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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.

About this comparison →

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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27,000 miles · Jul 13, 2005
Electrical SystemEquipmentExterior LightingCrash

AT THE TIME MY SATURN WAS INVOLVED IN AN ACCIDENT IT WAS UNDER 30,000 MILES AND STILL UNDER WARRENTY. I WAS DRIVING ON A BUSY HIGHWAY AND MY ACCELERATOR GOT STUCK. AT THE TIME I COULD NOT SEE WHAT WAS HOLDING DOWN MY ACCELERATOR. IT WAS A PIECE OF PANEL THAT CAME OFF PARTIALLY THAT WAS HOLDING THE ACCELERATOR REALLY HARD AND …

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AT THE TIME MY SATURN WAS INVOLVED IN AN ACCIDENT IT WAS UNDER 30,000 MILES AND STILL UNDER WARRENTY. I WAS DRIVING ON A BUSY HIGHWAY AND MY ACCELERATOR GOT STUCK. AT THE TIME I COULD NOT SEE WHAT WAS HOLDING DOWN MY ACCELERATOR. IT WAS A PIECE OF PANEL THAT CAME OFF PARTIALLY THAT WAS HOLDING THE ACCELERATOR REALLY HARD AND IT WAS STUCK MAKING MY PEDAL STUCK ALMOST ALL THE WAY TO THE FLOOR. I TRIED TO SLOW THE CAR DOWN WITH BOTH FEET ON THE BREAKS AND THE EMERGENCY BREAK TO NO AVAIL. I DIDN'T TURN THE IGNITION OFF BECAUSE I HAD CARS ON ALL SIDES OF ME GOING 50-70 MPH. IT WAS WHEN I CAME TO A RED LIGHT THAT I REALIZED MY CAR WASN'T GOING TO STOP AND I HAD NO OTHER CHOICE BUT TO HIT AN SUV AND MY CAR KEPT TRYING TO ACCELERATE AND PUSH THE SUV OUT OF THE WAY. THAT IS WHEN I TURNED OFF THE IGNITION. I HAD TO TURN OFF THE IGNITION BEFORE ANOTHER ACCIDENT OCCURRED. THE SUV WAS DAMAGED. MY CAR WAS DAMAGED. I HAVEN'T BEEN ABLE TO GET MY CAR FIXED BECAUSE I AM WAITING FOR SATURN TO ACKNOWLEDGE THE MANUFACTURING DEFECT WHICH CAUSED THE ACCIDENT, SO THAT THEY COULD LEND ME A RENT-A-CAR WHILE IT IS IN THE SHOP. BUT, I CANNOT GET THEM TO GIVE ME A CALL TO MAKE AN APPOINTMENT TO GET MY CAR IN THE SHOP OR SUPPLY A RENT-A-CAR. A FORENSIC INVESTIGATOR INSPECTED MY CAR ON FRIDAY AND AGREES THAT I DIDN'T CAUSE THE ACCIDENT. HE SUPPLIED THE INFORMATION TO SATURN AND STILL THREE DAYS LATER I CAN'T EVEN GET A COURTESY CALL. THE ACCIDENT WAS ON JUNE 16, 2005. I COULDN'T GET THEM TO CALL ME TO SPEAK ABOUT WHAT MY OPTIONS WERE UNTIL THE WEEK OF JULY 1, 2005. THEN AN INVESTIGATOR JULY 8, 2005. THEY HAVE NOT MADE ONE EFFORT TO WORK WITH ME ABOUT GETTING THE CAR INTO THE SHOP. THEY HAVE NOT GIVEN ME THE TIME OF DAY TO MAKE AN APPOINTMENT WITH A SATURN SHOP LOCATION TO GET MY CAR FIXED AND SO THAT THEY COULD SUPPLY A RENT-A-CAR.

