Wiring problems of the 2008 Saturn Outlook - part 1

When it rains water is leaking into the vehicle & throughout the 2 years I've owned it the rain has leaked in multiple locations despite having it fixed & causes the wiring, lighting & detrimental/safety sensors & electrical parts to be damaged. I became especially worried when I learned a friend with a 2008 GMC acadia (identical vehicle to Saturn Outlook) is having the exact same water issues. Within a month or 2 of having the leaking and damaged fixed new sensors get wet & issues arise due to leaking in new/different locations. I first noticed it leaking in the front by the windows & sunroof & causing the radio speakers to quit. Within a short while after fixing it the headlights, tail lights & air conditioning then started cutting out & not working. Once again I had the issue fixed but now it is leaking in the dash where water can be heard sloshing around when turning & occasionally leaks into the front floor board. Now the �stabilitrak� & traction control are all having issues as well as transmission sensors making my car undrivable and unable to shift from second gear until the car sits in the sun or dries out for a few days. The speakers are also not working making the back up cam, and even the warning dash lights have no sound. ** as mentioned before there are many online forums that talk about this leaking issue in both the Saturn Outlook & GMC acadia�s. It is very worrisome that things will seem to work & suddenly stop working due to water log damage & when driving at night & headlights/tail lights flicker or quit it is very scary & dangerous. The serious issues with sensors (transmission sensors & stability) just began on my car recently & since I've had this issue fixed so many times it needs to be investigated further before someone gets hurt.

Engine power reduced- this has happened on several occasions, where the engine just stopped running while driving, in town. Main wiring harness was repaired the first time because insulation was deteriorated and wiring was stuck together. Less than two weeks later, engine stops again while driving in town, was able to coast to the side of road, car restarted, trying to get home, car died again, would not restart, towed to auto shop again. Auto repair is unable to diagnose the problem, it will run great and just randomly stop running while driving, car has been in the shop for almost 2 weeks now. Nothing is coding when they run diagnostics. They have checked everything possible! I am having them keep the car until problem is resolved because I am scared to drive it and end up in a wreck. I have been fortunate that I was in town when this has happened, that I was in town and my grandkids were not in the car with me! this is a very serious safety risk!!! thank goodness I didn't go on a planned 12 hour trip to colorado! note: I have already put $6500. 00 in repairs within the last year because of random issues with the vehicle.

Drivers side low beam headlight wiring harness and plug have melted and I have had replaced and it happens again. The air bag warning light keeps coming on, saying service airbags now. All the speakers in the car have quit working, but if you open and close drivers side rear door they will work until you hit a bump in the road.

We kept getting a service airbag warning, took it to a Saturn certified mechanic and he said the passenger sensor in the seat is bad and could prevent the airbag from inflating in the event of an impact. Wondering why since he said this is a known problem that there hasn't been a recall. Also, the auxiliary amplifier went bad. . . He thinks this is from a leak, and the way the wiring harness was done apparently water gets into it and shorts the amp. Another known problem he said. . . Unfortunately, all warning/safety chimes do not sound because of this and all the speakers don't work except for the front tweeters.

Driving late one night when my low beam lights stopped working, I was left with my high beam lights and my fog lights only. Ended up getting pulled over by a police officer on my way home, who advised that it is a common problem with the wiring in similar vehicles. After writing me a warning, I went home with little light for driving. Woke up this morning, attempted to check fuses and bulbs, no issues noted. Can smell a burnt wire smell near headlight. Did my research and apparently is is a very common problem indeed. Please recall headlight wiring harnesses.

Driver's side headlight stopped working. Got pulled over and was given a fix it ticket. Replacing the bulb didn't fix it. I've read this is a very common issue with the wiring harness due to manufacturer defect or faulty equipment which shouldn't be the responsibility of the owner to pay to fix. Driving in the dark without a working driver side headlight is very dangerous, especially in the winter which is when this happened to me. There needs to be a recall because this causes a big safety issue.

Low beam passenger side light went out and I replaced the light. Two weeks later the light went out again, I moved the connector and the light came back on. The light worked for two weeks and it went out again. I went to change the bulb and it smelled line burnt plastic. I removed the bulb and the connector was burnt on one of the sides. The wire was barely hanging on the side the connector was burnt. The wire harness seems very flimsy and very poor quality. I'm very surprised and disappointed of the poor quality of the wiring harness. This can also possibly be a safety hazard.

While driving on the tollway, all electrical parts on instrument panel went completely out, and the air conditioner stopped blowing, and the radio went out. Even the speedometer stopped displaying. The entire instrument panel showed nothing. The service technician at jupiter Chevrolet in dallas charged us $770 to repair a wiring harness that they said was ruined due to a leak in a drainage hose in the sunroof and that this is common with this vehicle. I don't understand why there is no recall. This could have been very dangerous. Water had leaked into the passenger floor board as well.

