← New search

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
Clear category filter
30,000 miles · Feb 13, 2010
Electrical System

I HAVE A 2003 SATURN ION AND IT HAS THE SAME STARTING PROBLEMS REPORTED EXTENSIVELY ON THIS WEBSITE. ON COLD DAYS, THE CAR WILL NOT START AT TIMES. IT ALWAYS SEEMS TO HAPPEN AT THE MOST IMPORTUNE TIMES AND LOCATIONS. WHEN THIS HAPPENS, THERE IS NO NOISE AND NO CRANKING SOUND WHEN I TURN THE IGNITION KEY ON. HOWEVER, WHEN I TRY …

Read full complaint

I HAVE A 2003 SATURN ION AND IT HAS THE SAME STARTING PROBLEMS REPORTED EXTENSIVELY ON THIS WEBSITE. ON COLD DAYS, THE CAR WILL NOT START AT TIMES. IT ALWAYS SEEMS TO HAPPEN AT THE MOST IMPORTUNE TIMES AND LOCATIONS. WHEN THIS HAPPENS, THERE IS NO NOISE AND NO CRANKING SOUND WHEN I TURN THE IGNITION KEY ON. HOWEVER, WHEN I TRY TO START THE CAR ABOUT 5 TO 15 MINUTES LATER, IT STARTS WITHOUT ANY PROBLEM. I REPLACED THE BATTERY, BUT IT DID NOT MAKE ANY DIFFERENCE. THE ALTERNATOR CHECKS OUT FINE. I BELIEVE THE PROBLEM IS A FAULTY IGNITION MODULE, BUT THAT IS A GUESS ON MY PART BASED ON THE NUMEROUS ONLINE COMPLAINTS BY OTHER SATURN OWNERS. THERE IS ONLY ONE AUTHORIZED SATURN DEALER/SERVICE FACILITY LEFT IN THE HOUSTON. THE TECHNICIAN THERE TOLD ME HE HAS SERVICED NUMEROUS SATURNS WITH THE SAME EXACT PROBLEM AND THAT REPLACING THE IGNITION MODULE SEEMS TO FIX THE PROBLEM, ALTHOUGH NOT IN EVERY CASE. HE SAID THAT GM HAS NOT ISSUED A BULLETIN OR RECALLED SATURNS TO REPAIR THE UNITS. GM'S DENIAL OF A POTENTIALLY LETHAL PROBLEM IS NOT UNLIKE THAT OF TOYOTA IN ADDRESSING STUCK ACCELERATORS AND BRAKING PROBLEMS. MAYBE GM DOES NOT CARE BECAUSE IT IS CLOSING DOWN ITS SATURN DIVISION. I CAN SEE WHERE SATURN OWNERS, WHO ARE UNAWARE OF THE EXTENT OF THE STARTING PROBLEM, WIND UP HAVING THEIR BATTERIES, ALTERNATORS AND OTHER COMPONENTS REPLACED AT ENORMOUS COST AND INCONVENIENCE BEFORE SATURN SUGGESTS REPLACING THE IGNITION UNIT. THIS IS A SITUATION THAT IS RIPE FOR EXPLOITATION BECAUSE THE PROBLEM IS INTERMITTENT. THE NATIONAL TRANSPORTATION SAFETY BOARD NEEDS TO WEIGH IN ON THIS SAFETY ISSUE AND NOT WAIT FOR PEOPLE TO GET HURT. *TR

NHTSA ODI #10310143

65,000 miles · Feb 11, 2010
Electrical System

I'VE BEEN HAVING COLD STARTING PROBLEMS WITH MY 2003 SATURN ION. I'VE HAD THIS PROBLEM FIX BY DEALER 3 TIMES IN THE PAST. AT 620.00 A POP THAT'S HARD . NOW AFTER TALKING TO A TECHNICIAN THAT USED TO WORK FOR SATURN BEFORE THEY CLOSED ,THAT THE PROBLEM IS CAUSED BY OIL THAT RELEASES FROM THE PART WHEN COLD AND LEAKS DOWN FROM T…

