seal during extremely cold weather. *tt | 05/11/2004 | |
| 040601010 | 04/01/2004 | 10006740 | Blue smoke at engine start-up. *tt | 05/11/2004 | |
| 040604027 | 04/01/2004 | 10006725 | Service manual update - add diagnostic trouble code (dtc) p0504. *tt | 05/11/2004 | |
| 040601004 | 09/01/2004 | 040601004A | 10006088 | Service information regarding engine support during removal of right front engine mount assembly. *tt | 04/16/2004 |
| 030090003 | 09/01/2003 | 10003976 | Oil filter cap assembly and oil filter element design change. *tt | 11/10/2003 | |
| 030604043 | 09/01/2003 | 10003592 | Malfunction indicator lamp (mil) service engine soon telltale lamp on, reduced power lamp may illuminate with diagnostic trouble codes p0121, p0221, and/or p2135. *tt | 10/24/2003 | |
| 030601017 | 06/01/2003 | 10002122 | Timing chain design change and revised service procedures. *tt | 08/13/2003 | |
| 030601015 | 05/01/2003 | 10001668 | Service manual update for removal of the sealer used on oil pump gasket during oil pump installation. *tt | 06/18/2003 | |
| 030601014 | 05/01/2003 | 10001667 | Service manual update regarding the use of saturn special tool j-42065 crank hub holding tool. *tt | 06/18/2003 | |
| 030604016 | 03/01/2003 | 10001199 | Service information regarding the engine control module (ecm) connector and terminal locations on saturn v6 engines. *tt | 04/22/2003 | |
| 03T04 | 02/01/2003 | 10001127 | Spark plug usage change, and if necessary, update pcm (power train control module) calibration. *tt | 04/15/2003 | |
| 03T01 | 01/01/2003 | 10000876 | Service engine misfire on paired cylinders (1 and 4 or 2 and 3), diagnostic trouble codes p0300 - p0304 2.2l 4 cyl revised repair procedure. *tt | 04/02/2003 | |
| 02T86 | 12/01/2002 | 10000789 | Service information regarding elimination of auxiliary water pump and instruments to install 2nd design heater inlet hose and heater inlet elbow in place of the 1st design water pump and heater inlet hose. *tt | 03/31/2003 | |
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | ||||||
| PE06006 | GENERAL MOTORS CORP. | 01/24/2006 | 06/06/2006 | TIMING CHAIN FAILURE | ||
| 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 | GENERAL MOTORS CORP. | 12/20/2005 | 02/06/2006 | TIMING CHAIN FAILURE | ||
| 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. | ||||||
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||
| 08/15/2003 | 15758 | 10 | 01/31/2003 |
| Problems with vehicle's power steering system.*mr consumer noticed the failure when driving off the lot but thought i was due to cold weather. later she learned the rack and pinion needed to be replaced due to fluid leaking. after the repair, consumer started hearing grinding noise when turning. on 10/08/03, the consumer learned the steering pump had to be replaced. after picking up the vehicle on this date, consumer heard more noises. this time it was a air pocket in the steering fluid. in addition, the automatic climate control system fails to work as designed. it's programmed at 87 degrees when its cold outside. instead of heat, it would blow warm then cold air. the computer was reprogrammed and the problem became worst than at first. there were countless other problems with this vehicle. *ph | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||
| 02/25/2007 | 48000 | 5 | 03/01/2004 |
| Tl*- the contact owns a 2003 saturn l series. while driving at 30 mph the electrical warning light illuminated ,and the front end began to shake. the check engine light also illuminated. the contact stated that she pulled over and turned the vehicle off, and restarted the vehicle after waiting about ten minutes. the check engine light remained illuminated, white smoke started exiting the exhaust pipe and the vehicle began to shake. the dealer was unable to diagnose the failure. the contact stated this occurred on five different occasions. the dealer had replaced the pump and/or gas coolant, insulator assembly front suspension support, oxygen sensor and exhaust system. the current mileage was 48,000. *ak | |||