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2003 Saturn Ion

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2003 Saturn Ion do not stand out strongly from the model-year median of 816.5.

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When problems were reported

Mileage at the reported incident

553 reports with mileage · 204 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Electrical System. Review the 382 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Steering. Review the 139 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 58 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

43 crash reports4 fire reports22 injury reports

Electrical System complaints

382 reports
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21,223 miles · Feb 15, 2007
Electrical System

2003 SATURN ION-3 FAILS TO START IN COLD WEATHER. THIS APPEARS TO BE A KNOWN MANUFACTURER DEFECT IN THE IGNITION SWITCH. (REFERENCE SATURN TSB 040845005 OF NOV 2005 OR NHTSA 10007431 OF MARCH 2006). IT APPEARS THAT SATURN IS COUNTING ON WARM WINTERS TO GET THE CARS OUT OF THE WARRANTY PERIOD (WHICH HAPPENED TO ME) AND THEN HIT …

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2003 SATURN ION-3 FAILS TO START IN COLD WEATHER. THIS APPEARS TO BE A KNOWN MANUFACTURER DEFECT IN THE IGNITION SWITCH. (REFERENCE SATURN TSB 040845005 OF NOV 2005 OR NHTSA 10007431 OF MARCH 2006). IT APPEARS THAT SATURN IS COUNTING ON WARM WINTERS TO GET THE CARS OUT OF THE WARRANTY PERIOD (WHICH HAPPENED TO ME) AND THEN HIT YOU WITH A $40 PART AND $156 LABOR CHARGE TO FIX AN ITEM THEY MIS-MANUFACTURED. *NM

NHTSA ODI #10182712

36,000 miles · Feb 15, 2007
Electrical System

MY SATURN ION (2003) HAS HAD A LOT OF PROBLEMS THIS WINTER WITH INTERMITTENT STARTS. I TRY TO START THE CAR IN THE MORNING, AND IT JUST WON'T CRANK OVER. I HAVE MISSED WORK, AND BEEN STRANDED IN THE FREEZING COLD. A RECALL NEEDS TO BE ISSUED ON THE STARTER SWITCH. I HAVE HAD MULTIPLE DIAGNOSTIC TESTS DONE, AND HAD THE BATTERY RE…

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MY SATURN ION (2003) HAS HAD A LOT OF PROBLEMS THIS WINTER WITH INTERMITTENT STARTS. I TRY TO START THE CAR IN THE MORNING, AND IT JUST WON'T CRANK OVER. I HAVE MISSED WORK, AND BEEN STRANDED IN THE FREEZING COLD. A RECALL NEEDS TO BE ISSUED ON THE STARTER SWITCH. I HAVE HAD MULTIPLE DIAGNOSTIC TESTS DONE, AND HAD THE BATTERY REPLACED. I CANNOT AFFORD A $200 REPAIR ON SOMETHING THAT SHOULD BE REPLACED BY SATURN. THIS IS A CASE OF NEGLIGENCE. *JB

NHTSA ODI #10182640

23,000 miles · Feb 14, 2007
Electrical System

WHEN MY 2003 SATURN ION IS IN WEATHER THAT IS 32 DEGREES OR UNDER, THE GREASE IN THE IGNITION FREEZES THUS TRIGGERING THE SECURITY SYSTEM TO LOCK THE CAR DOWN FOR A PERIOD OF 15 MINUTES. THIS HAS HAPPENED MORE THAN ONE TIME DURING THIS WINTER SEASON. HAD I BEEN WITH A SMALL CHILD OR ELDERLY ADULT THIS COULD HAVE BEEN A SERIOUS…