Read full complaint

I'VE BEEN HAVING COLD STARTING PROBLEMS WITH MY 2003 SATURN ION. I'VE HAD THIS PROBLEM FIX BY DEALER 3 TIMES IN THE PAST. AT 620.00 A POP THAT'S HARD . NOW AFTER TALKING TO A TECHNICIAN THAT USED TO WORK FOR SATURN BEFORE THEY CLOSED ,THAT THE PROBLEM IS CAUSED BY OIL THAT RELEASES FROM THE PART WHEN COLD AND LEAKS DOWN FROM THE IGNITION TO THE PASS LOCK SWITCH THIS SHOULD HAVE A RECALL BEFORE THIS BURNS SOMEONE UP AND KILLS THEM . THEY SHOULD HAVE TO FIX ALL THESE CARS .DO IT RIGHT AND STOP CHARGING PEOPLE FOR SOMETHING THAT REALLY CANT BE FIXED SIMPLY BY REPLACING A PART THAT WILL CONTINUE LEAKING OIL WHEN COLD. I AM REALLY SURPRISED THIS HASN'T ALREADY BEEN RECALLED. I CAN ONLY WAIT TO SEE IF THIS HAPPENS THEY NEED TO PAY ,I CANT AFFORD TO GO BUY A CAR WITH WORK SLOW SO SATURN AND GM SHOULD BE HELD RESPONSIBLE. ALL THIS IS IN THE IGNITION SWITCH INSIDE THE CAR AND IF A FIRE STARTS WITH YOU IN IT AT THE WHEEL YOU LOSE A CAR AND POSSIBLE A LIFE OR MORE IF IN HEAVY TRAFFIC AND THIS LOCKS DOWN YOUR CAR. IT'S NOT ONLY ME ITS MY KIDS AND OTHERS ON THE ROAD AT DANGER IT'S ALL WHO DRIVE A SATURN ION 2003. *TR

NHTSA ODI #10308713

Mileage unknown · Feb 8, 2010
Electrical System

CAR HAS FREQUENT INTERMITTENT STARTING PROBLEMS (ABOUT ONE IN 4 STARTING ATTEMPTS IS A NO-GO). INTERNET RESEARCH BRINGS UP MANY COMPLAINTS OF THE IGNITION SWITCH SENDING THE WRONG SIGNAL TO THE COMPUTER WHICH IN TURN ACTIVATES THE SECURITY SYSTEM (PASSLOCK, IN GM SPEAK) AND PREVENTS THE CAR FROM STARTING. GM RECOGNIZES THE ISS…

Read full complaint

CAR HAS FREQUENT INTERMITTENT STARTING PROBLEMS (ABOUT ONE IN 4 STARTING ATTEMPTS IS A NO-GO). INTERNET RESEARCH BRINGS UP MANY COMPLAINTS OF THE IGNITION SWITCH SENDING THE WRONG SIGNAL TO THE COMPUTER WHICH IN TURN ACTIVATES THE SECURITY SYSTEM (PASSLOCK, IN GM SPEAK) AND PREVENTS THE CAR FROM STARTING. GM RECOGNIZES THE ISSUE IN TSB #3493A WHICH RECOMMENDS REPLACING THE IGNITION SWITCH. SINCE THIS IS A KNOWN FAILURE TO GM, I BELIEVE THE SWITCH REPLACEMENT SHOULD BE DONE AT THE MANUFACTURER'S COST, NOT THE CONSUMER'S COST. IT IS AN EXPENSIVE PROCEDURE AND CONSUMERS ARE FORCED TO GO TO THE DEALER FOR THE REPAIR BECAUSE THE CAR'S COMPUTER (BCM) HAS TO BE REPROGRAMMED AFTER THE SWITCH REPLACEMENT. *TR

NHTSA ODI #10307510

Mileage unknown · Feb 2, 2010
Electrical System

CAR WILL NOT START IN THE COLD WEATHER. WHEN ATTEMPTING TO START SECURITY LIGHT TURN ON AND WON'T START FOR AT LEAST 15 MINUTES. I HAVE REPLACED THE BATTERY BUT THAT'S NOT THE SOLUTION. THIS HAPPENS AT LEAST THREE TIMES A WEEK. ITS HORRIBLE BEING STRANDED OUT IN THE COLD WHEN IS BELOW ZERO FOR AT LEAST 15 MINUTES. SATURN NEED…

