2004 Saturn Ion
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
Have the VIN?
Vehicles › Saturn › Ion › 2004
These records cover every 2004 Saturn Ion. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
10 recalls name the 2004 Saturn Ion. Newest first.
UCI-FRAM Group is recalling certain LS1328 ignition Switches sold as Wells LS1328, Duralast LS1328, Airtex 1S6097, and Carquest 53-27479, and LS1497 Ignition Switches sold as Wells LS1497, Duralast LS1497, Airtex 1S10961, and Carquest 53-27967, for use on various General Motors model and model year vehicles during repair and replacement of the original…
Risk and remedy
Risk
If the ignition switch moves from the run position to accessory, the car would stall and the air bags will not deploy in the event of a crash, increasing the risk of personal injury to the occupants.
Remedy
UCI-FRAM Group has notified its purchasers to quarantine and return all inventory. Any switches already installed in vehicles will be replaced by GM dealers as part of NHTSA recall 14V-047, free of charge. UCI-Fram's purchasers should contact UCI-FRAM Group at 1-800-890-2075. GM vehicle owners requiring additional information on that recall campaign should contact GM at 1-800-222-1020 (Chevrolet), 1-800-762-2737 (Pontiac) or 1-800-553-6000 (Saturn).
General Motors LLC (GM) is recalling certain model year 2005-2010 Chevrolet Cobalt, 2006-2011 Chevrolet HHR, 2007-2010 Pontiac G5, 2006-2010 Pontiac Solstice, 2003-2007 Saturn Ion, and 2007-2010 Saturn Sky vehicles. In the affected vehicles, the key can be removed from the ignition when the ignition is not in the "Off" position.
Risk and remedy
Risk
If the key can be removed from the ignition when the ignition is not in the "off" position, the vehicle could roll away: (a) for an automatic transmission, if the transmission is not in the "Park" position; or (b) for a manual transmission, if the parking brake is not engaged and the transmission is not in the "Reverse" position. This potential for rollaway increases the risk for a crash and occupant or pedestrian injuries.
Remedy
General Motors will notify owners, and for vehicles that were built with the defective ignition cylinder and have not previously had the ignition cylinder replaced with the redesigned part, dealers will replace the ignition cylinder and cut and, if necessary, re-learn two ignition/door keys for each vehicle. For vehicles that were built with the redesigned ignition cylinder or had the ignition cylinder replaced with the redesigned part, dealers will cut and, if necessary, re-learn two ignition/door keys for each vehicle. The recall began on April 18, 2014. Chevrolet owners may contact General Motors at 1-800-222-1020, Pontiac owners at 1-800-762-2737, and Saturn owners at 1-800-553-6000. General Motors' number for this recall is 14113 for the ignition lock cylinder and key replacement, and 14133 for only key replacements. Note: Until a vehicle has been remedied, owners and operators are advised that when exiting, to be sure that the vehicle is in "Park," or in the case of a manual transmission, that the vehicle is in the "Reverse" position and the parking brake is engaged.
General Motors LLC (GM) is recalling certain model year 2004-2006 and 2008-2009 Chevrolet Malibu, 2004-2006 Malibu Maxx, 2009-2010 HHR (non-turbo), 2010 Cobalt, 2008-2009 Saturn Aura and 2004-2007 Ion, and 2005-2009 Pontiac G6. In the affected vehicles, there may be a sudden loss of electric power steering (EPS) assist that could occur at any time while…
Risk and remedy
Risk
If power steering assist is lost, greater driver effort would be required to steer the vehicle at low speeds, increasing the risk of a crash.
