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2006 Saturn Ion

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2006 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

1,073 reports with mileage · 162 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.

  • Steering. Review the 544 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 392 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel System, Gasoline. Review the 127 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

44 crash reports7 fire reports23 injury reports

Fuel System, Gasoline complaints

127 reports
Clear category filter
130,000 miles · Oct 4, 2011
Fuel System, Gasoline

2006 ION. STRONG GAS SMELL DEVELOPED OVER A WEEK IN SEPT 2011. AN INDEPENDENT TECHNICIAN FOUND GAS LEAKING FROM TOP OF TANK. RESEARCH LEAD ME TO NHTSA CAMPAIGN ID NUMBER: 09V419000. GM PERFORMED THE RECALL ON ONLY 53K CARS IN AZ AND NV IN OCT 2009. SEEMS THE FUEL PUMP MODULE CONNECTIONS ARE MADE OF PLASTIC AND CRACK WITH HEAT AN…

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2006 ION. STRONG GAS SMELL DEVELOPED OVER A WEEK IN SEPT 2011. AN INDEPENDENT TECHNICIAN FOUND GAS LEAKING FROM TOP OF TANK. RESEARCH LEAD ME TO NHTSA CAMPAIGN ID NUMBER: 09V419000. GM PERFORMED THE RECALL ON ONLY 53K CARS IN AZ AND NV IN OCT 2009. SEEMS THE FUEL PUMP MODULE CONNECTIONS ARE MADE OF PLASTIC AND CRACK WITH HEAT AND ROAD VIBRATION. HOWEVER, A CALL TO SATURN REVEALED THEY ARE HIDING BEHIND A VIN SPECIFIC RECALL AND THAT THE OTHER THOUSANDS OF IONS WITH THIS SERIOUS SAFETY-DEFECT ARE ONLY COVERED BY GM FOR 10 YR/120K MILE "SPECIAL COVERAGE WARRANTY" EXTENDED TO THIS DEFECTIVE PART. HAD SATURN/GM INFORMED ME MY CAR MIGHT BURST INTO FLAMES BACK IN FEB 2010, WHEN THEY WERE TO NOTIFY THE 53K OWNERS IN AZ AND NV, I WOULD HAVE HAD THIS REPAIR DONE ASAP AS I WOULD STILL BE UNDER THEIR "SPECIAL COVERAGE" LIMITATION. I AM ANGERED AND OUTRAGED THAT GM SEEMS TO TAKE THE POSITION OF "LET'S WAIT UNTIL THE CAR BECOMES A DEATH-TRAP" BEFORE WE TELL PEOPLE THEY MIGHT BE IN DANGER AND REPLACE THE DEFECTIVE PARTS. WITH NO NOTIFICATION, I CONTINUED TO DRIVE MY ION. NOW THAT THE CAR ACTUALLY HAS BECAME LIFE-THREATENING, I AM "NOT COVERED" BY GM'S SPECIAL COVERAGE. MY ION DOES NOT QUALIFY BECAUSE I AM OVER THIS ARTIFICIAL LIMIT IF 120K MILES. ALL VEHICLES WITH THIS DEFECTIVE PART SHOULD HAVE BEEN NOTIFIED. THIS IS CRIMINALLY NEGLIGENT. BET YOU MY MILEAGE WAS BELOW THIS ARTIFICIAL LIMIT IN FEBRUARY 2010. BECAUSE THE PROBLEM DIDN'T SHOW UP UNTIL AFTER 200+ DAYS OF OVER 90 DEGREE DAYS IN EAST TEXAS - I HAVE TO PAY $600 TO REPAIR THEIR OBVIOUS DEFECT. THE REPAIR COSTS ARE UNFAIR, BUT THE SAFETY ISSUE SCREAMS FOR JUSTICE. I GUESS SOMEONE'S FAMILY WILL HAVE TO DIE IN A TRAGIC FIREBALL BEFORE SOMEONE TAKES GM TO TASK FOR THIS SERIOUSLY DANGEROUS FUEL SYSTEM DEFECT. *TR