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WHEN MY 2003 SATURN ION IS IN WEATHER THAT IS 32 DEGREES OR UNDER, THE GREASE IN THE IGNITION FREEZES THUS TRIGGERING THE SECURITY SYSTEM TO LOCK THE CAR DOWN FOR A PERIOD OF 15 MINUTES. THIS HAS HAPPENED MORE THAN ONE TIME DURING THIS WINTER SEASON. HAD I BEEN WITH A SMALL CHILD OR ELDERLY ADULT THIS COULD HAVE BEEN A SERIOUS EVENT. SATURN IS MORE THAN AWARE OF THIS SITUATION CLAIMING THE FIX DOZENS OF CARS A WEEK AT 200+ A POP. THIS IS A DOCUMENTED PROBLEM WITH SATURN AT THE DEALERSHIP AND AT THE CORPORATE LEVEL. THEIR CORPORATE OFFICE SAID THE ONLY WAY THEY WOULD DO A RECALL ON THIS PART IS IF PEOPLE WOULD FILE THE CLAIM ON THIS SITE. *JB

NHTSA ODI #10182577

Mileage unknown · Feb 13, 2007
Electrical System

THE IGNITION SWITCH FREQUENTLY FAILS TO MOVE INTO THE LOCKED POSITION AFTER THE ENGINE IS TURNED OFF. THIS REQUIRES REPETITIONS OF STARTING AND STOPPING THE ENGINE. THE DEALER FAILED TO CORRECT THE PROBLEM. *JB

NHTSA ODI #10182428

80,000 miles · Feb 12, 2007
Electrical System

CAR ROUTINELY WILL NOT START IN COLD WEATHER DUE TO FAULTY IGNITION SWITCH. A NEW IGNITION SWITCH MUST BE INSTALLED AND IS NOT COVERED UNDER WARRANTY. *JB

NHTSA ODI #10182420

72,000 miles · Feb 12, 2007
Electrical System

FOR THE PAST FEW MONTHS ANY TIME THERE IS COLD WEATHER, WHICH HAS BEEN EVERY DAY BECAUSE IT'S THE WINTER, MY 2003 SATURN ION 2 WON'T START FOR ABOUT 20-30 MINUTES. I TOOK IT TO A LOCAL SHOP AND HAD SOME WORK DONE; FUEL INJECTION CLEANING, SPARK PLUGS REPLACED, ETC. THE PROBLEM STILL CONTINUED AND I TOOK IT BACK. THE CAR START…

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FOR THE PAST FEW MONTHS ANY TIME THERE IS COLD WEATHER, WHICH HAS BEEN EVERY DAY BECAUSE IT'S THE WINTER, MY 2003 SATURN ION 2 WON'T START FOR ABOUT 20-30 MINUTES. I TOOK IT TO A LOCAL SHOP AND HAD SOME WORK DONE; FUEL INJECTION CLEANING, SPARK PLUGS REPLACED, ETC. THE PROBLEM STILL CONTINUED AND I TOOK IT BACK. THE CAR STARTED FINE AND FOR THE NEXT FEW DAYS WHILE WE WERE HAVING MILD WEATHER I HAD NO PROBLEMS. AS SOON AS THE WEATHER HIT 30 DEGREES IT STARTED AGAIN. WHEN I GO TO START THE CAR IT TURNS OVER BUT THEN DIES. 5 OR SO MORE TIMES AND IT AGAIN TRIES TO TURN OVER BUT NOTHING. EVENTUALLY AFTER 20 MINUTES OR SO THE CAR WILL START. THE BATTERY HAS BEEN REPLACED BECAUSE THAT'S WHAT WE FIRST THOUGHT WAS THE PROBLEM EVEN THOUGH IT DID NOT NEED TO BE REPLACED. WE'RE NOW OUT $100 FOR THAT PLUS THE WORK I'VE HAD DONE THAT DID NOT SOLVE THE PROBLEM. I CALLED SATURN AND THEY TOLD ME THAT THEY HAVE NEVER HEARD OF THIS, THAT THIS HAS NOT BEEN ISSUED INTO A RECALL AND THAT THEY WOULD NEED TO HOOK MY CAR UP TO THE COMPUTER FOR $100 JUST TO TELL ME WHAT THE PROBLEM IS. I SEARCHED ONLINE FOR THIS PARTICULAR PROBLEM AND FOUND THOUSANDS OF POSTS AND THAT THE PROBLEM IS THE "IGNITION SWITCH", BUT SOME PEOPLE WILL STILL HAVING PROBLEMS EVEN AFTER THAT WAS REPLACED. JUST THIS WEEKEND I WENT TO WORK AND CAME OUT TO START MY CAR AT 9:20 AND BY 10:00 THE CAR STILL WOULD NOT START AND I HAD TO FIND A RIDE HOME. I HAVE TWO YOUNG CHILDREN AND AM SCARED TO LEAVE THE HOUSE WITH THEM IN FEAR THAT MY CAR WON'T START WHEN I GET TO OR NEED TO LEAVE MY DESTINATION. I FEEL THAT THIS PROBLEM NEEDS TO BE ISSUED AS A RECALL OR LIKE MANY OTHERS "I WILL NOT BE BUYING ANOTHER SATURN". *JB

