NHTSA Complaint #10133509 — 1999 PONTIAC SUNFIRE

THE AIR CONDITIONING COMPRESSOR PUMP (A/C PUMP) COMES INTO CONTACT WITH THE (1999) OEM LOWER RADIATOR HOSE (HOSE), DENTING THE HOSE AND WEARING A HOLE IN THE HOSE OVER TIME. THIS CONDITION IS WORSE WHEN FRONT STRUTS AND/OR ENGINE MOUNTS BECOME WORN. INITIAL LEAK OF COOLENT IS ONLY DETECTABLE BY LOW FLUID LEVEL OVER EXTENDED PERIOD OF TIME (APPORXIMATELY 6 MONTHS TO A YEAR): NO WETNESS ON THE HOSE OR POOLING OF COOLENT FLUID UNDER THE VEHICLE IS DETECTABLE PRIOR TO A LARGER HOLE BEING WORN INTO THE HOSE. PRIOR TO LARGER HOLE BEING WORN INTO HOSE, COOLENT LOSS IS IN VAPOR FORM, BUT NOT IN A SUFFICIENT AMOUNT TO BE SEEN. ONCE THE HOLE IN THE HOSE BECOMES LARGE ENOUGH TO BE DETECTED BY FLUID POOLING UNDER THE VEHICLE, THE COOLENT FLUID WILL COME IN CONTACT WITH THE POWERTRAIN CONTROL MODULE (PCM) AND CAUSE FAILURE OF THE PCM. THE PCM CONTROLS MAJOR ENGINE AND BRAKING FUNCTIONS. A COMPLETE FAILURE OF THE PCM WILL CAUSE LOSS OF BRAKING CONTROL (VIA ABS) AND SHUT DOWN OF ENGINE (CAUSING LOSS OF STEERING CONTROL). THERE IS ALSO THE POSSIBILITY OF CAUSING A ELECTRIC SHORT IN THE 12 VOLT CIRCUIT RESULTING IN A FIRE. PLEASE NOTE THAT "AFTER MARKET" MANUFACTURERS REPLACEMENT HOSE IS REDESIGNED TO HELP PREVENT CONTACT BETWEEN A/C PUMP AND THE HOSE. AT THE TIME OF THIS COMPLAINT IT IS UNKNOWN WHETHER THE OEM HOSE HAS BEEN REDESIGN TO PREVENT CONTACT WITH THE A/C PUMP.