NHTSA ODI #10428449

45,000 miles · Sep 30, 2011
Fuel System, Gasoline

TL* THE CONTACT OWNS A 2006 SATURN ION. WHILE PARKED, THE CONTACT NOTICED A FUEL ODOR EMITTING IN THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THERE WAS A LEAK FROM THE FUEL PUMP MONITOR THROUGH THE FUEL LINE AND LEADING TO THE FUEL TANK. THE MECHANIC STATED THERE WAS A RECALL UNDER NHTSA CAMPAIGN ID…

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TL* THE CONTACT OWNS A 2006 SATURN ION. WHILE PARKED, THE CONTACT NOTICED A FUEL ODOR EMITTING IN THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THERE WAS A LEAK FROM THE FUEL PUMP MONITOR THROUGH THE FUEL LINE AND LEADING TO THE FUEL TANK. THE MECHANIC STATED THERE WAS A RECALL UNDER NHTSA CAMPAIGN ID NUMBER: 09V419000 (FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP) THAT COULD HAVE BEEN RELATED TO THE FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND ADVISED THAT THE VIN WAS NOT INCLUDED IN THE RECALL. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 45,000.

NHTSA ODI #10428036

65,000 miles · Sep 27, 2011
Fuel System, Gasoline

TL* THE CONTACT OWNS A 2006 SATURN ION. THE CONTACT STATED THAT WHILE DRIVING FUEL FUMES WERE EMITTED INTO THE VEHICLE. THE CONTACT ALSO MENTIONED THAT HE COULD SEE FUEL LEAKING UNDERNEATH THE VEHICLE. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE MANUFACTURE WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFERED ANY ASSISTANCE SINCE …

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TL* THE CONTACT OWNS A 2006 SATURN ION. THE CONTACT STATED THAT WHILE DRIVING FUEL FUMES WERE EMITTED INTO THE VEHICLE. THE CONTACT ALSO MENTIONED THAT HE COULD SEE FUEL LEAKING UNDERNEATH THE VEHICLE. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE MANUFACTURE WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFERED ANY ASSISTANCE SINCE THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 09V419000 (COMPONENT: FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP). THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 65,000.

NHTSA ODI #10427669

41,083 miles · Sep 20, 2011
Fuel System, Gasoline

BEGAN EXPERIENCING A STRONG ODOR OF RAW GAS AND FUMES IN AUGUST OF 2011. I SCHEDULED AN APPOINTMENT WITH MY LOCAL REPAIR FACILITY TO HAVE THE PROBLEM EVALUATED. UPON RAISING THE VEHICLE AND DOING A VISUAL INSPECTION OF THE FUEL SYSTEM, RUN MARKS FROM GASOLINE COULD BE SEEN COMING DOWN FROM THE TOP OF THE TANK. AN EVAP TEST WAS…

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BEGAN EXPERIENCING A STRONG ODOR OF RAW GAS AND FUMES IN AUGUST OF 2011. I SCHEDULED AN APPOINTMENT WITH MY LOCAL REPAIR FACILITY TO HAVE THE PROBLEM EVALUATED. UPON RAISING THE VEHICLE AND DOING A VISUAL INSPECTION OF THE FUEL SYSTEM, RUN MARKS FROM GASOLINE COULD BE SEEN COMING DOWN FROM THE TOP OF THE TANK. AN EVAP TEST WAS PERFORMED AS WELL AND SMOKE COULD BE SEEN RISING OUT OF THE TANK AREA. THE TANK IS PLASTIC AND NO VISUAL CRACKS COULD BE SEEN. MY TECHNICIAN FELT THIS WAS UNUSUAL AT SUCH LOW MILEAGE. AFTER FURTHER DIGGING THE TECHNICIAN DISCOVERED A RECALL ON THE FUEL PUMP MODULE FOR MY YEAR, MAKE AND MODEL. I WAS ADVISED TO RETURN TO THE DEALER TO SEE IF IT WAS COVERED WHICH I DID. I FOUND OUT THAT MY VEHICLE DID NOT FALL UNDER THE FACTORY RECALL. I RETURNED TO MY REGULAR MECHANIC TO HAVE THE PROBLEM RESOLVED. ONCE THE TANK WAS LOWERED ANOTHER EVAP TEST WAS PERFORMED. THE TEST REVEALED THAT THE FUEL SUPPLY LINES COMING OFF THE FUEL PUMP SENDING UNIT WERE LEAKING. THIS WAS WERE THE TWO HOSES WERE PRESS FITTED TO THE SENDING UNIT FROM THE FACTORY. THE ONLY MEANS OF CORRECTING WAS TO REPLACE THE ENTIRE FUEL PUMP MODULE. I HAD THE REPAIR COMPLETED USING AN OE FUEL PUMP MODULE. I FEEL AFTER READING THE PARAMETERS SET FORTH UNDER THIS RECALL THAT MY VEHICLE SHOULD HAVE BEEN REPAIRED UNDER THIS RECALL. I URGE NHTSA TO ONCE AGAIN EVALUATE THIS DEFECT. IN MY OPINION THESE DEFECTIVE PARTS WERE USED ON MORE VEHICLES THAN INITIALLY STATED. THIS IS A SEVERE SAFETY ISSUE AND HAS THE POTENTIAL FOR SERIOUS INJURY. *TR