Remedy
GM will notify owners, and dealers will perform one of four bulletins. Parts are not currently available. GM expects to send an interim notification around May 28, 2014. When parts are available, owners will be mailed a second letter to come in to have the applicable bulletin applied. Bulletin 14115 covers model year 2004-2007 Saturn Ion, 2009-2010 Chevrolet HHR and 2010 Chevrolet Cobalts. Dealers will replace the EPS motor. Bulletin 14116 covers model year 2004-2006 Chevrolet Malibu and Malibu Maxx, 2005-2006 Pontiac G6 and 2008-2009 Chevrolet Malibu, Pontiac G6 and Saturn Aura built from March 1, 2008, through June 27, 2008. Dealers will replace the torque sensor assembly. Bulletin 14117 covers model year 2008 Chevrolet Malibu, Pontiac G6 and Saturn Aura built from February 1, 2008, through February 28, 2008. Dealers will replace the torque sensor assembly and EPS motor controller unit. Bulletin 14118 covers model year 2008 Chevrolet Malibu, Pontiac G6 and Saturn Aura built from October 1, 2007, through January 31, 2008. Dealers will replace the EPS motor controller unit. The recall began on July 17, 2014. Owners may contact Chevrolet at 1-800-630-2438, Saturn at 1-800-553-6000, and Pontiac at 1-800-620-7668. GM's number for this recall is N140115. Note: GM bulletin number 14119 will be implemented for model year 2006-2008 and early production of 2009 Chevrolet HHR (non-turbo) and model year 2003 Saturn ION to provide EPS Motor replacement for the life of the vehicle.
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring. General Motors LLC (GM) notified the agency on February 10, 2014 that they are recalling 619,122 model…
Risk and remedy
Risk
If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a crash, increasing the risk of injury.
Remedy
GM will notify owners, and dealers will replace the ignition switch, free of charge. An interim notification was issued to owners of 2007 and earlier models on March 10, 2014, informing them of the safety defect. Owners of 2008 and later vehicles will be mailed an interim letter on April 21, 2014. All affected owners will receive another letter once parts are available. The recall began on April 18, 2014. Owners may contact Chevrolet at 1-800-222-1020, Pontiac at 1-800-762-2737 or Saturn at 1-800-553-6000. GM's number for the initial recall is 13454 and 14063 for the expansion. GMs recall number for the vehicles that may have received the replacement parts is 14092. Note: Until the recall repairs have been performed, it is very important that customers remove all items from their key rings, leaving only the vehicle key. The key fob (if applicable), should also be removed from the key ring. Always wear your seatbelt.
Sabersport IS recalling 16,270 combination corner and bumper lamp assemblies of various part numbers sold for use as aftermarket equipment for various passenger vehicles. these headlamps fail to conform to the requirements of federal motor vehicle safety standard no. 108, "lamps, reflective devices, and associated equipment." these lamps do not contain…
Risk and remedy
Risk
Decreased lighting visibility may result in a vehicle crash.
Remedy
Sabersport will notify owners and offer a full refund for the noncompliant combination lamps. the safety recall began on may 11, 2009. owners may contact sabersport at 1-909-598-7589.
Certain passenger vehicles have a condition in which the turn signal lamp and daytime running lamp (drl) on either front side can stop working because of loss of contact between the bulb and socket.
Risk and remedy
Risk
If a front turn signal lamp IS inoperative, others may react more slowly to a turning vehicle and a crash could occur.
Remedy
Dealers will replace the drl/turn signal bulb on both the left and right front side and inspect for and add a drl jumper kit if not present. the recall began november 17, 2004. owners should contact saturn at 1-800-972-8876.
Certain vehicles equipped with supercharged 2.0L 4-cylinder (lsj) engine were built with a fuel feed pipe that could crack and leak fuel near the fuel rail. If fuel leaks from the fuel feed pipe, there would be a noticeable fuel odor around the vehicle.
Risk and remedy
Risk
Fuel leakage, in the presence of an ignition source, could result in a fire.
Remedy
Dealers will replace the fuel feed pipe assembly. owner notification began on june 9, 2004. owners should contact saturn at 1-800-972-8876.
On certain passenger vehicles, some welds between the passenger's side motor rail and the front bumper bracket do not meet engineering specifications.
Risk and remedy
Risk
Long term durability of the joint may be reduced and separation of the bumper from the frame on the passenger's side of the vehicle may result, increasing the risk of a crash.
