TIMING CHAIN FAILURE

Engine And Engine Cooling

Summary

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).

Documents (86)

• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 01 J0820 FLEET GEOGRAPHIC DATAR INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 01 SATURN J-CAR CLAIMS FOR J0820_R INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 01 TO 02 LD8 J0820R INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 01_02 J0820 FLEET CLAIMS INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 01_02 J0820_RETAIL_QWIK INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 01_02 L61 SATURN J-CAR J0820 MOB_CUM CHARTS INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 01_02 L61 SATURN J-CAR J0820 PTTR DATA INFORMATION FROM CD
• GM RESPONSE 4/12/208 LETTER TO ODI
• GM RESPONSE 04/21/2006 Q7 BULLETIN 1480369 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 00_01 L61 J0820_J1840_J1880 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 00_03 L61 L-SERIES J0820_J1840_J1880 IPTV_CPV INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 WARRANTY ANANLYSIS J0820 RETAIL SOLD STATE GEOGRAPHIC DATA INFORMATION FROM CD
• GM RESPONSE 04/12/2006 ATTKKZX0 Q8 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 02 J0820 CLAIMS_011003 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 COPY OF 01 SATURN J-CAR MIC CLAIMS FOR J0820 Q8 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 J0820 FLEET SOLD STATE GEOGRAPHIC DATA INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 L61 J0820 ASSOCIATEDCLAIMS_102202 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 2002 J0820 RETAIL SOLD STATE GEOGRAPHIC CHART Q8 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 2002 L61 J0820 Q8 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 2002 L61 Q8 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 CAMDRCHAINBRKGSECTOR06AU02 Q8 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 ENGINE TEARDOWN REPORT L61 SATURNS INFORMATION FROM CD
• GM RESPONSE GM686 RESPONSE 04/12/2006 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 COPY OF 01 SATURN J-CAR MIC CLAIMS FOR J0820 Q8 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 HANDWRITTEN DOCS INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 01 TO 02 L36 J0820R INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 01_02 L61 J0820_FLEET_QWIKR INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 02 J-CAR CLAIMS FOR J0820 INFORMATION FROM CD
• GM RESPONSE 04/12/ 2006 Q8 ACTION, AJ WARRANTY FILES 02_03 L61 N-CAR J0820 CUM_MOB CHARTS INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 03 J0820 CLAIMS_022003 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q7 BULLETIN 1341990 INFORMATION FROM CD
• GM REPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 00 J0820 CLAIMS_022003 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 00_01 L61 J0820 CUM_MOB CHARTS INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 00_02 CUM CHART J0820 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 00_02 L61 J0820 CUM_MOB CHARTS-5 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 00_02 L61 J0820 CUM_MOB CHARTS INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION AJ, WARRANTY FILES 2000 CLAIMS FOR J0820_J1840_J1880 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION AJ, WARRANTY FILES 2001 J0820 RETAIL SOLD STATE GEOGRAPHIC DATA INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 00_02 L61 J0820 CUM_MOB CHARTS_022103R INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 00_02 MOB_CUM CHART J0820R INFORMATION FROM CD
• GM RESPONSE 04/12/2006Q8 ACTION, AJ WARRANTY FILES 00TO02J0820LC INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 00TO02J08202 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 01 CLAIMS_021903 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 01 J0820 CLAIMS_022003 INFORMATION FROM CD
• OCC 5/31/2006 LETTER TO GENERAL MOTORS GRANTIING CONDFIDENTIAL TREATMENT OT GM 4/28/2006 LETTER TO OCC
• GENERAL MOTORS 4/28/2006 LETTER TO OCC REQUEST FOR CONFIDENTIAL TREATMENT
• OPENING RESUME APPROVED * 01/24/06 * p
• GM 4/12/2006 LETTER TO ODI
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 02 CLAIMS_021803 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 02 J0820 CLAIMS_022003 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 02 N-CAR MIC CLAIMS FOR J0820 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 02_03 L61 J-CAR J0820 CUM_MOB CHARTS INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 02_03 L61 J-CAR J0820 PTTR DATA INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 02_03 L61 J-CAR J0820_J1840_J1880 PTTR DATA INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 02_03 L61 N-CAR J0820 PTTR DATA INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 2001 L61 SATURN J J0820 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 2001 TIMING CHAIN 5 LABOR OPS INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 2001 TIMING CHAIN WORK UPDATE INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 02_03 L61 N-CAR J0820_J1840_J1880 PTTR DATA INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 03 J-CAR CLAIMS FOR J0820 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION AJ, WARRANTY FILES 03 N-CAR CLAIMS FOR J0820 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 RISK ASSESMENT 03-P-24 REVISED BULLETIN INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 2000-2003 SATURN L61 ENGINE-TIMING CHAIN REPLACE INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION AJ, WARRANTY FILES 2001 CLAIMS FOR J0820_J1840_J1880 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 ACTION AJ, WARRANTY FILES 2001 J0820 FLEET SOLD STATE GEOGRAPHIC CHART INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION AJ, WARRANTY FILES 2001 J0820 FLEET SOLD STATE GEOGRAPHIC DATA INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION AJ, WARRANTY FILES 2001 J0820 RETAIL SOLD STATE GEOGRAPHIC CHART INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION AJ, WARRANTY FILES 2001 L61 MILEAGE ANALYSIS COMPARISON INFORMATION FROM CD
• GM RESPONSE 04/21/2006 Q8 ACTION AJ, WARRANTY FILES 2001 L61 MILEAGE IPTV DATA CONFIRMED CASES INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION AJ, WARRANTY FILES 2001 L61 MILEAGE IPTV DATA J0820 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 2001 L61 MILEAGE IPTV DATA J0820_J1840_J1880 INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION, AJ WARRANTY FILES 2001 L61 MILEAGE IPTV DATA INFORMATION FROM CD
• GM RESPONSE 04/21/2006 Q8 ACTION AJ, WARRANTY FILES 2001 L61 RETAIL VS. FLEET MILEAGE ANALYSIS INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q8 ACTION AJ, WARRANTY FILES 2001 L61 SATURN J CAR INFORMATION FROM CD
• GM RESPONSE 04/12/2006 Q9 TABLE MODIFICATIONS GM 686, CD
• GM RESPONSE 04/12/2006 ACTION 8K, GM'S ASSESSMENT OF THE VOQ'S, CD
• MEMO 4/12/2006 TO TIS, ONE CD, GM 4/12/2006 ATTACHMENT 1
• OCC 2/13/2007 LETTER TO GM GRANT CONFIDENTIAL TREATMENT TO GM 12/22/2006 LETTER TO OCC
• GM 12/22/2006 LETTER TO OCC REQUEST FOR CONFIDENTIAL TREATMENT
• OCC 7/7/2006 LETTER TO GM GRANTED CONFIDENTIAL TREATMENT TO GM 6/7/2006 LETTER TO OCC
• MEMO 7/14/2006 TO TIS, ONE CD, GM 7/14/2006 SUPPLEMENT 3
• IR TO MFR * 02/16/02 * P
• GM 07/14/2006 LETTER TO ODI
• GENERAL MOTORS 4/28/2006 LETTER TO ODI
• CLOSING RESUME APPROVED * 06/06/06 * P
• GM 6/7/2006 LETTER TO OCC REQUEST FOR CONFIDENTIAL TREATMENT

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