Read full complaint

CAR WILL NOT START IN THE COLD WEATHER. WHEN ATTEMPTING TO START SECURITY LIGHT TURN ON AND WON'T START FOR AT LEAST 15 MINUTES. I HAVE REPLACED THE BATTERY BUT THAT'S NOT THE SOLUTION. THIS HAPPENS AT LEAST THREE TIMES A WEEK. ITS HORRIBLE BEING STRANDED OUT IN THE COLD WHEN IS BELOW ZERO FOR AT LEAST 15 MINUTES. SATURN NEEDS TO DO SOMETHING OUT THIS PROBLEM. *TR

NHTSA ODI #10303956

70,000 miles · Jan 27, 2010
Electrical System

TL*THE CONTACT OWNS A 2003 SATURN ION. DURING COLD WEATHER THE VEHICLE FAILED TO START SINCE THERE IS A DEFECT IN THE IGNITION SWITCH. THE VEHICLE RESETS TO A SECURITY MODE AS IF IT HAS BEEN STOLEN. THE DEALER ADVISED THE CONTACT TO REPLACE THE SWITCH; HOWEVER, THEY WOULD USE THE DEFECTIVE SWITCH WHEN THEY REPAIR THE VEHICLE. T…

Read full complaint

TL*THE CONTACT OWNS A 2003 SATURN ION. DURING COLD WEATHER THE VEHICLE FAILED TO START SINCE THERE IS A DEFECT IN THE IGNITION SWITCH. THE VEHICLE RESETS TO A SECURITY MODE AS IF IT HAS BEEN STOLEN. THE DEALER ADVISED THE CONTACT TO REPLACE THE SWITCH; HOWEVER, THEY WOULD USE THE DEFECTIVE SWITCH WHEN THEY REPAIR THE VEHICLE. THE FAILURE MILEAGE WAS 70,000.

NHTSA ODI #10302511

77,230 miles · Jan 22, 2010
Electrical SystemEngine And Engine Cooling

CAR WILL NOT START IN COLD WEATHER. THIS BEGAN 3 MONTHS AGO AT THE BEGINNING OF THE WINTER SEASON, UNFORTUNATELY THE FIRST DAY OF A NEW JOB. THIS HAPPENED A NUMBER OF TIMES UNTIL I WAS LET GO FOR SHOWING UP LATE TO WORK (APPARENTLY, A CAR THAT PROBLEMATIC WAS INCONCEIVABLE). I HAD THE BATTERY REPLACED, BUT THAT DIDN'T HELP. T…

Read full complaint

CAR WILL NOT START IN COLD WEATHER. THIS BEGAN 3 MONTHS AGO AT THE BEGINNING OF THE WINTER SEASON, UNFORTUNATELY THE FIRST DAY OF A NEW JOB. THIS HAPPENED A NUMBER OF TIMES UNTIL I WAS LET GO FOR SHOWING UP LATE TO WORK (APPARENTLY, A CAR THAT PROBLEMATIC WAS INCONCEIVABLE). I HAD THE BATTERY REPLACED, BUT THAT DIDN'T HELP. THIS HAPPENS SPORADICALLY, BUT MOSTLY IN THE EARLY MORNING OR LATE EVENING WHEN IT'S COLDEST OUTSIDE. THIS PAST WEEK ALONE, MY CAR WOULDN'T START 3 TIMES. I'VE DONE SOME RESEARCH ON THE INTERNET AND HAVE FOUND HUNDREDS OF COMPLAINTS OF THE SAME PROBLEM IN SATURN ION'S (2003-2006 MODELS). SOME COMPLAINTS HAVE SUGGESTED IT'S THE IGNITION, THE PASSLOCK KEY, OR AN ELECTRICAL ISSUE, AND MY MECHANIC IS LOOKING INTO THE FUEL PUMP. THE PROBLEM IS THAT THE DIAGNOSTIC DOESN'T READ A PROBLEM IF THE CAR IS STARTING, WHICH SEEMS TO BE THE CASE BY THE TIME THE MECHANIC'S SHOP OPENS (WEATHER CONDITIONS ARE FAIRLY GOOD IN SOUTHERN CALIFORNIA ON MOST DAYS). THE OTHER DAY, MY CAR HAD STALLED WHILE DRIVING IN HEAVY RAIN CONDITIONS, THANKFULLY ON A SMALL RESIDENTIAL STREET, BECAUSE IT DID NOT WANT TO RESTART. IT TOOK 10 MINUTES TO GET THE CAR GOING AGAIN. YOU CAN IMAGINE HOW DISASTROUS THIS SITUATION COULD HAVE BEEN WHILE DRIVING ON THE FREEWAY OR BUSY CITY ROAD. THIS IS AN EXTREMELY DANGEROUS ISSUE THAT MUST BE TAKEN SERIOUSLY BY GM. I HAVE ALSO MADE COMPLAINTS TO THE FTC & TO SATURN. FROM WHAT I'VE READ ONLINE, REPLACING THE PART DOESN'T EVEN HELP BECAUSE ALL OF THESE ION PARTS ARE FAULTY. PLEASE SEE TO IT THAT CONSUMERS ARE PROTECTED. THANK YOU. *TR