Remedy
All vehicles are still in dealer's possessions.
Certain passenger vehicles equipped with 2.2L 4-cylinder (L61) engines were built with a fuel filter that could corrode prematurely on the exterior surface.
Risk and remedy
Risk
If corrosion on the exterior surface of the fuel filter progresses to the point of creating a hole in the shell, fuel droplets could form and drop to the ground. if an ignition source IS present, a fire could result.
Remedy
Dealers will replace the fuel filter assembly. owner notification began on december 30, 2003. owners should contact saturn at 1-800-972-8876.
Certain passenger vehicles fail to comply with the requirements of federal motor vehicle safety standard no. 118, "power-operated window, partition, and roof panel systems." the power windows and/or sunroof may be operable after the ignition has been turned to the "off" position and the front passenger door IS opened.
Risk and remedy
Risk
If unsupervised children are left unattended in the vehicle and operate the power windows or sunroof, there IS an increased risk of injury to the child.
Remedy
Dealers will upgrade the body control module (bcm) calibration. owner notification began on december 30, 2003. owners should contact saturn at 1-800-972-8876.
Owner complaints
898 complaints51 involved a crash4 involved a fire35 injuries3 deaths
What owners report most
Latest complaints
- Steering
The car doesn't always want to release the key. I have to stick my finger up in the column to push the little button to release it which is not convenient at all. It seems to do it if the wheels aren't completely straight. But still even with the steering wheel straight, sometimes it wont come out…
The car doesn't always want to release the key. I have to stick my finger up in the column to push the little button to release it which is not convenient at all. It seems to do it if the wheels aren't completely straight. But still even with the steering wheel straight, sometimes it wont come out if its on a slight hill. Ive had a new key made and it makes no difference, no check engine light and auto technician said the ignition looks fine. Ive read tons of reports like this on the 2004 saturn ion 2-why isn't this being addressed?
- Air bags · Electrical system
The contact owns a 2004 Saturn Ion. The contact stated that while driving at an undisclosed speed, the vehicle stalled. Additionally, the contact stated that the key was stuck in the ignition. The failure was intermittent. The vehicle was taken to the dealer, who replaced the ignition switch and…
The contact owns a 2004 Saturn Ion. The contact stated that while driving at an undisclosed speed, the vehicle stalled. Additionally, the contact stated that the key was stuck in the ignition. The failure was intermittent. The vehicle was taken to the dealer, who replaced the ignition switch and the ignition lock cylinder; however, the failure recurred. The contact stated that while driving at an undisclosed speed, the vehicle stalled. The contact related the failure to NHTSA Campaign Numbers: 14V047000 (Air Bags, Electrical System) and 14V171000 (Electrical System). The manufacturer was made aware of the failure. The failure mileage was approximately 230,000.
- Visibility/wiper
The drivers side windshield wiper linkage failed at the junction of the metal rod and the plastic wiper mount causing the wiper to stop working. And the wiper arms are almost impossible to remove, even with a puller. Obviously this condition is a safety issue, and other GM vehicles have been recalled for the same issue. Why not the 2004 Saturn Ion?
- Air bags
Airbags did not deploy
- Steering
The contact owns a 2004 Saturn Ion. The contact stated while driving at various speeds, excessive force was needed to maneuver the steering wheel on several occasions. The power steering assist warning light was illuminated. The contact stated that he replaced the electric power steering motor…
The contact owns a 2004 Saturn Ion. The contact stated while driving at various speeds, excessive force was needed to maneuver the steering wheel on several occasions. The power steering assist warning light was illuminated. The contact stated that he replaced the electric power steering motor; however, the failure persisted. The vehicle was not taken to a local dealer or independent mechanic for additional diagnostic test or repair. The manufacturer was not made aware of the failure. The failure mileage was unknown.