NHTSA ODI #10182403

Mileage unknown · Feb 12, 2007
Electrical System

MY CAR WAS HAVING PROBLEMS STARTING IN THE COLD WEATHER, IT WOULD ALMOST START THEN NOTHING WOULD HAPPEN. IT WOULD TAKE ABOUT 15 MINUTES OF TRYING BEFORE IT WOULD START UP. ALSO THE SERVICE VEHICLE MESSAGE WOULD FLASH AND VARIOUS LIGHTS ON THE DASH WOULD FLASH ALSO. I TOOK IT IN FOR SERVICING AT THE SATURN DEALER WHERE THEY CHAR…

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MY CAR WAS HAVING PROBLEMS STARTING IN THE COLD WEATHER, IT WOULD ALMOST START THEN NOTHING WOULD HAPPEN. IT WOULD TAKE ABOUT 15 MINUTES OF TRYING BEFORE IT WOULD START UP. ALSO THE SERVICE VEHICLE MESSAGE WOULD FLASH AND VARIOUS LIGHTS ON THE DASH WOULD FLASH ALSO. I TOOK IT IN FOR SERVICING AT THE SATURN DEALER WHERE THEY CHARGED ME 200 DOLLARS TO DIAGNOSE AND FIX THE PROBLEM WHICH ENDED UP BEING THE IGNITION SWITCH. *NM

NHTSA ODI #10182327

56,000 miles · Feb 12, 2007
Electrical System

I HAVE A 2003 SATURN ION 2, AND IT HAS HAD INTERMITTENT STARTING PROBLEMS SINCE 2004. I ALWAYS THOUGHT IT WAS THE BATTERY, BUT I WOULD CHANGE THE BATTERY AND TEST THE OLD ONE, AND IT ALWAYS TESTED FINE. ONCE THE WEATHER GOT COLD THIS WINTER, IT STARTED HAVING MORE FREQUENT STARTING PROBLEMS. SOMETIMES IT WOULD START AFTER WAIT…

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I HAVE A 2003 SATURN ION 2, AND IT HAS HAD INTERMITTENT STARTING PROBLEMS SINCE 2004. I ALWAYS THOUGHT IT WAS THE BATTERY, BUT I WOULD CHANGE THE BATTERY AND TEST THE OLD ONE, AND IT ALWAYS TESTED FINE. ONCE THE WEATHER GOT COLD THIS WINTER, IT STARTED HAVING MORE FREQUENT STARTING PROBLEMS. SOMETIMES IT WOULD START AFTER WAITING 20-30 MINUTES. LAST WKEND, I WAS UNABLE TO START IT AT ALL AND HAD TO HAVE IT TOWED. I WAS LUCKY TO HAVE IT AT A FRIEND'S HOUSE WHEN THIS HAPPENED. THE IGNITION SWITCH IS BEING REPLACED, SINCE THE DEALER SAYS THIS IS A VERY FREQUENT PROBLEM. PLEASE RECALL THESE IGNITION SWITCHES! SO MANY PEOPLE HAVE PROBLEMS WITH THEM - CHECK THE INTERNET! JUST TYPE IN '2003 SATURN ION STARTING PROBLEMS' IN GOOGLE AND YOU'LL SEE MANY SITES COME UP WITH PEOPLE IN THE LAST MONTH ALONE HAVING THE SAME ISSUES. COSTS ABOUT 200 BUCKS TO FIX, AND THAT'S RIDICULOUS IF SATURN KNOWS THERE'S AN ISSUE. *NM