NHTSA ODI #10426522

55,000 miles · Sep 19, 2011
Fuel System, Gasoline

TL* THE CONTACT OWNS A 2006 SATURN ION. THE CONTACT SMELLED GASOLINE COMING FROM THE VEHICLE. THE FUMES WERE SO STRONG THAT AT TIMES SHE WAS UNABLE TO SIT INSIDE THE VEHICLE. THE VEHICLE WAS TOWED TO THE DEALER WHERE THE FUEL SENSOR INJECTOR MODULE WAS REPLACED. THE MANUFACTURER HAD NOT BEEN NOTIFIED. THE CURRENT MILEAGE WA…

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TL* THE CONTACT OWNS A 2006 SATURN ION. THE CONTACT SMELLED GASOLINE COMING FROM THE VEHICLE. THE FUMES WERE SO STRONG THAT AT TIMES SHE WAS UNABLE TO SIT INSIDE THE VEHICLE. THE VEHICLE WAS TOWED TO THE DEALER WHERE THE FUEL SENSOR INJECTOR MODULE WAS REPLACED. THE MANUFACTURER HAD NOT BEEN NOTIFIED. THE CURRENT MILEAGE WAS 56,000. THE APPROXIMATE FAILURE MILEAGE WAS 55,500 AND THE VIN WAS UNAVAILABLE.

NHTSA ODI #10426250

54,000 miles · Sep 16, 2011
Fuel System, Gasoline

INITIAL SIGNS WERE A STONG SMELL OF FUEL INSIDE AND OUTSIDE OF THE VEHICLE, AND LONGER CRANK TIMES WHEN STARTING. THIS WAS FILLING OUR GARAGE WITH A VERY STRONG FUEL ODOR. TOOK IT TO DEALER TO DIAGNOSE, AND THEY DETERMINED THAT THERE WAS A CRACK IN THE FUEL PUMP MODULE AND RECOMMEND REPLACING AT A COST OF $650. THE FUEL PUMP M…

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INITIAL SIGNS WERE A STONG SMELL OF FUEL INSIDE AND OUTSIDE OF THE VEHICLE, AND LONGER CRANK TIMES WHEN STARTING. THIS WAS FILLING OUR GARAGE WITH A VERY STRONG FUEL ODOR. TOOK IT TO DEALER TO DIAGNOSE, AND THEY DETERMINED THAT THERE WAS A CRACK IN THE FUEL PUMP MODULE AND RECOMMEND REPLACING AT A COST OF $650. THE FUEL PUMP MODULE IS A PLASTIC CASE THAT SITS ON TOP OF THE FUEL TANK. IT IS NOT ACCESSABLE UNLESS YOU TAKE THE FUEL TANK OFF. WE ARE JUST FINISHING A SUMMER OF RECORD SETTING HEAT. LOOKING ONLINE IT HAS CRACKED FOR PEOPLE IN HOT CLIMATES. THERE IS A RECALL FOR A PROBLEM THAT SOUNDS VERY SIMILAR, GM RECALL NUMBER 090226. OUR CAR IS NOT COVERED BY THIS BECAUSE IT IS NOT LOCATED IN AZ OR NV. *TT