- Fuel/propulsion system
My car started getting a strong odor of gas. A fuel pipe leak is causing the odor
- Fuel/propulsion system
Hi I am a kind of new owner of an 04 saturn ion, this is actually the second complaint I've filled out. Last July I had a mechanic friend look at my fuel filter and he had said the fuel line needed to be cut off becuase of how rusted on to the original fuel filter I'd got it with was and I didn't…
Hi I am a kind of new owner of an 04 saturn ion, this is actually the second complaint I've filled out. Last July I had a mechanic friend look at my fuel filter and he had said the fuel line needed to be cut off becuase of how rusted on to the original fuel filter I'd got it with was and I didn't believe him so I replace it myself and when I got it off I had cleaned up the metal fuel line the best I could and put a new filter on. Well now it leaks gas right where the hook up is and very strong fuel smells come from there too, I've gotten numerous comments about how un safe that is to be driving it but I need to have a way to work and then someone had mentioned to check for recalls and I seen on there that this car did have a recall for faulty fuel filter gas lines. If you could get back to me as soon as possible about an inspection if needed or whatever else you'd need on my behalf. Please and thank you for your time
- Fuel/propulsion system
Tried taking fuel filter off last july took a whole weekend of using penatrating oil and freeze off then I finally got the tabs to come loose, I thought maybe I messed up the new filter or didnt get enough rust off the fuel line and that's what was causing the strong smell of gas nd poor…
Tried taking fuel filter off last july took a whole weekend of using penatrating oil and freeze off then I finally got the tabs to come loose, I thought maybe I messed up the new filter or didnt get enough rust off the fuel line and that's what was causing the strong smell of gas nd poor performance but changed it again and still that same problem but now theres a leak. The car was on back tire ramps the girl fuel filter change then the 2ND one was done with a hoist and currently this car IS the only thing I can count on to make it to work, thank you for your time and consideration.
- Fuel/propulsion system · Steering
The fuel pump IS leaking, gm refuses to fix it because the vin isn't associated with the recall, but the same year make and model of my car says it has a recall for the fuel system and pump.
- Fuel/propulsion system
Fuel leak on rear driver side when the engine IS running while car IS stationary. It may have happened before the date and mileage stated below but that's when I first noticed the fuel leak.
- Steering
Power steering sticks. I take a 55mph curve and the steering wheel doesn't come back to center. It wants to take me off the roadway.
- Electrical system · Fuel system, gasoline · Steering
TL* the contact owns a 2004 saturn ion. The contact stated that while driving at an undisclosed speed, the vehicle loss power steering without warning. The contact turned off and restarted the vehicle and the vehicle operated as intended. Additionally, the windows rolled up and down independently.…
TL* the contact owns a 2004 saturn ion. The contact stated that while driving at an undisclosed speed, the vehicle loss power steering without warning. The contact turned off and restarted the vehicle and the vehicle operated as intended. Additionally, the windows rolled up and down independently. The contact also stated there was an abnormal fuel outside the vehicle. The vehicle was not taken to be diagnosed. A dealer was not contacted however, the manufacturer was made aware of the failure. The contact was referred to the local dealer to have the vehicle diagnosed. The vehicle was not repaired. The failure mileage was 172,639.
- Steering · Wheels
We have been having trouble removing the key from the ignition the past few days. As I was making a left turn the steering wheel locked then made a loud popping sound. Now the steering wheel just spins in a complete circle and does not turn the wheels. I was in motion in a parking lot.
- Unknown or other
When the key IS in the off position and removed from the car the lights on the dash stay on. car IS parked when this happens.
- Steering
TL* the contact owns a 2004 saturn ion. The contact stated that the power steering assist failed to function as designed intermittently which caused difficulty while attempting to maneuver the vehicle. The vehicle was taken to vera cadillac located at (300 s university dr, pembroke pines, fl 33025…
TL* the contact owns a 2004 saturn ion. The contact stated that the power steering assist failed to function as designed intermittently which caused difficulty while attempting to maneuver the vehicle. The vehicle was taken to vera cadillac located at (300 s university dr, pembroke pines, fl 33025, (954) 417-8998) to be diagnosed. The mechanic was unable to duplicate the failure or retrieve a fault code. The vehicle was not repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 244,000.