NHTSA ODI #10182304

46,300 miles · Feb 9, 2007
Electrical System

IN COLD TEMPERATURES MY 2003 SATURN ION 2 WOULD NOT START. ALL OF MY LIGHTS WOULD COME ON BUT WHEN I ATTEMPTED TO START THE CAR THE SECURITY LIGHT WOULD COME ON AND I WOULD BE LOCKED OUT OF STARTING MY CAR FOR THE NEXT 8-10 MINUTES DUE TO A FAULTY IGNITION SWITCH. I TOOK MY CAR TO THE DEALERSHIP THAT I PURCHASED IT FROM AND COD…

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IN COLD TEMPERATURES MY 2003 SATURN ION 2 WOULD NOT START. ALL OF MY LIGHTS WOULD COME ON BUT WHEN I ATTEMPTED TO START THE CAR THE SECURITY LIGHT WOULD COME ON AND I WOULD BE LOCKED OUT OF STARTING MY CAR FOR THE NEXT 8-10 MINUTES DUE TO A FAULTY IGNITION SWITCH. I TOOK MY CAR TO THE DEALERSHIP THAT I PURCHASED IT FROM AND CODES B2930 B3033 WERE FOUND IN THE SYSTEM. THE IGNITION SWITCH SN 10392423 WAS REPLACED. THE OLD PART WAS KEPT BY SATURN. *JB

NHTSA ODI #10182076

75,000 miles · Feb 8, 2007
Electrical System

FREQUENT INABILITY TO START VEHICLE DUE TO IGNITION CYLINDER WEAR. SATURN CLAIMS SECURITY SYSTEM IS ACTIVATED DUE TO INTERNAL IGNITION SWITCH NOT BEING ABLE TO "READ" CHIP IN SATURN VEHICLE KEY. FAILURE OF SUCH PROCESS RESULTS IN OPERATOR OF VEHICLE HAVING TO WAIT UNTIL SECURITY SYSTEM "RESETS" (10-15 MINS.) SATURN WILL NOT HO…

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FREQUENT INABILITY TO START VEHICLE DUE TO IGNITION CYLINDER WEAR. SATURN CLAIMS SECURITY SYSTEM IS ACTIVATED DUE TO INTERNAL IGNITION SWITCH NOT BEING ABLE TO "READ" CHIP IN SATURN VEHICLE KEY. FAILURE OF SUCH PROCESS RESULTS IN OPERATOR OF VEHICLE HAVING TO WAIT UNTIL SECURITY SYSTEM "RESETS" (10-15 MINS.) SATURN WILL NOT HONOR THE FACT THAT THIS MAY BE A DESIGN FLAW, AND HOLDS OWNER RESPONSIBLE FOR $200 REPAIR. THIS OWNER IS JUST GLAD THE STEERING WHEEL HASN'T FALLEN OFF THE DASHBOARD YET. GOOD CAR ! *JB

NHTSA ODI #10182043

Official recalls

5

14V171000 · Electrical System:ignition

Apr 10, 2014

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.

Consequence & remedy

Consequence: 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.

14V047000 · Air Bags; Electrical System:ignition:switch

Feb 10, 2014

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 year 2005-2007 Chevrolet Cobalt, and 2007 Pontiac G5 vehicles. On February 25, 2014, GM increased the recall to include an additional 748,024 model year 2006-2007 Chevrolet HHR and Pontiac Solstice vehicles and 2003-2007 Saturn Ion vehicles and 2007 Saturn Sky vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine. On March 27, 2014, GM notified the agency that the defective ignition switches may have been used as service replacement parts on other vehicles, and as a result GM will be recalling certain model year 2008-2010 Chevrolet Cobalt, Saturn Sky, and Pontiac G5 and Solstice, and 2008-2011 Chevrolet HHR vehicles. The part numbers for the service parts are 10392423 (a/k/a ACDelco D1461F), 10392737, 15857948, 15854953, 15896640, and 25846762. This expansion represents an additional 823,788 vehicles.

Consequence & remedy

Consequence: 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. GM’s 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.