Last night when I went to drive my vehicle I noticed the left front low beam headlight was not working. Took vehicle in to have the light bulb changed and the technician said the bulb socket/wiring was burnt and the bulb was damaged. They said I would need a new bulb and low beam headlight wiring harness. This is the third time this part has failed since the vehicle was new. The dealership replaced both the right and left side harnesses when the vehicle was under warranty and the left side harness and bulb was replaced last year approx. 10,000 miles ago and now it is burnt up again. I feel this part is defective and could cause a fire. Gm should do something to upgrade the wiring harness so this problem does not continue.

My driver side headlight (low beam) was working intermittently. Finally it stopped working. I bought a new bulb and was replacing it this weekend. While removing the old bulb, I saw that one wire had pulled out of the socket. I looked closer at the socket and realized that it was melted. There were also burn marks on the bulb plug and a green plastic piece. To my knowledge, this is an oem part. The part says phillips h11 ll and made in germany. It also says 55 w, 12 v. This would imply almost 5 a of current, which seems alot for the very small wiring size. While trying to find a replacement socket, I found out that this seems to be a very common problem on these vehicles.

The passenger side running light went out. I had the bulb replaced. About a month later the same light went out again. I had the light taken out and was told the wiring harness was melted and had caused the bulb to go out. So I now have to replace the wiring harness for that side. I have also been told by other Saturn Outlook owners that is a common problem with most of them.

Headlamp failed, wiring melted. Next time the car may go up in flames. Dangerous!!!!!.

Passenger side headlamp wiring harness found melted during hid lamp replacement. This is a fire hazard. It appears the melted wire was due to a design\manufacturing defect in that the wiring going to the hid headlamp needs to be made from a larger gauge. Also, there is not enough slack in the bulb assembly to easily replace the bulb.

Upon inspection, I noticed that the passenger front head lamp was inoperative. The vehicle was taken to the dealer, and a technician concluded that wiring harness had melted and caused the bulb to fail. He then added that the other head lamp would soon fail. The vehicle was repaired at an expense of$ 360. 00. The failure mileage was 40,000.

The passenger headlight burned out and was replaced. Two weeks later the same light burned out. This time all the wiring was pulled out and it was discovered that the wiring harness was melted. Looking on online it has been shown to be a big problem. As I am driving my 3 children around, I would like my headlights to work and not be melting in my car. Please have GMC fix this problem. A car that cost as much as mine should have working lights and non-melting parts.

Complete loss of low beam headlights under similar or identical circumstances as other voqs and various websites forums. Inspection revealed melted wiring harness connectors inside the headlamp assembly at the low beam headlamp bulb. Vehicle date of manufacture 10-2007. No known body work. Passenger low beam headlight connector is not melted as bad as the driver side low beam headlight connector. Appears to be coming predominantly from the black wire going into the connector. All insulation is melted away. Connector melted and brittle that it fell apart removing the bulb. Bulb part # appears to be h11, 12v 55w u 64211 l+dot. Osram. Germany e1 25s. W0 q3. Driver head light assembly casting date September 2007. Part number 25876413, which appears to have been superseded. Appears manufactured under automotive lighting with number lh hal 6143101907c2824. The inside connector area of the bulb itself also appears melted. The bulb is available for inspection. The headlamp assembly is still in use on the vehicle after receiving a pigtail splice repair and new bulb. The passenger side headlamp is now working and has received no repairs. Updated ivoq 11/29/11.

I have 130,000 miles on my 2008 Saturn Outlook and I have had to replace the headlight wire harnesses on both sides and multiple light bulbs. The most recent time I replaced the lightbulb ~30 days ago and it is burnt out already.

Head lamp wiring harness was melted due to poor wiring and thin wires.

Low beam driver's side headlamp on Saturn Outlook. Bulb appeared to fail but on further inspection of the wiring harness it was melted at the connector. This happened in Jan/Feb of 2011 and now (Jul) the passenger side is out. Replaced the light bulb initially on both only to have it continuously go out. Inspecting wiring harness on the passenger side later today. This clearly appears to be a fire hazard.

The failure that occurred in my 2008 Saturn Outlook was a faulty driver's side wiring harness for the headlight, which resulted in the lowbeam headlight being inoperable. This occurred on may 8th, 2011 and was continuous. I had the wiring harness replaced at my cost due to the safety issue of only driving with one working headlight at night as well as the fact it's against the law in the state of ohio. Additionally, I was traveling to canada and did not want to risk the possibility of a crash or collision with an animal due to the faulty light. I paid out of pocket over $270 for the necessary repairs including parts and labor (the old part is not available). Gm published a bulletin regarding this issue: (#09-08-42-004: low beam headlamp bulb inoperative - replace harness and fill connector cavity for low beam bulb connector with nyogel grease may 29, 2009) this is most definitely a safety issue and should be recalled immediately. Thank you for your time and consideration with this matter.

Low beam headlight wiring harness and bulb connection melted causing loss of headlights.