- Fuel/propulsion system
It looks like my car IS leaking fuel. Don't know if it's the fuel injector line or fuel pump but I know there IS a recall for this on my car but it's not showing up on my vin number
- Electrical system
When placing the vehicle in park, it will not always register that it IS park; therefore, it will not release the key from the ignition. After multiple attempts of moving the gear shift from drive to park, it will eventually allow the key to be removed from the ignition. It started with just a few days a week, but IS now happening at least one time a day.
- Steering
I recently bought a 2004 saturn ion 1 from a private party. I was not aware that there IS a recall on the the elecrtic power steering assist. The dealer in my area says the recall has expired and they are refusing to fix it. I bought this car may 2019 used every dollar I had to buy it. Im a single…
I recently bought a 2004 saturn ion 1 from a private party. I was not aware that there IS a recall on the the elecrtic power steering assist. The dealer in my area says the recall has expired and they are refusing to fix it. I bought this car may 2019 used every dollar I had to buy it. Im a single mother of 4, I live in a small town there IS nothing for jobs here. I work part time at a fast food resturant and can barley afford to feed my family. I just spent 2000.00 on this car and cant risk driving it now that this IS an issue. I have kids to get back and forth to school and a job to report to everyday I need my car fixed asap.
- Steering
TL* the contact owns a 2004 saturn ion. While driving, the power steering assist warning indicator illuminated and the steering wheel became difficult to turn. The vehicle was driven without power steering ability to the contact's residence. The contact called schumacher chevrolet of denville…
TL* the contact owns a 2004 saturn ion. While driving, the power steering assist warning indicator illuminated and the steering wheel became difficult to turn. The vehicle was driven without power steering ability to the contact's residence. The contact called schumacher chevrolet of denville (located at 281 US-46 e, denville, nj 07834, (973) 644-7584) to schedule an appointment and was informed that the part was not available. The vehicle was not taken to a dealer. The contact stated that the vin was included in nhtsa campaign number: 14v153000 (steering). The manufacturer was not notified of the failure. The approximate failure mileage was 17,800.
- Steering
TL* the contact owns a 2004 saturn ion. The contact received notification of nhtsa campaign number: 14v153000 (steering). While reversing, the check power steering warning message illuminated. The vehicle seized and the engine failed to restart. The vehicle was not diagnosed or repaired. The dealer and manufacturer were not notified. The failure mileage was 147,000.
- Electrical system
TL* the contact owns a 2004 saturn ion. When attempting to start the vehicle, it failed to start. The contact mentioned that the failure was intermittent. The vehicle was towed to an independent mechanic three times and the battery and crank sensor were replaced, but the failure recurred. The…
TL* the contact owns a 2004 saturn ion. When attempting to start the vehicle, it failed to start. The contact mentioned that the failure was intermittent. The vehicle was towed to an independent mechanic three times and the battery and crank sensor were replaced, but the failure recurred. The vehicle was not taken to a dealer or independent mechanic for diagnostic testing. The vehicle was not repaired. The manufacturer was not made aware of the failure. The vin was not provided. The failure mileage was approximately 130,000.
- Steering
The steering wheel just stopped. It stiffened up as if the car was turned off while I was driving nearly causing me to crash. I took the car to the dealership to ask them to consider repairing the problem based upon the fact that there are so many (400,000 saturn ions on the road) complaining of the same problem. GMC told me that since the vehicle has no recall; they could not repair my car.
- Steering · Suspension · Wheels
The power steering stops working while you are driving without notice .when you are truning it IS hard,also the bearing and struts are also very ruff.almost had a wreck when turing
- Steering
While on a neighbor hood driving at approx. 35 mph I steering while was difficult to turn and then locked itself in straight position. it IS parked next to home on city curb side.