Additional source detail variants (2)

Air Bags

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 year 2005-2007 Chevrolet Cobalt, and 2007 Pontiac G5 vehicles. On February 25, 2014, GM increased the recall to include an additional 748,024 model year 2006-2007 Chevrolet HHR and Pontiac Solstice vehicles and 2003-2007 Saturn Ion vehicles and 2007 Saturn Sky vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine. On March 27, 2014, GM notified the agency that the defective ignition switches may have been used as service replacement parts on other vehicles, and as a result GM will be recalling certain model year 2008-2010 Chevrolet Cobalt, Saturn Sky, and Pontiac G5 and Solstice, and 2008-2011 Chevrolet HHR vehicles. The part numbers for the service parts are 10392423 (a/k/a ACDelco D1461F), 10392737, 15857948, 15854953, 15896640, and 25846762. This expansion represents an additional 823,788 vehicles.

Consequence: 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. GM’s 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.

Electrical System:ignition:switch

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 year 2005-2007 Chevrolet Cobalt, and 2007 Pontiac G5 vehicles. On February 25, 2014, GM increased the recall to include an additional 748,024 model year 2006-2007 Chevrolet HHR and Pontiac Solstice vehicles and 2003-2007 Saturn Ion vehicles and 2007 Saturn Sky vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine. On March 27, 2014, GM notified the agency that the defective ignition switches may have been used as service replacement parts on other vehicles, and as a result GM will be recalling certain model year 2008-2010 Chevrolet Cobalt, Saturn Sky, and Pontiac G5 and Solstice, and 2008-2011 Chevrolet HHR vehicles. The part numbers for the service parts are 10392423 (a/k/a ACDelco D1461F), 10392737, 15857948, 15854953, 15896640, and 25846762. This expansion represents an additional 823,788 vehicles.

Consequence: 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. GM’s 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.

04V547000 · Exterior Lighting:turn Signal

Nov 16, 2004

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.

Consequence & remedy

Consequence: 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.

04V003000 · Fuel System, Gasoline

Jan 5, 2004

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.

Consequence & remedy

Consequence: 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.

04V004000 · Visibility:power Window Devices And Controls

Jan 5, 2004

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.

Consequence & remedy

Consequence: 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.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

5

PE07011 · Windshied Wiper Linkage Failure

Opened Feb 28, 2007 · Closed Aug 9, 2007

Status: closed (inferred from source dates) · Visibility:windshield Wiper/washer; Visibility:windshield Wiper/washer:linkages

INVESTIGATION DISCLOSED THAT THE MANUFACTURER ISSUED A SERVICE BULLETIN IN AUGUST 2003, REGARDING SERVICE THAT REQUIRED REMOVAL OF THE WIPER ARMS.GM ISSUED THE BULLETIN AT THAT TIME TO ADDRESS CUSTOMER COMMENTS ON WINDSHIELD WIPER CHATTERING OR HOPPING ACROSS THE WINDSHIELD DURING WIPER OPERATION.THE CORRECTION WAS TO REPLACE THE WIPER ARM AND BLADE.HOWEVER, THE BULLETIN DID NOT PLACE SPECIFIC EMPHASIS ON THE IMPORTANCE OF USING THE PROPER TOOL AND PROCEDURES TO REMOVE THE WIPER ARM AND TO PREVENT DAMAGE TO THE PIVOT SHAFT HOUSING.IN GM'S RESPONSE TO ODI'S INFORMATION REQUEST LETTER, GM STATES, ...THE WIPER PIVOT HOUSING IN THE SUBJECT VEHICLE MAY CRACK AND/OR FRACTURE AS A RESULT OF AN OVERLOAD CONDITION APPLIED TO THE WIPER PIVOT HOUSING DURING IMPROPER REMOVAL OF THE WIPER ARMS.GM'S FIELD SURVEY FOUND THAT ...DEALERS DO NOT ROUTINELY USE THE WIPER ARM REMOVAL TOOL WHEN SERVICING THE WIPER ARMS.ODI CONCLUDES THAT THE FAILURE AND WARRANTY REPORTS IN THIS INVESTIGATION DO NOT IDENTIFY A SAFETY RELATED DEFECT TREND.ODI DOES HAVE CONCERN, HOWEVER, THAT PRIOR AND IMPROPERLY PERFORMED WIPER ARM REMOVAL MAY HAVE CONTRIBUTED TO THE FAILURES IDENTIFIED DURING THIS INVESTIGATION.IN AUGUST 2007, GM ISSUED A NEW TECHNICAL SERVICE BULLETIN (GM NUMBER 07-08-43-007) TO SPECIFICALLY EMPHASIZE THE IMPORTANCE OF USING THE PROPER TOOL FOR REMOVAL OF THE WIPER ARMS TO PREVENT PIVOT SHAFT DAMAGE DURING THE PROCEDURE.THIS INVESTIGATION IS CLOSED.