NHTSA ODI #10128630

15,165 miles · May 6, 2005
Electrical SystemLatches/locks/linkagesStructure

WHILE DRIVING. UPON STOPPING THE VEHICLE. THE CONSUMER GOT OUT TO TAKE THE CHILD OUT OF THE VEHICLE WITH THE IGNITION RUNNING. THE DOORS LOCKED, AND THE CONSUMER COULD NOT GET HER CHILD OUT OF THE VEHICLE. CONSUMER CONTACTED THE DEALER. HOWEVER, THE PROBLEM STILL EXIST. *NM DOORS LOCKED AUTOMATICALLY UPON EXITING DRIVER'S SI…

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WHILE DRIVING. UPON STOPPING THE VEHICLE. THE CONSUMER GOT OUT TO TAKE THE CHILD OUT OF THE VEHICLE WITH THE IGNITION RUNNING. THE DOORS LOCKED, AND THE CONSUMER COULD NOT GET HER CHILD OUT OF THE VEHICLE. CONSUMER CONTACTED THE DEALER. HOWEVER, THE PROBLEM STILL EXIST. *NM DOORS LOCKED AUTOMATICALLY UPON EXITING DRIVER'S SIDE. ADDITIONAL SERVICE INCLUDE, THE A/C AND HEATER FUNTION FAILED DUE TO FAULTY CONNECTION FROM SWITCH TO RESISTOR CARD, COLLAPSE OF HORN COVER CAUSING LOSS OF AIRBAG. IGNITION SWITCH FAILED. THE SIGNAL AND RUNNING LAMPS WERE INOPERATIVE. *BF

NHTSA ODI #10111698

55,310 miles · Apr 21, 2005
Electrical System

I PURCHASED A SATURN ION IN JUNE OF 2003. I BEGAN HAVING PROBLEMS STARTING THE CAR IN OCTOBER OF 2004. IT WOULD NOT START AND WOULD JUST MAKE A CLICKING NOISE WHEN THE KEY WAS TURNED. THERE WAS POWER TO ALL ACCESSORIES SO IT WAS NOT A BATTERY FAILURE. THE SERVICE ENGINE LIGHT WOULD COME ON. AFTER ABOUT 30 MINUTES OF TRYING …

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I PURCHASED A SATURN ION IN JUNE OF 2003. I BEGAN HAVING PROBLEMS STARTING THE CAR IN OCTOBER OF 2004. IT WOULD NOT START AND WOULD JUST MAKE A CLICKING NOISE WHEN THE KEY WAS TURNED. THERE WAS POWER TO ALL ACCESSORIES SO IT WAS NOT A BATTERY FAILURE. THE SERVICE ENGINE LIGHT WOULD COME ON. AFTER ABOUT 30 MINUTES OF TRYING TO GET THE VEHICLE TO START, IT WOULD FINALLY START ONCE AGAIN (ROUGHLY AT FIRST) AND THE SERVICE ENGINE LIGHT WOULD DISAPPEAR. I TOOK IT TO THE NEARBY SATURN DEALERSHIP AFTER THE FIRST OCCURRENCE AND WAS TURNED AWAY BECAUSE THEY "WERE TOO BUSY". I TOOK IT THERE THE NEXT DAY AND THEY SAID THAT NOTHING WAS WRONG WITH IT EXCEPT FOR AN OXYGEN SENSOR WHICH THEY REPLACED. I DROVE IT HOME. IT DID IT AGAIN TWICE IN THE NEXT TWO DAYS. I TOOK THE CAR BACK AGAIN AND THEY REPLACED THE IGNITION MODULE. I THOUGHT THAT EVERYTHING WAS OK UNTIL THIS PAST WEEKEND (APRIL 2005) WHEN IT DID THE EXACT SAME THING. I TOOK IT TO SATURN ON TUESDAY AND THEY COULD NOT RECREATE THE PROBLEM AND WOULD NOT PROVIDE ME WITH A LOANER CAR FOR MORE THAN ONE DAY. I HAD NO CHOICE BUT TO TAKE MY UNRELIABLE VEHICLE BACK. I CONTACTED SATURN CORPORATE AND FILED A COMPLAINT. THEY STATED THAT THEY WOULD ALLOW ME TO TAKE THE CAR BACK TO THE DEALERSHIP AND WOULD GET ME A LOANER FOR A FEW DAYS BUT IT WAS DOUBTFUL THAT THEY COULD GET IT TO REPEAT THE PROBLEM AS IT IS INTERMITTENT. I HAVE BEEN TOLD TO NOT START IT THE NEXT TIME AND JUST HAVE IT TOWED TO SATURN. THAT'S FINE EXCEPT WHAT IF IT DIES IN THE MIDDLE OF THE NIGHT AND I AM AWAY FROM HOME WITH MY TWO SMALL CHILDREN? MY VEHICLE IS LESS THAN TWO YEARS OLD AND I SHOULD NOT BE AFRAID TO DRIVE IT ANY DISTANCE FOR FEAR OF BEING STRANDED! *NM

