This Sunday is World Industrial Design Day, a day when the ID Community brings awareness of this profession’s value. Though I left The College for Creative Studies with my tail between my legs, ID’s blending of business/entrepreneurship, art and science still charms me. So let’s examine two ignition keys that owe their existence to the craft known as industrial design.
The House Energy & Commerce Committee recently released the documents GM submitted for investigation, which includes emails and internal reports documenting GM’s response to reports of their early Chevrolet Cobalt and Saturn Ion models inadvertently shutting the car “off” while driving due to an ignition cylinder that was, simply, too easy to turn out of the “run” position; and in the case of several accidents, allowed the ignition cylinder to rotate out of the run condition before or during accidents, causing the airbags to not deploy when required.
The documents, totaling 619 pages (some with repeat info), reveal just how deep seated “old GM” was in their cost cutting ways (Driving down supplier costs to the point of sacrificing quality, admittedly poorly designed ignition cylinder, and removing internal quality control on the parts), and just how blind sided “new GM” was during their investigations. It also confirms how suspended engineers Ray DeGiorgio and Gary Altman were involved in the ignition switch response, and fuzzy problem solving. Full text and an analysis of key documents below. (Read More…)
General Motors released their updated chronology to the recall effecting the 2007 and earlier Chevrolet Cobalt and HHR; Pontiac G5 and Solstice; and Saturn Ion and Sky. Most of the new chronology works just to update the document with the expanded recall, but there’s a key update:
During the Saturn Ion development in 2001, a preproduction model had an ignition cylinder problem that was caused by, you guessed it, “low detent plunger force,” the result being that it takes a low amount of effort to knock the key out of the “run” position.
GM is recalling 778,000 units of the 2005 through 2007 Chevrolet Cobalt and Pontiac G5 over an issue where the ignition cylinder inadvertently turns out of the “Run” position, there by turning the car’s main electrical systems “off”. These systems include the engine, anti-lock brakes, and airbag systems. According to USA Today, GM knew of six deaths, and twenty-two other wrecks related to the ignition failure, and was aware of the defect since 2004.
Recently I took my 1999 Toyota Camry (2.2L 4-cylinder) to a touchless car wash with underbody sprayers. This was a car wash that I used often, so I had good luck with it until this one particular day. Prior to getting it washed the Camry ran fine all afternoon, including during the wash. (Read More…)
Long time lurker here. Since you asked so nice, here’s a problem that I haven’t managed to troubleshoot myself, and so far my own searches & forum postings haven’t nailed an answer. My girlfriend drives a 99 Mazda Protégé. If driven for an extremely short distance (like from the street into the garage), it will not start the next morning. It turns over just fine, but doesn’t catch. (Read More…)
I just bought a 2000 Saturn LW1 6 weeks ago. It has a L4 2.2 Liter engine with 200,000 miles on it. After 3 weeks out of the country I came back and started it up. Was a little rough then smoothed out. I just changed parking spots. Did this one more time. The third time starting it up it would not fire. No strange noises, just no running engine. I suspected bad ignition coil. I had just changed the spark plugs before my trip and they had about 50 miles on them. Ignition coil was fine at all four points using a ignition tester. I even put new plugs in again. Fuel rail has the specified 60 PSI. Theorizing that may the fuel injectors were shut down i tried starter spray in the air intake. The motor will not fire. A compression test with a gauge picked up at advance gave me less than 10 PSI on the two outer cylinders and about 24 on the two inner. The Haynes manual is very unhelpful and only states for compression specs. that the lowest compression cylinder value should be no less that 70% of the highest compression cylinder value.
I read on-line (http://www.saturnfans.com/forum/showthread.php?p=1781795) the same but that no cylinder should be less than 100 PSI. While cranking the engine there was some light smoke visible behind the engine above the exhaust manifold, but unable to determine the source.
My question is: are you aware of catastrophic head gasket failures on these engines? I am surprised that the engine will not fire at all even if the head gasket does have a problem. I have removed the valve cover and see that the timing chain is still there and working.
When I changed the plugs last month I applied anti-seize thread sealant to the plugs as instructed in the manual. I am now having wild imaginings that the anti-seize thread sealant got into the cylinders and impregnated the gasket and is somehow responsible for this catastrophic failure. I am going to tear into the engine tomorrow and try to replace the head gasket, because i need to get this car running again ASAP. I am being hopeful and unrealistically optimistic that I cold get some input/ thoughts from you before morning when I start this laborious task…
Ideas? (Read More…)