Additional source detail variants (2)

Visibility:windshield Wiper/washer

INVESTIGATION DISCLOSED THAT THE MANUFACTURER ISSUED A SERVICE BULLETIN IN AUGUST 2003, REGARDING SERVICE THAT REQUIRED REMOVAL OF THE WIPER ARMS.GM ISSUED THE BULLETIN AT THAT TIME TO ADDRESS CUSTOMER COMMENTS ON WINDSHIELD WIPER CHATTERING OR HOPPING ACROSS THE WINDSHIELD DURING WIPER OPERATION.THE CORRECTION WAS TO REPLACE THE WIPER ARM AND BLADE.HOWEVER, THE BULLETIN DID NOT PLACE SPECIFIC EMPHASIS ON THE IMPORTANCE OF USING THE PROPER TOOL AND PROCEDURES TO REMOVE THE WIPER ARM AND TO PREVENT DAMAGE TO THE PIVOT SHAFT HOUSING.IN GM'S RESPONSE TO ODI'S INFORMATION REQUEST LETTER, GM STATES, ...THE WIPER PIVOT HOUSING IN THE SUBJECT VEHICLE MAY CRACK AND/OR FRACTURE AS A RESULT OF AN OVERLOAD CONDITION APPLIED TO THE WIPER PIVOT HOUSING DURING IMPROPER REMOVAL OF THE WIPER ARMS.GM'S FIELD SURVEY FOUND THAT ...DEALERS DO NOT ROUTINELY USE THE WIPER ARM REMOVAL TOOL WHEN SERVICING THE WIPER ARMS.ODI CONCLUDES THAT THE FAILURE AND WARRANTY REPORTS IN THIS INVESTIGATION DO NOT IDENTIFY A SAFETY RELATED DEFECT TREND.ODI DOES HAVE CONCERN, HOWEVER, THAT PRIOR AND IMPROPERLY PERFORMED WIPER ARM REMOVAL MAY HAVE CONTRIBUTED TO THE FAILURES IDENTIFIED DURING THIS INVESTIGATION.IN AUGUST 2007, GM ISSUED A NEW TECHNICAL SERVICE BULLETIN (GM NUMBER 07-08-43-007) TO SPECIFICALLY EMPHASIZE THE IMPORTANCE OF USING THE PROPER TOOL FOR REMOVAL OF THE WIPER ARMS TO PREVENT PIVOT SHAFT DAMAGE DURING THE PROCEDURE.THIS INVESTIGATION IS CLOSED.