NHTSA ODI #10118245

56,000 miles · Jan 18, 2005
Electrical System

OVER THE PAST 2 AND 1/2 WEEKS WE HAVE HAD A PROBLEM STARTING OUR 2003 SATURN ION. THE CAR WOULD NOT START LEADING ONE TO BELIEVE THERE WAS A PROBLEM WITH THE BATTERY. THEN A FEW HOURS LATER THE CAR STARTED AND THE SERVICE ENGINE LIGHT CAME AND WENT VERY QUICKLY. A WEEK LATER, THE SAME THING HAPPENED AND THE CAR STARTED UP AGA…

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OVER THE PAST 2 AND 1/2 WEEKS WE HAVE HAD A PROBLEM STARTING OUR 2003 SATURN ION. THE CAR WOULD NOT START LEADING ONE TO BELIEVE THERE WAS A PROBLEM WITH THE BATTERY. THEN A FEW HOURS LATER THE CAR STARTED AND THE SERVICE ENGINE LIGHT CAME AND WENT VERY QUICKLY. A WEEK LATER, THE SAME THING HAPPENED AND THE CAR STARTED UP AGAIN LATER WITH NO PROBLEM. A FEW DAYS LATER THE SAME THING HAPPENED. THE LOCAL SATURN SERVICE TECH ADVISED US THAT THIS PROBLEM HAS BEEN SEEN WITH OTHER IONS AND THAT THE IGNITION SWITCH WOULD HAVE TO BE REPLACED. *NM

NHTSA ODI #10106560

Mileage unknown · Dec 28, 2004
Electrical System

WHILE DRIVING,THE VEHICLE STALLED. THE CONSUMER WAS UNABLE TO RESTART THE VEHICLE. THE CONSUMER HAD THE VEHICLE TOWED TO THE DEALER. THE MECHANIC INFORMED THE DRIVER THAT THE FUSES AND CIRCUIT BREAKERS NEEDED TO BE REPLACED. THE CONSUMER INFORMED THE MECHANIC THIS PROBLEM HAS OCCURRED MORE THAN ONCE AND HAS NOT BEEN RESOLVED…

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WHILE DRIVING,THE VEHICLE STALLED. THE CONSUMER WAS UNABLE TO RESTART THE VEHICLE. THE CONSUMER HAD THE VEHICLE TOWED TO THE DEALER. THE MECHANIC INFORMED THE DRIVER THAT THE FUSES AND CIRCUIT BREAKERS NEEDED TO BE REPLACED. THE CONSUMER INFORMED THE MECHANIC THIS PROBLEM HAS OCCURRED MORE THAN ONCE AND HAS NOT BEEN RESOLVED. PLEASE FILL IN FURTHER INFORMATION. *JB

