Wiring problems of the 2001 Saturn LS

The contact owns a 2001 Saturn l200. While parked, the contact noticed that the air conditioner would not activate. The vehicle was taken to a dealer for diagnostics where the technician stated that the wiring harness was found to have been melted. The vehicle was repaired. The approximate failure mileage was 109,000. . . Updated 09-26-12 updated 10/01/2012.

I replaced the heater control switch, blower motor, and resistor due to the fact that the heater blower would not work. After doing all the above, the heater still did not work. It appears that the wiring harness behind the heater control was the problem. Two of the prongs in the white plug were burnt and did not allow the DC electric current to go into the heater control unit. It is lucky that the fan went out before it had caught fire. There are two children who ride in the car, one 5 years old and one 9 years old. I was surprised that the 40 amp fuse did not blow even though the circuit kept coming on and off. We had already changed the engine 3-4 years ago because the timing chain broke and Saturn would not fix.

I have had to replace the heater control switch two times over the past three years. There appears to be a problem with the wiring harness overheating at the white clip (where it plugs into the heater control unit. If left undetected, it melts the plastic of the switch making it impossible to switch from hi to low. Research on this make and model does not indicate a recall, however, I found an indication that Saturn is aware of this problem and has made repairs to correct the situation. I am concerned this may eventually lead to a fire hazard, if not that then a costly repair. I have replaced the blower motor, blower motor resistor and heater control unit. Could cost nearly $1000. 00 based on estimates through dealership.

The blinker / light handle on the left hand side of the steering wheel, which also controls the bright lights. When I turn the blinker on either turning left or right, the bright lights come on, and causes the blinker electrical wiring to arc and cause a small fire in the steering column area, which emits smoke into the cabin of the vehicle, also an odor of burning wires. At one point there was a small fire in that area, which caused me to have to pull over and blow out manually (do not have a place for a fire extinguisher in the vehicle). Ever since that day, it has done this, arcing and causing the smoke in the cabin. One time only has it flared up with visible flames and it did not destroy the vehicle, nor caused any other damage of any sort. However it still does cause the arcing in the wiring and cause the smoke to fill part of cabin.

A short circuit of some sort in the the headlight/turn signal switch caused a small electrical fire. While driving, the dashboard indicators showed that the daytime running lights and high beams were turning on and off on their own. When the car was turned off, the daytime running lights remained on. After a few moments, I began to smell the odor of something burning and smoke began to come out of the steering column. The smoke subsided only after I pulled the fuses on the two headlamps. The fuses did not break the circuit on their own -- the headlights did not go out until I pulled the fuses. I then called the Saturn roadside assistance hotline and asked them how to completely turn off the electrical power to the entire car (to prevent anything else from catching fire) but they were of little help. I was looking for a master circuit breaker but they could not tell me whether or not the vehicle has one. They suggested disconnecting the battery at the terminals, but I was wary of doing this for fear that the airbag might deploy.

Uneven wear of tires; (tires replaced under warranty once); tail light shorts (received a ticket) the bulbs have been replaced three times (problem is from faulty wiring. . . Problems with shift moving from p to r & d. Must tap on the brake several times in order for the gear to move.