Visibility:windshield Wiper/washer:linkages

INVESTIGATION DISCLOSED THAT THE MANUFACTURER ISSUED A SERVICE BULLETIN IN AUGUST 2003, REGARDING SERVICE THAT REQUIRED REMOVAL OF THE WIPER ARMS.GM ISSUED THE BULLETIN AT THAT TIME TO ADDRESS CUSTOMER COMMENTS ON WINDSHIELD WIPER CHATTERING OR HOPPING ACROSS THE WINDSHIELD DURING WIPER OPERATION.THE CORRECTION WAS TO REPLACE THE WIPER ARM AND BLADE.HOWEVER, THE BULLETIN DID NOT PLACE SPECIFIC EMPHASIS ON THE IMPORTANCE OF USING THE PROPER TOOL AND PROCEDURES TO REMOVE THE WIPER ARM AND TO PREVENT DAMAGE TO THE PIVOT SHAFT HOUSING.IN GM'S RESPONSE TO ODI'S INFORMATION REQUEST LETTER, GM STATES, ...THE WIPER PIVOT HOUSING IN THE SUBJECT VEHICLE MAY CRACK AND/OR FRACTURE AS A RESULT OF AN OVERLOAD CONDITION APPLIED TO THE WIPER PIVOT HOUSING DURING IMPROPER REMOVAL OF THE WIPER ARMS.GM'S FIELD SURVEY FOUND THAT ...DEALERS DO NOT ROUTINELY USE THE WIPER ARM REMOVAL TOOL WHEN SERVICING THE WIPER ARMS.ODI CONCLUDES THAT THE FAILURE AND WARRANTY REPORTS IN THIS INVESTIGATION DO NOT IDENTIFY A SAFETY RELATED DEFECT TREND.ODI DOES HAVE CONCERN, HOWEVER, THAT PRIOR AND IMPROPERLY PERFORMED WIPER ARM REMOVAL MAY HAVE CONTRIBUTED TO THE FAILURES IDENTIFIED DURING THIS INVESTIGATION.IN AUGUST 2007, GM ISSUED A NEW TECHNICAL SERVICE BULLETIN (GM NUMBER 07-08-43-007) TO SPECIFICALLY EMPHASIZE THE IMPORTANCE OF USING THE PROPER TOOL FOR REMOVAL OF THE WIPER ARMS TO PREVENT PIVOT SHAFT DAMAGE DURING THE PROCEDURE.THIS INVESTIGATION IS CLOSED.

PE06006 · Timing Chain Failure

Opened Jan 24, 2006 · Closed Jun 6, 2006

Status: closed (inferred from source dates) · Engine And Engine Cooling

ON DECEMBER 12, 2005, ODI RECEIVED A DEFECT PETITION (DP05-008) REQUESTING THE INVESTIGATION OF TIMING CHAIN FAILURES THAT COULD CAUSE STALLING IN SATURN VEHICLES EQUIPPED WITH THE 2.2L (L61) ENGINE. ODI OPENED PE06-006 ON JANUARY 24, 2006, WITH 24 VEHICLE OWNER COMPLAINTS THAT ALLEGED A BROKEN TIMING CHAIN CAUSED THE VEHICLE TO STOP OPERATING.ON APRIL 12, 2006, ODI RECEIVED INFORMATION FROM GENERAL MOTORS (GM) CONCERNING TIMING CHAIN FAILURES IN APPROXIMATELY 412,000 MODEL YEAR (MY) 2000 THROUGH 2003 SATURN L-SERIES AND ION VEHICLES WITH 2.2L ENGINES. GM'S RESPONSE INCLUDED 1,020 OWNER COMPLAINTS AND FIELD REPORTS CONCERNING TIMING CHAIN FAILURE, INCLUDING 228 THAT ALLEGED THE FAILURE CAUSED THE VEHICLE TO STALL WHILE DRIVING.GM ALSO PROVIDED WARRANTY CLAIM DATA THAT SHOWED 1,902 SUBJECT VEHICLES RECEIVING TIMING CHAIN REPAIRS, INCLUDING 261 WHICH INDICATED THAT A STALL WHILE DRIVING RESULTED FROM THE FAILURE.THE GM COMPLAINTS, FIELD REPORTS AND WARRANTY CLAIMS THAT DID NOT CONTAIN SUFFICIENT INFORMATION TO DETERMINE THAT A STALL WHILE DRIVING OCCURRED WERE PROVIDED IN THE CATEGORY OTHER.GM STATED THAT THE MAJORITY OF THESE INCIDENTS PROBABLY OCCURRED WHILE THE VEHICLES WERE PARKED SINCE THE TIMING CHAIN IS MORE LIKELY TO BREAK DURING HIGH CHAIN LOAD SITUATIONS, SUCH AS ENGINE STARTUP.GM'S DATA SHOWED ELEVATED FAILURE RATES IN APPROXIMATELY 20,500 MY 2001 L-SERIES VEHICLES PRODUCED DURING A FOUR MONTH PERIOD FROM NOVEMBER 2000 THROUGH FEBRUARY 2001.OVER ONE-THIRD OF GM'S TOTAL COMPLAINTS AND FIELD REPORTS (34.3%) AND WARRANTY CLAIMS (38.2%) INVOLVED L-SERIES VEHICLES BUILT DURING THE 4-MONTH PERIOD, WHICH ARE ONLY ABOUT 5% OF SUBJECT VEHICLE PRODUCTION.THE TIMING CHAIN FAILURE RATE IN THE VEHICLES BUILT DURING THIS RANGE IS OVER 10 TIMES GREATER THAN THE REMAINING SUBJECT VEHICLE POPULATION. FOR THE MY 2001 L-SERIES VEHICLES BUILT DURING THE 4-MONTH PERIOD, THE 36-MONTH FAILURE RATE FOR REPAIRS INVOLVING STALL WHILE DRIVING IS SLIGHTLY UNDER ONE PERCENT.HOWEVER, IF THE INCIDENTS CODED AS OTHER ARE ADDED, THE 36-MONTH FAILURE RATE RISES TO NEARLY FIVE PERCENT FOR THOSE VEHICLES.ODI AND GM ARE CONTINUING TO ASSESS THE NUMBER OF COMPLAINTS AND WARRANTY CLAIMS CODED BY GM AS OTHER THAT INVOLVE INCIDENTS OF STALL WHILE DRIVING.GM'S STATISTICAL MODELING OF THE FAILURE DATA INITIALLY CONCLUDED THAT THE FAILURE RATES WERE DECLINING WITH AGE AND MILEAGE FOR ANY SET OF WARRANTY DATA ANALYZED (E.G., STALL WHILE DRIVING, OTHER OR COMBINED).HOWEVER, SUBSEQUENT ANALYSIS SHOWED THAT THE FAILURE RATES ARE INCREASING. BASED ON THE HIGH COMPLAINT AND WARRANTY RATES FOR TIMING CHAIN FAILURE IN THE 4-MONTH PRODUCTION PERIOD FOR THE MY 2001 L-SERIES VEHICLES, THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS TO FURTHER ASSESS THE FREQUENCY OF STALL INCIDENTS DUE TO TIMING CHAIN FAILURES IN THOSE VEHICLES (EA06-009).