NHTSA ODI #10105464

Mileage unknown · Jun 4, 2004
Electrical System

THE HORN ASSEMBLY REQUIRED EXCESSIVE EFFORT TO ACTIVATE. THE CONSUMER DROVE THE VEHICLE TO THE DEALER FOR INSPECTION, AND MECHANIC DETERMINED THAT HORN WAS DESIGNED THAT WAY. *AK *NM

NHTSA ODI #10072189

7 miles · Mar 31, 2004
Electrical System

SATURN HORN IS HARD TO ACTIVATE (ALMOST IMPOSSIBLE IN WINTER CLIMATES) DUE TO A POOR HORN BUTTON DESIGN. IN A PANIC SITUATION YOU HAVE TO LOOK DOWN AND HUNT FOR THE "G" SPOT ON THE HORN BUTTON IN ORDER TO SOUND THE HORN WITHIN SUFFICIENT TIME TO BE USEFUL IN WARNING OTHER MOTORISTS. I HAVE EXPERINCED THIS MANY TIMES IN A PARKI…

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SATURN HORN IS HARD TO ACTIVATE (ALMOST IMPOSSIBLE IN WINTER CLIMATES) DUE TO A POOR HORN BUTTON DESIGN. IN A PANIC SITUATION YOU HAVE TO LOOK DOWN AND HUNT FOR THE "G" SPOT ON THE HORN BUTTON IN ORDER TO SOUND THE HORN WITHIN SUFFICIENT TIME TO BE USEFUL IN WARNING OTHER MOTORISTS. I HAVE EXPERINCED THIS MANY TIMES IN A PARKING LOT SITUATION, AND ALSO DURING INTERSTATE DRIVING. SOMETIMES THE HORN FAILS TO SOUND AT ALL. SATURN CORP. REFERRED ME TO THE DEALER FOR REPAIRS. DEALER CLAIMS THERE IS NOTHING THEY CAN DO BECAUSE OF THE INHERENT DESIGN WITH THE AIR BAG. OTHER IONS THAT I TEST DROVE ALSO DISPLAYED THIS BEHAVIOR AND SATURN CORP. SHOULD BE WORKING ON A SOLUTION TO THIS POTENTIAL SAFETY ISSUE.*AK

NHTSA ODI #10064300

6,692 miles · Mar 27, 2004
Electrical SystemExterior LightingVisibility

TO DATE, VEHICLE HAS HAS MULTIPLE PROBLEMS WHICH DEALER/SERVICE DEPARTMENT HAS BEEN UNABLE TO RESOLVE. 10 SERVICE VISITS IN LESS THAN 6 MONTHS AND NO END IN SIGHT. PROBLEMS INCLUDE: DAYTIME RUNNING LIGHTS/BLINKER LIGHTS INOPPERABLE (REPAIRED 6 TIMES); OUTSIDE TEMPERATURE GUAGE MALFUNCTIONING (REPAIRED 3+ TIMES); AIR CONDITIONING…

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TO DATE, VEHICLE HAS HAS MULTIPLE PROBLEMS WHICH DEALER/SERVICE DEPARTMENT HAS BEEN UNABLE TO RESOLVE. 10 SERVICE VISITS IN LESS THAN 6 MONTHS AND NO END IN SIGHT. PROBLEMS INCLUDE: DAYTIME RUNNING LIGHTS/BLINKER LIGHTS INOPPERABLE (REPAIRED 6 TIMES); OUTSIDE TEMPERATURE GUAGE MALFUNCTIONING (REPAIRED 3+ TIMES); AIR CONDITIONING INOPPERABLE AND COMPASS MALFUNCTIONING.*AK

NHTSA ODI #10063993

5,900 miles · Mar 11, 2004
Electrical System

THE HORN MALFUNCTIONED WITHOUT WARNING. THE CONSUMER HAD TO USE EXCESSIVE FORCE IN ORDER TO HEAR THE HORN. *AK

NHTSA ODI #10056083

98,090 miles · Feb 26, 2004
Electrical System

HORN FAILED WITHOUT WARNING. *AK *MR

NHTSA ODI #10055368

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.