NHTSA Complaint #11013448 — 2006 SATURN VUE

ON THE FIRST START OF THE DAY, AT OR BELOW 24 DEGREES F, THE INTERIOR ITEMS FLASH ON AND OFF UNTIL THE ELECTRICAL SYSTEM WARMED UP. I ALSO LEARNED THAT IF THE IGNITION WAS ON FOR ABOUT 3 MINUTES IT WAS THE SAME AS IF IT WAS RUNNING. I LIVE IN NASHVILLE AND FOR THE LAST 3 YEARS IT ONLY OCCURRED WHEN THE OUTSIDE TEMP WAS 24 DEGREES OR BELOW. THE FLASHING ON AND OFF OF THE LIGHTS AND EQUIPMENT IS THE BODY CONTROL MODULE PROTECTING THEM WHEN THE CHARGE RATE IS TOO HIGH. IT WAS CONSIDERED AN INTERMITTENT PROBLEM AND WHO CAN TROUBLESHOOT AT OR BELOW 24 DEGREES? A MONTH AGO (JULY) IT STARTED ALL THE TIME, NO FLASHING, NO STEERING, NO DASH INSTRUMENTS, ETC. LONGER STORY SHORT WITH THE PLUG REMOVED FROM THE ALTERNATOR (IT CONTROLS THE FIELD VOLTAGE THROUGH THE ECM/PCM) THE ALTERNATOR WAS STILL PUTTING OUT 18.5 VOLTS. THIS DEFINITELY SHOULD NOT OCCUR BUT SOMETHING WAS BAD WRONG INSIDE THE ALTERNATOR. IT WAS BOILING THE ACID OUT OF THE BATTERY TOO. ONCE THE ALTERNATOR WAS REMOVED (BENCH CHECKED FAILED) AND REPLACED IT ALL WENT AWAY. IT WILL BE INTERESTING TO SEE WHAT HAPPENS WHEN THE WEATHER GETS BELOW 24 DEGREES AGAIN. THIS ALTERNATOR IS MANUFACTURED BY GM, IS DISCONTINUED AND NO LONGER AVAILABLE FROM GM. ONLY REMANUFACTURED UNITS FROM CHINA ARE AVAILABLE AT THE AFTERMARKET PARTS STORES. THERE IS NO TROUBLESHOOTING PROCEDURE IN THE MAINTENANCE MANUAL FOR THIS PROBLEM. THE ALTERNATOR PLUG CAN BE DISCONNECTED WITHOUT ANY DISASSEMBLY. THIS WAS THE SECOND FAILURE OF THE ALTERNATOR ON THIS VUE THE FIRST OCCURRED AT 87,000 MILES. IT SEEMS THERE IS A DESIGN FLAW IN THE COMPONENTS OF THIS ALTERNATOR.