Saturn EV1 recalls by model year

Reported: 2000-03-03 (March 3, 2000) · Model years: 1997

VEHICLE DESCRIPTION: GENERATION 1 ELECTRIC PASSENGER VEHICLES. THESE VEHICLES WERE BUILT WITH A CHARGE PORT ASSEMBLY THAT COULD FAIL DURING A CHARGING EVENT.

Consequence: HEAT COULD BUILD UP WITHIN THE CHARGE PORT AND A FIRE COULD RESULT.

Remedy: THESE PASSENGER VEHICLES WERE REPURCHASED BY SATURN/GM.

Reported: 2000-11-13 (November 13, 2000) · Model years: 1997, 1999

VEHICLE DESCRIPTION: ELECTRIC VEHICLES. THESE VEHICLES WERE PRODUCED WITH WHEEL SPEED CIRCUITRY IN THE BRAKE TORQUE CONTROL MODULE (BTCM) WHICH CAN CEASE TO OPERATE PROPERLY.

Consequence: IF THIS OCCURS, INVOLVED VEHICLES WILL EXHIBIT ONE OR MORE OF THE FOLLOWING: A LOSS OF FRONT BRAKE ASSIST, A DISABLED REAR BRAKE SYSTEM, A DISABLED ANTI-LOCK BRAKE SYSTEM, AND/OR A DISABLED REGENERATIVE BRAKE SYSTEM. THIS COULD INCREASE BRAKE PEDAL TRAVEL AND VEHICLE STOPPING DISTANCE.

Remedy: DEALERS WILL REPLACE THE BTCM, THE BALLSCREW ASSEMBLIES IN THE BRAKE PRESSURE MODULATOR VALVE, AND INSTALL NEW SOFTWARE.

Reported: 1997-03-20 (March 20, 1997) · Model years: 1997

VEHICLE DESCRIPTION: ELECTRIC VEHICLES. THESE VEHICLES WERE BUILT WITH A DRIVE MOTOR CHARGER RECEPTACLE ASSEMBLY THAT WAS INCOMPLETELY SEALED. INCOMPLETE SEALING CAN ALLOW WATER TO INTRUDE INTO THE CIRCUIT BOARD.

Consequence: DURING CHARGING A SHORT CIRCUIT COULD OCCUR. AN ARC AT THE SHORT CIRCUIT CAN GENERATE ENOUGH HEAT TO CREATE SMOKE AND/OR A FLAME. IF A FLAME OCCURS, A FIRE COULD RESULT.

Remedy: DEALERS WILL INSPECT THE DRIVE MOTOR BATTERY CHARGER RECEPTACLE ASSEMBLY AND REPLACE IT, IF NECESSARY.

Reported: 1997-07-01 (July 1, 1997) · Model years: 1997

VEHICLE DESCRIPTION: PASSENGER VEHICLES. THESE VEHICLES WERE BUILT WITH A DAMAGED O-RING IN THE BRAKE PRESSURE MODULATOR VALVE SOLENOID(S) ON THE BRAKE PRESSURE MODULATOR. INVOLVED VEHICLES CAN DEVELOP AN EXTERNAL BRAKE FLUID LEAK IN ONE OR BOTH OF THE BRAKE PRESSUREMODULATOR VALVE SOLENOIDS.

Consequence: BRAKE FLUID LEAKAGE COULD REDUCE BRAKE EFFECTIVENESS AND INCREASE STOPPING DISTANCES.

Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE SOLENOID(S) ON THE BRAKE PRESSURE MODULATOR.

Reported: 1998-07-28 (July 28, 1998) · Model years: 1997

VEHICLE DESCRIPTION: ELECTRIC VEHICLES. A TRANSISTOR WITHIN THE BRAKE TORQUE CONTROL MODULE (BTCM) CAUSES AN ELECTRICAL SHORT TO GROUND. THIS DOES NOT COMPLY WITH THE REQUIREMENTS OF FMVSS NO. 105, "HYDRAULIC BRAKE SYSTEM."

Consequence: AS A RESULT, VEHICLES CAN EXPERIENCE A LOSS OF FRONT BRAKE ASSIST, INCREASING THE BRAKE PEDAL TRAVEL, AND VEHICLE STOPPING DISTANCE.

Remedy: DEALERS WILL REPLACE THE BRAKE TORQUE CONTROL MODULE.

Reported: 2000-11-13 (November 13, 2000) · Model years: 1999

VEHICLE DESCRIPTION: CERTAIN GENERATION II ELECTRIC VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FMVSS NO. 101, "CONTROLS AND DISPLAYS." THESE VEHICLES WERE PRODUCED WITH A COURTESY LAMP CONTROL CIRCUIT IN THE RIGHT-HAND JUNCTION BLOCK WHICH CAN FAIL. IF THIS OCCURS, THE INTERIOR LAMPS WILL REMAIN ILLUMINATED AND CANNOT BE CONTROLLED BY THE DRIVER ONCE THE DOORS ARE CLOSED AND THE VEHICLE IS IN MOTION.

Consequence: IF THIS WERE TO OCCUR DURING A NIGHT-TIME DRIVING SITUATION, THE DRIVER'S VISION COULD BE IMPAIRED.

Remedy: DEALERS WILL REPLACE THE RIGHT-HAND JUNCTION BLOCK.

Reported: 2000-11-13 (November 13, 2000) · Model years: 1999

VEHICLE DESCRIPTION: GENERATION II ELECTRIC VEHICLES. SOME REPLACEMENT CHARGER RECEPTACLE ASSEMBLIES USED FOR WARRANTY REPAIRS WERE BUILT WITH INTERNAL COMPONENT VARIATION. THIS VARIATION CAN GENERATE ARCING DURING THE CHARGE CYCLE.

Consequence: EXTENDED ARCING DURING THE CHARGE CYCLE COULD LEAD TO A VEHICLE FIRE AND/OR PERSONAL INJURY.

Remedy: DEALERS WILL INSPECT THE SERIAL NUMBER ON THE CHARGE RECEPTACLE AND, IF NECESSARY, REPLACE THE CHARGE RECEPTACLE ASSEMBLY.

Reported: 2000-11-13 (November 13, 2000) · Model years: 1999

VEHICLE DESCRIPTION: ELECTRIC PASSENGER VEHICLES AND PICKUP TRUCKS CONTAINING A NICKEL METAL HYDRIDE (NIMH) BATTERY PACK. THESE VEHICLES CONTAIN SOFTWARE WITHIN THE BATTERY PACK MODULE INTENDED TO DISABLE THE VEHICLE FROM BEING DRIVEN IF THE ELECTRICAL RESISTANCE WITH THE BATTERY PACK EXCEEDS A PRESCRIBED VALUE. AFFECTED VEHICLES WILL ILLUMINATE THE "SERVICE NOW" AND "REDUCED PERFORMANCE" TELLTALES AND CONTINUE TO FUNCTION IN A REDUCED PERFORMANCE MODEL INSTEAD OF BEING DISABLED.

Consequence: IF THE TELLTALES ARE IGNORED AND THE AFFECTED VEHICLE CONTINUES TO BE DRIVEN, HEAT COULD BUILD UP AND A FIRE COULD RESULT.

Remedy: DEALERS WILL INSTALL REVISED SOFTWARE IN THE BATTERY PACK MODULE.