- Steering
TL* the contact owns a 2004 saturn ion. While driving various speeds, the power steering suddenly malfunctioned and the steering wheel became very difficult to turn in either direction. In addition, "power steering" displayed on the instrument panel. The failure was not diagnosed or repaired. The manufacturer and local dealer were not notified. The failure mileage was 111,000.
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Electric Power Steering Failure
On March 31, 2014, General Motors Company (GM) submitted a Defect Information Report (DIR) to NHTSA describing a safety defect that may result in a sudden loss of power steering assist in approximately 1,340,447 model year (MY) 2004 through 2010 vehicles equipped with electric power steering (EPS), including 334,728…
On March 31, 2014, General Motors Company (GM) submitted a Defect Information Report (DIR) to NHTSA describing a safety defect that may result in a sudden loss of power steering assist in approximately 1,340,447 model year (MY) 2004 through 2010 vehicles equipped with electric power steering (EPS), including 334,728 MY 2004 through 2007 Saturn ION vehicles that are the subject of EA11-014.GM has assigned the recall number N140115.The NHTSA recall number is 14V-153.According to the DIR, if power steering assist is lost, a message is displayed on the Driver Information Center and a chime sounds to inform the driver.GM indicated that steering control can be maintained in manual (unassisted) steering mode, but would require greater driver effort at low vehicle speeds, which could increase the risk of a crash.Sudden loss of power steering assist can occur in the subject vehicles if the system loses electrical power or whenever the system detects a fault that requires it to enter fail-safe operation mode, removing power from the EPS motor.GM?s DIR identifies three basic conditions that may result in loss of power steering assist in the recalled vehicles:power steering motor faults, torque sensor assembly faults, and power steering motor controller unit faults.GM will issue four service bulletins providing different repair procedures for recalled vehicles.Bulletin 14115 will provide repair instructions for replacing the power steering motor in MY 2004-2007 Saturn ION, 2009-2010 Chevrolet HHR (non-turbo), 2010 Chevrolet Cobalt and vehicles repaired in recall 10V-073 that received repairs prior to May 31, 2010.Bulletin 14116 will provide repair instructions for replacing the torque sensor assembly in MY 2004-2006 Chevrolet Malibu and Malibu Maxx, 2005-2006 Pontiac G6 and 2008-2009 Malibu, Pontiac G6 and Saturn Aura vehicles built from March 1, 2008 through June 27, 2008.Bulletin 14117 will provide repair instructions for replacing the torque sensor assembly and power steering motor controller unit in MY 2008 Malibu, G6 and Aura vehicles built from February 1, 2008 through February 28, 2008.Bulletin 14118 will provide repair instructions for replacing the power steering motor controller unit in MY 2008 Malibu, G6 and Aura vehicles built from October 1, 2007 through January 31, 2008.Analysis of information from all sources identified a total of 4,787 complaints and 30,560 warranty claims related to loss of power steering assist while driving in the MY 2004 through 2007 Saturn ION vehicles, resulting in a complaint rate of 14.3 incidents per thousand vehicles and a warranty claim rate of 9.1 percent.ODI?s analysis of alleged steering related crashes identified 12 with evidence indicating the incident was related to a loss of power steering assist. Two of the crash allegations involved low-speed curb impacts and are excluded from the resume crash count.Three incidents occurred in parking lots, six occurred while turning at street intersections, and one occurred on a highway exit ramp.The crashes in parking lots or intersections all occurred at speeds less than 30 mph.The crash on the highway exit ramp involved impact into a guard rail at approximately 35 mph.Two of the crashes resulted in injuries to the drivers.This investigation is closed.All ODI complaints associated with this closing resume are listed in the attachment pages.