NHTSA ODI #10425754

Mileage unknown · Sep 7, 2011
Fuel System, Gasoline

STRONG FUEL ODOR WHILE DRIVING, LINGERS WHEN PARKED. LEAK NOTICED COMING FROM TOP OF GAS TANK. *TR

NHTSA ODI #10424078

Mileage unknown · Aug 23, 2011
Fuel System, Gasoline

2006 SATURN ION. CONSUMER STATES DIFFICULTY STARTING VEHICLE AND ODOR OF GASOLINE *TGW THE CONSUMER TOOK THE VEHICLE TO HIS LOCAL MECHANIC AND HE TRACED THE PROBLEM TO THE AREA OF THE FUEL PUMP. UPON FURTHER RESEARCH, THE MECHANIC FOUND THE A RECALL RELATED TO THE PROBLEM. THE CONSUMER THEN TOOK THE VEHICLE TO THE DEALER, BUT…

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2006 SATURN ION. CONSUMER STATES DIFFICULTY STARTING VEHICLE AND ODOR OF GASOLINE *TGW THE CONSUMER TOOK THE VEHICLE TO HIS LOCAL MECHANIC AND HE TRACED THE PROBLEM TO THE AREA OF THE FUEL PUMP. UPON FURTHER RESEARCH, THE MECHANIC FOUND THE A RECALL RELATED TO THE PROBLEM. THE CONSUMER THEN TOOK THE VEHICLE TO THE DEALER, BUT WAS INFORMED THE VEHICLE DID NOT QUALIFY FOR RECALL #09V419000. *JB

NHTSA ODI #10420568

72,000 miles · Aug 22, 2011
Fuel System, Gasoline

I WAS SMELLING GASOLINE IN MY GARAGE AND TOOK MY CAR TO MY LOCAL GM DEALER. THEY CONFIRMED THAT IT WAS A CRACKED FUEL PUMP IN MY 2006 SATURN ION REDLINE. THIS WAS A RECALL (NHTSA RECALL ID NUMBER: 09V419000), BUT DID NOT INCLUDE MY VIN NUMBER, SO IT COST ME $576 OUT OF POCKET FOR THIS REPAIR. THE RECALL NEEDS TO BE EXPANDED. …

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I WAS SMELLING GASOLINE IN MY GARAGE AND TOOK MY CAR TO MY LOCAL GM DEALER. THEY CONFIRMED THAT IT WAS A CRACKED FUEL PUMP IN MY 2006 SATURN ION REDLINE. THIS WAS A RECALL (NHTSA RECALL ID NUMBER: 09V419000), BUT DID NOT INCLUDE MY VIN NUMBER, SO IT COST ME $576 OUT OF POCKET FOR THIS REPAIR. THE RECALL NEEDS TO BE EXPANDED. *TR

NHTSA ODI #10421079

53,040 miles · Aug 15, 2011
Fuel System, Gasoline

VEHICLE STARTED TO HAVE A STRONG ODOR OF GASOLINE, I CHECKED WITH MY DEALERSHIP ABOUT MY WARRANTY AND IT EXPIRED JUNE 2011. I TOOK THE CAR TO LOCAL REPAIR SHOP AS IT WAS UNSAFE TO DRIVE. THEY DISCOVERED THE FUEL PUMP MODULE WAS LEAKING FUEL (AS IN BUBBLING AROUND THE TOP OF THE TANK). THE VEHICLE WAS REPAIRED ALTHOUGH THE FI…