DP05008 · Timing Chain Failure

Opened Dec 20, 2005 · Closed Feb 6, 2006

Status: closed (inferred from source dates) · Engine And Engine Cooling

ANALYSIS UNDERTAKEN IN RESPONSE TO THE PETITION IDENTIFIED 26 COMPLAINTS ALLEGING TIMING CHAIN FAILURES IN MY 2000-2003 SATURN L-SERIES VEHICLE EQUIPPED WITH THE 2.2L L4 ENGINE.MOST COMPLAINTS OF TIMING CHAIN FAILURE REPORTEDLY RESULTED IN A SUDDEN LOSS OF ENGINE POWER AND STALLING.ODI ALSO NOTED THAT CERTAIN MY 2002-2003 SATURN VUE AND MY 2003 SATURN ION MODEL VEHICLES WITH THE 2.2L ENGINE VEHICLESCOVERED BY A TECHNICAL SERVICE BULLETIN (03-06-01-017) THAT ADDRESSED TIMING CHAIN DESIGN AND SERVICE PROCEDURE CHANGES, EXHIBITED NO COMPLAINTS OF TIMING CHAIN FAILURE.ODI WILL GRANT THE PETITION AND OPEN A PRELIMINARY EVALUATION TO ASSESS THE FREQUENCY, TREND, SCOPE AND SAFETY CONSEQUENCES ASSOCIATED WITH THE ALLEGED DEFECT IN THE SUBJECT VEHICLES.REFER TO PE06-006.

EA04035 · Front Turn Signal/drl Failure

Opened Dec 22, 2004 · Closed Oct 20, 2005

Status: closed (inferred from source dates) · Exterior Lighting:turn Signal

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.

PE04061 · Front Turn Signal/drl Failure

Opened Aug 17, 2004 · Closed Dec 22, 2004

Status: closed (inferred from source dates) · Exterior Lighting:turn Signal

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.