Known Recalls

Model year record

2004 Saturn ION

8 recall campaigns on file for this model year. 1,125 owner complaints on file.

Recalls

Recall campaignNHTSA 14V171000

Electrical system: ignition

Component
Electrical system: ignition
Manufacturer
General Motors LLC
Vehicles affected
2,191,014
Reported to NHTSA
2014-04-10
Owners notified
2014-04-18

Defect description

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.

Safety risk

If the key can be removed from the ignition when the ignition is not in the "off" position, the vehicle could roll away: (a) for an automatic transmission, if the transmission is not in the "Park" position; or (b) for a manual transmission, if the parking brake is not engaged and the transmission is not in the "Reverse" position. This potential for rollaway increases the risk for a crash and occupant or pedestrian injuries.

Manufacturer 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.

Recall campaignNHTSA 14V153000

Steering: electric power assist system

Component
Steering: electric power assist system
Manufacturer
General Motors LLC
Vehicles affected
1,373,177
Reported to NHTSA
2014-03-31
Owners notified
2014-07-17

Defect description

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.

Safety risk

If power steering assist is lost, greater driver effort would be required to steer the vehicle at low speeds, increasing the risk of a crash.

Manufacturer 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.

Recall campaignNHTSA 14V047000

Air bags

Component
Air bags
Manufacturer
General Motors LLC
Vehicles affected
2,190,934
Reported to NHTSA
2014-02-10
Owners notified
2014-04-18

Defect description

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.

Safety risk

If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a crash, increasing the risk of injury.

Manufacturer 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.

Recall campaignNHTSA 04V547000

Exterior lighting: turn signal

Component
Exterior lighting: turn signal
Manufacturer
GENERAL MOTORS CORP.
Vehicles affected
178,798
Reported to NHTSA
2004-11-16
Owners notified
2004-11-17

Defect description

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.

Safety risk

IF A FRONT TURN SIGNAL LAMP IS INOPERATIVE, OTHERS MAY REACT MORE SLOWLY TO A TURNING VEHICLE AND A CRASH COULD OCCUR.

Manufacturer 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.

Recall campaignNHTSA 04V281000

Fuel system, other: delivery: fuel pump

Component
Fuel system, other: delivery: fuel pump
Manufacturer
GENERAL MOTORS CORP.
Vehicles affected
670
Reported to NHTSA
2004-06-08
Owners notified
2004-06-09

Defect description

CERTAIN VEHICLES EQUIPPED WITH SUPERCHARGED 2.0L 4-CYLINDER (LSJ) ENGINE WERE BUILT WITH A FUEL FEED PIPE THAT COULD CRACK AND LEAK FUEL NEAR THE FUEL RAIL. IF FUEL LEAKS FROM THE FUEL FEED PIPE, THERE WOULD BE A NOTICEABLE FUEL ODOR AROUND THE VEHICLE.

Safety risk

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

Manufacturer remedy

DEALERS WILL REPLACE THE FUEL FEED PIPE ASSEMBLY. OWNER NOTIFICATION BEGAN ON JUNE 9, 2004. OWNERS SHOULD CONTACT SATURN AT 1-800-972-8876.

Recall campaignNHTSA 04V002000

Structure: body: bumpers

Component
Structure: body: bumpers
Manufacturer
GENERAL MOTORS CORP.
Vehicles affected
344
Reported to NHTSA
2004-01-06
Owners notified
2004-01-06

Defect description

ON CERTAIN PASSENGER VEHICLES, SOME WELDS BETWEEN THE PASSENGER'S SIDE MOTOR RAIL AND THE FRONT BUMPER BRACKET DO NOT MEET ENGINEERING SPECIFICATIONS.

Safety risk

LONG TERM DURABILITY OF THE JOINT MAY BE REDUCED AND SEPARATION OF THE BUMPER FROM THE FRAME ON THE PASSENGER'S SIDE OF THE VEHICLE MAY RESULT, INCREASING THE RISK OF A CRASH.

Manufacturer remedy

ALL VEHICLES ARE STILL IN DEALER'S POSSESSIONS.

Recall campaignNHTSA 04V004000

Visibility: power window devices and controls

Component
Visibility: power window devices and controls
Manufacturer
GENERAL MOTORS CORP.
Vehicles affected
79,204
Reported to NHTSA
2004-01-05
Owners notified
2003-12-30

Defect description

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.

Safety risk

IF UNSUPERVISED CHILDREN ARE LEFT UNATTENDED IN THE VEHICLE AND OPERATE THE POWER WINDOWS OR SUNROOF, THERE IS AN INCREASED RISK OF INJURY TO THE CHILD.

Manufacturer 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.

Recall campaignNHTSA 04V003000

Fuel system, gasoline

Component
Fuel system, gasoline
Manufacturer
GENERAL MOTORS CORP.
Vehicles affected
127,285
Reported to NHTSA
2004-01-05
Owners notified
2003-12-30

Defect description

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.

Safety risk

IF CORROSION ON THE EXTERIOR SURFACE OF THE FUEL FILTER PROGRESSES TO THE POINT OF CREATING A HOLE IN THE SHELL, FUEL DROPLETS COULD FORM AND DROP TO THE GROUND. IF AN IGNITION SOURCE IS PRESENT, A FIRE COULD RESULT.