- Electric Power Steering Failure
ODI has received 846 complaints and GM identified 3,489 reports alleging sudden loss of steering power assist in model year (MY) 2004 through 2007 Saturn Ion vehicles manufactured and sold by General Motors Corporation (GM).Sixteen of these complaints alleged that the EPS warning lamp had illuminated before or during…
ODI has received 846 complaints and GM identified 3,489 reports alleging sudden loss of steering power assist in model year (MY) 2004 through 2007 Saturn Ion vehicles manufactured and sold by General Motors Corporation (GM).Sixteen of these complaints alleged that the EPS warning lamp had illuminated before or during the loss of steering assist and the increased steering effort contributed to a crash. Two of the GM crash claims indicated that the driver was injured in the crash. In a previous Preliminary Evaluation PE10-005, ODI investigated the sudden loss of power steering assist in MY 2005 through 2010 Chevrolet Cobalt vehicles. In May 2011, in response to an ODI information request letter for RQ10-004, GM provided ODI with complaint, warranty and EPS system information related to EPS loss of assist for the Saturn ION and Peer vehicles Pontiac G6 and Chevrolet Malibu. In that response, GM indicated that the EPS system used in the subject vehicles was the same as that used in the MY2005 to 2010 Chevrolet Cobalt and Pontiac G5. In March 2010, GM recalled approximately 1.05 million Chevrolet Cobalt and Pontiac G5 vehicles (NHTSA recall no. 10V-073) to correct a defect with the EPS assist motor. The defect identified was described as a buildup of brush debris mixed with oily material on the EPS electric motor armature which causes the motor to stop functioning; the same problem identified in the current subject vehicles.ODI has duplicated this failure in both a Chevrolet Cobalt and Saturn Ion previously tested at the Vehicle Research and Test Center (VRTC). In the defect notification letter for the previously recalled Cobalt and G5 vehicles, GM stated that the vehicles may experience a sudden loss of assist that could occur at any time while driving and that if power steering was lost the vehicle would revert to manual steering mode and would require increased steering effort from the driver.ODI believes that, depending on driving circumstances this increase in steering effort could result in some loss of control and a crash.This investigation has been upgraded to an engineering analysis (EA11-014) to further assess the frequency, scope and safety consequences of a sudden loss of steering assist in the subject vehicles.
- Front turn signal/drl failure
The combination front turn signal/drl in my 2003 saturn ion coupes experienced significant early-life failures due to various bulb quality issues due to inadequate design and manufacture.this problem trend appears to have disappeared after the fall of 2003.the change of lead wire material near the start of my 2004…
The combination front turn signal/drl in my 2003 saturn ion coupes experienced significant early-life failures due to various bulb quality issues due to inadequate design and manufacture.this problem trend appears to have disappeared after the fall of 2003.the change of lead wire material near the start of my 2004 vehicle production appears to have reduced the failure rate for my 2004 saturn ion coupes.although operating temperatures in the subject vehicles' lamp assemblies are below the socket material maximum temperature specification, they are only slightly below the specification.in december 2004, gm reduced the voltage to the lamp assembly in order to reduce the temperature in the assembly of the subject vehicles.warranty claims on the subject vehicles do not indicate an increasing trend over time.warranty claim rate of subject vehicles (excluding early my 2003 claims) IS not significantly higher than other gm vehicles that use combination turn signal/drls.a safety-related defect trend has not been identified at this time.further use of agency resources does not appear to be warranted.accordingly, this investigation IS closed.the closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist.the agency will take further action if warranted by the circumstances.see attached summary report.