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VEHICLE STARTED TO HAVE A STRONG ODOR OF GASOLINE, I CHECKED WITH MY DEALERSHIP ABOUT MY WARRANTY AND IT EXPIRED JUNE 2011. I TOOK THE CAR TO LOCAL REPAIR SHOP AS IT WAS UNSAFE TO DRIVE. THEY DISCOVERED THE FUEL PUMP MODULE WAS LEAKING FUEL (AS IN BUBBLING AROUND THE TOP OF THE TANK). THE VEHICLE WAS REPAIRED ALTHOUGH THE FIRST TWO PARTS SHIPPED IN WERE BROKEN UPON ARRIVAL AT THE SHOP. I WAS PROVIDED WITH A COPY OF THE SPECIAL COVERAGE BULLETIN #09275A ADDRESSING THIS EXACT FAILURE. MY VIN FALLS WITHIN THE PARAMETERS BUT MY LOCATION (VIRGINIA) DOES NOT. THE APPROVED STATES ALL APPEAR TO BE SOUTHERN, HOT, STATES. THE RECENT TEMPS IN NORTHERN VIRGINIA/ DC AREA HAS BEEN VERY HOT OVER THE LAST TWO MONTHS. I FEEL THAT GM SHOULD REIMBURSE ME FOR THE REPAIR COSTS OR AT LEAST THE COST OF THE PARTS.

NHTSA ODI #10420243

Official recalls

4

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.

14V153000 · Steering:electric Power Assist System

Mar 31, 2014

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 driving.

Consequence & remedy

Consequence: 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.

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.

09V419000 · Fuel System, Gasoline:delivery:fuel Pump

Oct 29, 2009

GENERAL MOTORS IS RECALLING CERTAIN MODEL YEAR 2006 CHEVROLET COBALT AND SATURN ION VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF ARIZONA AND NEVADA; AND MODEL YEAR 2007 CHEVROLET COBALT, PONTIAC G5 AND SATURN ION VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF ARIZONA, CALIFORNIA, FLORIDA, NEVADA AND TEXAS. THE PLASTIC SUPPLY OR RETURN PORT ON THE MODULAR RESERVOIR ASSEMBLY MAY CRACK. IF EITHER OF THESE PORTS DEVELOPS A CRACK, FUEL WILL LEAK FROM THE AREA. IF THE CRACK BECOMES LARGE ENOUGH, FUEL MAY BE OBSERVED DRIPPING ONTO THE GROUND AND VEHICLE PERFORMANCE MAY BE AFFECTED.

Consequence & remedy

Consequence: FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

Remedy: DEALERS WILL REPLACE THE FUEL PUMP MODULE FREE OF CHARGE. A SPECIAL COVERAGE WILL BE IMPLEMENTED IN THE SAME TIME FRAME FOR MODEL YEAR 2006 VEHICLES REGISTERED IN ALABAMA, ARKANSAS, CALIFORNIA, FLORIDA, GEORGIA, HAWAII, LOUISIANA, MISSISSIPPI, NORTH CAROLINA, NEW MEXICO, OKLAHOMA, SOUTH CAROLINA, TENNESSEE AND TEXAS AND MODEL YEAR 2007 VEHICLES REGISTERED IN: ALABAMA, ARKANSAS, GEORGIA, HAWAII, LOUISIANA, MISSISSIPPI, NORTH CAROLINA, NEW MEXICO, OKLAHOMA, SOUTH CAROLINA AND TENNESSEE. THE SAFETY RECALL IS EXPECTED TO BEGIN ON OR BEFORE FEBRUARY 4, 2010. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438, SATURN AT 1-800-972-8876 AND PONTIAC AT 1-800-620-7668 OR AT THE OWNER CENTER AT WWW.GMOWNERCENTER.COM.

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

2

EA11014 · Electric Power Steering Failure

Opened Sep 29, 2011 · Closed Apr 15, 2014

Status: closed (inferred from source dates) · Steering:electric Power Assist System

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.

Additional source detail variants (2)

Steering:electric Power Assist System

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.

Steering:electric Power Assist System

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.

RQ10004 · Electric Power Steering Failure

Opened Dec 15, 2010 · Closed Oct 5, 2011

Status: closed (inferred from source dates) · Steering; Steering:electric Power Assist System

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.

Additional source detail variants (2)

Steering:electric Power Assist System

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.

Steering

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.