Chronic failure of GM pn# 90566947 causing loss of coolant and possible fire damage due to proximity of exhaust manifold and catalytic converter. There have been 3 replacements in 62,580 miles. The first @ 16,586 miles, second @ 34,503 miles, and the latest at 62,580 miles. The leaks begin as an odor of coolant, then spots begin on the pavement, then finally the coolant reservoir empties itself. The valve is located at the rear of the engine block up against the firewall, and adjacent to the exhaust pipe on the passenger side. The part has been replaced all 3 times, once under warranty and twice at my expense. GM refuses to acknowledge a design problem, even though this is not a maintenance part. It is constructed from plastic and does not withstand the hot environment of the application. It is used on the 3 litre 6 cylinder engine of the Cadillac Catera and cts, and the Saab 9-5. dealer use records show a very high incidence of failure even though there are not that many vehicles using this engine. There is a possibility of fire due to the coolant spraying on the catalytic converter when moving, as well as disabling the engine due to the loss of coolant.

- Calera, AL, USA

The purpose of this memo is to request NHTSA to evaluate and take appropriate action to have the manufacturer correct design defect in the hot water valve of the 2001 Cadillac Catera cooling system. Recently the hot water valve, fp number 90566947, in the cooling system of my 2001 Catera failed for the second time. The first failure occurred in 2005 with less than 50,000 miles on the car and was repaired under warranty. The second failure occurred last month with less than 75,000 miles on the car and was repaired at my expense. Both repairs were performed by val ward Cadillac, fort myers, Florida, where I purchased the vehicle. I have owned many cars, including four General Motors (GM) cars, and this cooling system problem has never occurred on any of them. On June 5, 2007 I sent a letter to GM asking that they issue a recall of the 2001 Catera to correct this design defect. I was advised, via a telephone call from Ms. Jolene blazukiewicz, in their executive office, that GM does not believe this is a design defect or safety hazard and no recall has been issued. She went on to say the failed part is made of plastic, as though this was a reason for the failure. I suggested they may want to consider making the part from a stronger material, she said she would forward my letter to the design department. I live in a relatively rural part of central Florida and sudden loss of cooling fluid on a road far from a town or service station, could present a very real and significant safety hazard and result in severe engine damage. The fact that this valve has now failed twice indicates it is a design defect. It would seem appropriate for General Motors to issue a recall and replace the valve with a more robust part. I therefore request the NHTSA to evaluate the problem and, if appropriate, direct GM to issue a recall for the replacement of the defective part. Sincerely, torsten rothman

- Lake Placid, FL, USA

On 8/20/05, I have filed a complaint (file # 1-357-445-124) with Cadillac customer relations, in order to request full reimbursement for repair of two safety-related issues and one service-related issue that have come to my knowledge recently. I believe these issues did not happened overnight and have been developing prior to the expiring of the warranty in December 2004. Car has only 35K miles and is driven avg of 4K miles per year. Complaint is as follows: 1) defective original factory chrome rims: As per tires plus and lindsay Cadillac service shop technicians, the chrome is peeling from inside rim, causing tires to constantly lose air (deflate), which at any time may be a hazard to my safety, as well as for other passengers). I have asked Cadillac to repair/replace 4 rims; 2) defective car jack: Although not previously used, on 8/19/05 the new jack slid and bended when I used it according to instructions to replace a flat tire, almost causing personal injury and car damage). I have asked Cadillac to replace defective jack; and, 3) leaking engine coolant: According to lindsay's Cadillac dealership diagnosis, engine coolant is leaking through water heater control valve (as per archives from www.cadillacforums.com, this seems to be a known and recurring issue reported by Cadillac Catera owners, and should be addressed under Cadillac's warranty and they should assume the cost of repairs). Cadillac pressured me over the phone to take 50% cost assistance on repairs (approx $3,500 estimated), and when I refused, offer was withdrawn from the table. I complained that process was not transparent, and when I requested that Cadillac's offer and claim information be in writing, representative refused to provide me with copies of case file.

- Alexandria, VA, USA

There was a recall regarding a defective water pump, timing belt and engine pulley, however the dealer only replaced the water pump.

- Williamsburg, VA, USA