In March, 2011, my cars left headlight burned out. When I changed the light, I discovered that the wiring harness had melted. I replaced the harness with a gm part bought at a dealership. Last week, the right headlight burned out. Again, when I changed the light, I discovered that the wiring harness also had melted. The wires seem small to me, and are smaller than the wires on the replacement harness.

Driver side low beam head light wiring harness melted. Insulating sleeve on wiring at wiring harness was melted.

I have a 2008 Saturn Outlook xr. There are now over 150 complaints filed with the NHTSA regarding electrical problems and failure of the low beam lights on both sides. My passenger side failed and when repairs were started the gm repair shop noted the wiring harness where the bulb is inserted was burned (melted and blackened) as is the case in all the complaints I reviewed. Gm issued a TSB in may 2009 addressing this problem (TSB# 09-08-42-004) which included filling the connector cavity with nyogel grease after removing and replacing the harness. My vehicle is out of warranty with just over 41,000 miles. The gm shop acknowledged that they have seen other vehicles in this model line with the same failure. However they had no directions to cover the repairs since the vehicle was out of warranty. It was recommended that I call gm customer assistance. That call resulted in an apparent lack of knowledge of this problem in spite of the numerous NHTSA complaints and internet discussions regarding this problem. This is an obvious safety issue should a failure occur while driving at night. I can also expect that the drivers side will also fail which will result in an additional repair cost beyond just replacing a burned out bulb.

Upon noticing a headlight out on my wife's 2008 Saturn Outlook, it was noted upon disassembly of the headlight that there was significant melting damage to the electrical wiring harness to the passenger side hid headlight fixture. The wiring harness was charred and blackened in the area of the headlight connector assembly. It appears there was significant heat/arcing during the failure event. The damaged wiring harness caused the passenger side headlight to become non functional. The vehicle has approximately 50000 miles on it. This is the first such failure for this vehicle, however, upon reading various online postings about this matter, it appears to be a very common failure mode in these model vehicles. The headlight wiring harness assembly has been replaced, along with the headlight assembly due to heat damage to the headlight lamp wiring connector. Old parts are not available due to being thrown away.

Headlight wiring defect.

Overheating of low beam headlamp wiring causing melting of plastic components. Headlamps will loose electrical connection and all lamp light will be lost.

Drivers side light bulb burned out. After investigation, the wire bundle to the light overheated/burnt and melted, resulting in the halogen bulb failure. Unbelievable amount of online complaints involving the same issue, which repeats itself, even after the dealer replaces the wiring harness. The wiring harness is plastic, under-engineered and repeatedly fails. This item needs to be recalled and repaced with a metal wiring harness. Reference Saturn' s TSB #09-08-42-004. This is a known problem and a serious safety issue.

Driver's side wiring harness melted on headlight, Saturn Outlook 2008.

One evening while driving my children home from an event, we smelled a toxic burning type smell. When we arrived home, I saw that the front headlamp was out (a bit surprising for a 2 year old vehicle). The dealer discovered that the wiring harness connector was burned. A bit frightening and not tro mention costly. Although the car was 2 years old, it has just above 36,000 miles and thus out of warranty. My fault for not getting to the dealer immediately when the mileage would have been just below the 36,000 mile mark.

The contact owns a 2008 Saturn Outlook. The contact stated that while driving at various speeds or at a stop light the right headlight would shut off and he was unable to turn it back on. The vehicle was inspected by a dealer who informed the contact that the headlight wiring and socket melted and needed to replaced. The right headlight wiring and socket were replaced. The left headlight had also experienced the same failure as the right headlight. The left headlight has yet to be inspected by a dealer or repaired. The failure mileage was approximately 35,000. Updated 02/23/lj the head light wiring harness was replaced. Updated 05/20/11.

My husband and I will be taking our 2008 Saturn Outlook in for the 5th time, yes I said 5th time, to get the headlight fixed. The drivers side has had a bulb replaced as well as the wiring harness replaced. . . Same with the passenger side. It only has 40,000 miles on it and we have owned it less than a year. We are lucky that our dealership is taking pity on us, and fixing it for free because our warranty just expired. Please recall this. This is a dangerous defect that needs to be fixed!.

2008 Outlook had a burned out low beam on the driver side at 31,750 miles. Dealer confirmed that the wiring harness was melted causing the failure and need replacing. Gm needs to recall both wiring harnesses as I am sure the next one will go and it will be past the warranty. This is clearly a safety defect having a lights wiring harness melt. Apparently, this is a common problem with '08 Outlooks. Please issue a recall!.

Driver side low beam headlight is not working even after light bulb was changed. Taken in to dealer and told that the left front wiring harness is melted.

The wiring harness on the passengers side low beam has melted twice. It was last replaced two weeks ago, and has since gone out again, I suspect that it has melted again but will not know for sure until I take the car back to the shop. Why are these harness melting and why hasn't gm made a recommendation to fix this problem.