- Front turn signal/drl failure
On november 16, 2004, gm notified nhtsa that it will conduct a safety recall of 178,798 model year (my) 2003 and 2004 saturn ion sedan vehicles for inoperative front turn signal/drl bulbs.gm stated that temperatures in the lamp assembly exceed the material specification for the bulb sockets and bulb base sleeves…
On november 16, 2004, gm notified nhtsa that it will conduct a safety recall of 178,798 model year (my) 2003 and 2004 saturn ion sedan vehicles for inoperative front turn signal/drl bulbs.gm stated that temperatures in the lamp assembly exceed the material specification for the bulb sockets and bulb base sleeves, which cause deformation.the deformed sockets can cause loss of bulb and socket contact.the deformed sleeves can cause stress cracks to form on the bulb that can lead to premature bulb failure.the recall remedy IS to replace the front turn signal/drl bulbs and inspect for voltage-reducing jumper (which reduces temperature in lamp assembly) and add if not present.see nhtsa recall no. 04V547 for details.the bulbs for the turn signal/drl in the saturn ion sedan and ion coupe are identical in design and made by the same supplier.but the turn signal/drl sockets, wiring and housing are different in design for the sedan and coupe, and were made by different suppliers.gm's data shows a lower operating temperature for the coupe's lamp assembly that does not exceed the material specification for the bulb socket and the bulb base sleeve.complaint and warranty rate IS also lower for the coupe.however, gm's warranty data shows a continuing trend for the coupe.this preliminary evaluation has been upgraded to an engineering analysis (ea04-035) for further investigation of the my 2003 and 2004 saturn ion coupe vehicles.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 11009156This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and Vehicle Data Recorder tools, giving website address and step by step instructions to complete the update.
- 11007744This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.
- 11007743This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.
- 11007208This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection.
- 11006621Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers.
- 11004557This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.
- 11002312This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information.
- 11000576This Warranty Administration bulletin provides retail and wholesale service personnel with the policies/procedures and the warranty transaction submission procedures that support the Personal Property Damage process.
- 10252735This bulletin provides information for electrical ground repairs using new General Motors replacement fasteners with conductive finish.
- 10252163XM Audio Traffic And Travel Link Availability And Operation.
- 10251890This technical bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up.
- 10250775This service bulletin provides service information to technicians on guidelines to replace Oil Cooler, Oil Cooler Lines and Oil Tank if the engine was replaced where large amounts of debris has flowed throughout the oiling system.
- 10250094Special Coverage Adjustment ? Power Steering Assist
- 10249980This Preliminary Information communication provides information to the technician about vibration complaints that are one of the most challenging complaints to accurately diagnose and repair. Technician will need to use Pico Oscilloscope Diagnostic Kit to effectively diagnosis vehicles. Technician should drive the vehicle will using the Pico Oscilloscope to record data. After the data is recorded it should be reviewed to determine the root cause of the concern. If a repair attempt made the concern better but not eliminated or had no affect at all, and are requesting assistance from General Motors Technical Assistance Center record another Pico file and save it to the computer. After the new Pico Oscilloscope data has been saved email the data to General Motors Technical Assistance Center in the subject line include ?Vibration? ?Business Associate Code? and the last 8 of the Vehicle Identification Number.
- 10249579This PI bulletin advises the technician on the proper way to install the pistons in an engine.
- 10249011This informational bulletin provides information for dealers/technicians on Headlamp, Tail Lamp, License Lamp or Fog/Driving Lamp Damage.
- 10248444Vehicle Recalls
- 10247780This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.
- 10247681Information On Requests To Add OnStar Bluetooth Option.
- 10247336Replace Ignition Key
- 10247335Replace Ignition Key
- 10247334Replace Ignition Key
- 10247333Replace Ignition Key
- 10247332Replace Ignition Key
- 10247317Electric Power Steering Assist
- 10247316Electric Power Steering Assist
- 10247315Electric Power Steering Assist
- 10247313Replace Ignition Lock Cylinder and Ignition Key
- 10247312Replace Ignition Lock Cylinder and Ignition Key
- 10247311Replace Ignition Lock Cylinder and Ignition Key
- 10247310Replace Ignition Lock Cylinder and Ignition Key
- 10247309Replace Ignition Lock Cylinder and Ignition Key
- 10247279Ignition Switch Replacement
- 10247278Ignition Switch Replacement
- 10247277Ignition Switch Replacement
- 10247276Ignition Switch Replacement
- 10247228Special Coverage Adjustment ? Unable to Remove Ignition Key
- 10246952Programming And Activation Of Replacement OnStar Modules.
- 10246951Programming And Activation Of Replacement OnStar Modules.
- 10246631Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules
Every Saturn Ion model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.