Manufacturer remedy

DEALERS WILL REPLACE THE FUEL FILTER ASSEMBLY. OWNER NOTIFICATION BEGAN ON DECEMBER 30, 2003. OWNERS SHOULD CONTACT SATURN AT 1-800-972-8876.

Owner complaints

A complaint is one person's report to a federal agency. It is not a finding.

ComponentComplaintsMedian mileage
Steering32487,000 mi
Electrical system23362,720 mi
Electrical system: ignition4736,000 mi
Electrical system: ignition: switch4438,500 mi
Air bags4260,000 mi
Fuel/propulsion system36101,000 mi
Power train26100,000 mi
Engine23107,000 mi
Power train: automatic transmission2335,700 mi
Vehicle speed control21110,000 mi
Unknown or other2073,000 mi
Engine and engine cooling1763,270 mi
Fuel system, gasoline15104,000 mi
Electrical system: ignition: anti-theft: control module1440,000 mi
Exterior lighting: turn signal1430,000 mi
Steering: electric power assist system1343,300 mi
Engine and engine cooling: engine1136,000 mi
Exterior lighting10118,000 mi
Suspension10117,525 mi
Air bags: frontal924,800 mi
Equipment925,000 mi
Service brakes980,940 mi
Steering: column853,500 mi
Visibility757,000 mi
Visibility/wiper785,000 mi
Wheels7130,000 mi
Electrical system: ignition: module614,703 mi
Electronic stability control (ESC)6131,000 mi
Service brakes, hydraulic616,272 mi
Power train: manual transmission521,000 mi
Structure540,000 mi
Tires522,000 mi
Steering: hydraulic power assist system45,000 mi
Suspension: front419,000 mi
Vehicle speed control: accelerator pedal4150 mi
Visibility: windshield wiper/washer448,012 mi
Electrical system: 12V/24V/48V battery310,000 mi
Seat belts3120,000 mi
Structure: body3130,000 mi
Structure: body: door370,559 mi
Electrical system: starter assembly27,000 mi
Engine and engine cooling: engine: gasoline21,597 mi
Latches/locks/linkages225,106 mi
Service brakes, hydraulic: antilock/traction control/electronic limited slip247 mi
Service brakes, hydraulic: foundation components: disc: rotor250 mi
Suspension: front: control arm: lower arm237,000 mi
Wheels: rim240,000 mi
Air bags: frontal: sensor/control module1—
Child seat1—
Electrical system: instrument cluster/panel1—
Electrical system: horn1—
Electrical system: wiring1—
Electrical system: wiring: fuses and circuit breakers18,000 mi
Electronic stability control: automatic (ASC)1—
Engine and engine cooling: cooling system155,305 mi
Engine and engine cooling: engine: gasoline: belts and associated pulleys162,000 mi
Engine and engine cooling: exhaust system1—
Engine and engine cooling: exhaust system: emission control: catalytic convertor1—
Equipment: appliance: air conditioner1—
Equipment: electrical: anti-theft devices1110,000 mi
Equipment: electrical: radio/tape deck/CD etc.114,703 mi
Equipment: mechanical: accessory scissor/screw/bottle jack/lift189,000 mi
Equipment: recreational vehicle/trailer1—
Exterior lighting: headlights1118,000 mi
Exterior lighting: turn signal: flasher unit16,537 mi
Fuel system, gasoline: storage: tank assembly: filler pipe and cap12,011 mi
Fuel system, other: delivery: fuel pump123,800 mi
Interior lighting166,000 mi
Latches/locks/linkages: doors: latch1200 mi
Latches/locks/linkages: hood: latch1—
Latches/locks/linkages: trunk lid: lock150,000 mi
Power train: automatic transmission: control module (TCM/PCM/TECM)113,400 mi
Power train: axle assembly11,500 mi
Power train: clutch assembly125,000 mi
Power train: clutch assembly: pedal/hand lever(motorcycle)132,062 mi
Power train: manual transmission: column shift assembly113,200 mi
Power train: manual transmission: floor shift assembly117,160 mi
Seat belts: front1—
Seat belts: rear/other1—
Seats18,600 mi
Seats: mid/rear assembly112,800 mi
Steering: column locking: anti-theft device149,000 mi
Steering: rack and pinion189,000 mi
Structure: body: bumpers16,537 mi
Structure: body: hatchback/liftgate: support device/strut158,000 mi
Structure: body: roof and pillars1545 mi
Structure: frame and members145,000 mi
Structure: frame and members: underbody shields1—
Suspension: front: macpherson strut1—
Suspension: front: wheel bearing150 mi
Suspension: rear16,500 mi
Tires: sidewall16,000 mi
Vehicle speed control: cruise control13,500 mi
Vehicle speed control: linkages115,051 mi
Visibility: rear window wiper/washer157,000 mi
Visibility: rearview mirrors/devices: exterior1—
Visibility: windshield wiper/washer: linkages117,754 mi
Wheels: lugs/nuts/bolts/studs116,500 mi

The 2003 model has roughly the same number of complaints as this one. The 2005 model has about 1.5 times as many complaints as this one. These figures reflect raw complaint counts, not failure rates. Higher-selling model years naturally receive more complaints.

Safety recall repairs are provided free of charge by franchised dealers, regardless of vehicle age or mileage. This page displays aggregated data for the model year. To check recall status for a specific vehicle, search its VIN at nhtsa.gov.