NHTSA Complaint #10147402 — 1997 SATURN SL

IGNITION SWITCH FAILED TO START CAR. AFTER A FEW TRIES, THE CAR FINALLY STARTED ONLY TO HAVE MOUNDS OF SMOKE ROLLING OUT FROM UNDER THE DASH. AFTER TURNING THE VEHICLE OFF, THE SWITCH WORKED INTERMITTENTLY. WE REMOVED DASH COVERS AND IGNITION CYLINDER LOCK, AND LOWERED THE STEERING WHEEL TO FIND THAT THE WIRING HARNESS LEADING TO THE IGNITION SWITCH HAD WHAT WAS A BLACK WIRE THAT WAS MELTED BARE FOR A COUPLE INCHES, AND DISFIGURED THE ENTIRE WIRE, AND MELTED THE INSULATION TO OTHER WIRES WITHIN THE HARNESS. JUDGING BY THE DAMAGE OF DONE TO THE WIRE, IT APPEARS THAT THE MOST HEAT WAS IN AN AREA WHERE THE WIRE WAS CLOSEST TO THE STEERING COLUMN, LEADING ONE TO BELIEVE THAT IT WORE THROUGH AND GROUNDED ITSELF TO THE STEERING COLUMN, WHICH LED TO THE OVERHEATING OF THE WIRE AND SUBSEQUENT SMOKE/FIRE. *JB