NHTSA ODI #10301938

82,221 miles · Jan 19, 2010
Electrical System

TL*THE CONTACT OWNS A USED 2003 SATURN ION WHICH WAS PURCHASED IN 2008. IN COLD TEMPERATURES, THE VEHICLE WOULD NOT START. THE VEHICLE WAS TAKEN TO HER LOCAL REPAIR SHOP, AND THE FUEL INJECTOR WAS REPLACED. THERE WERE NO RECALLS FOR THE FAILURE. TWO WEEKS LATER, IN COLD AND RAINING TEMPERATURES THE VEHICLE WOULD NOT START. NO FU…

Read full complaint

TL*THE CONTACT OWNS A USED 2003 SATURN ION WHICH WAS PURCHASED IN 2008. IN COLD TEMPERATURES, THE VEHICLE WOULD NOT START. THE VEHICLE WAS TAKEN TO HER LOCAL REPAIR SHOP, AND THE FUEL INJECTOR WAS REPLACED. THERE WERE NO RECALLS FOR THE FAILURE. TWO WEEKS LATER, IN COLD AND RAINING TEMPERATURES THE VEHICLE WOULD NOT START. NO FURTHER REPAIRS WERE MADE TO THE VEHICLE TO DATE. THE FAILURE AND CURRENT MILEAGES WERE 82,221. UPDATED 02/03/10 *BF THE CONSUMER STATED THE GREASE IN THE IGNITION SWITCH IS FREEZING AND/OR HARDENING SO THAT THE IGNITION SWITCH WILL NOT ENGAGE. THE CONSUMER BELIEVED THE VEHICLE SHOULD BE RECALLED SO THE IGNITION SWITCH AND GREASE CAN BE REPLACED. UPDATED 02/11/10.*JB

NHTSA ODI #10300307

45,000 miles · Jan 13, 2010
Electrical System

MY 2003 SATURN ION REFUSES TO START WHEN IT IS COLD BUT AFTER 10 MINS IT WILL DECIDE IT WANTS TO START. I HAVE BEEN STRANDED AND PUT HUNDREDS OF DOLLARS INTO THIS PROBLEM WITH THE MECHANIC NOT SEEING THE PROBLEM. PUT A NEW IGNITION SWITCH IN THE CAR AND STILL HAS THE PROBLEM. AFTER DOING SOME RESEARCH ON THE WEB MANY SATURN O…

Read full complaint

MY 2003 SATURN ION REFUSES TO START WHEN IT IS COLD BUT AFTER 10 MINS IT WILL DECIDE IT WANTS TO START. I HAVE BEEN STRANDED AND PUT HUNDREDS OF DOLLARS INTO THIS PROBLEM WITH THE MECHANIC NOT SEEING THE PROBLEM. PUT A NEW IGNITION SWITCH IN THE CAR AND STILL HAS THE PROBLEM. AFTER DOING SOME RESEARCH ON THE WEB MANY SATURN OWNERS ARE HAVING THE SAME PROBLEMS. THIS NEEDS TO BE A RECALL AND SATURN IS REFUSING TO DO SO. *TR

NHTSA ODI #10299680

Mileage unknown · Jan 13, 2010
Electrical SystemEngine And Engine Cooling

CAR WON'T START WHEN THE TEMP IS BELOW 20 F, HAVE TO WAIT 10 MIN FOR ANTI THEFT TO RESET AND THEN TRY AGAIN. SOME TIMES HAVE TO TRY 3 OR 4 TIMES. DEALER SAY IT'S A KNOW PROBLEM AND I HAVE TO REPLACE THE IGNITION SWITCH AT MY EXPENSE. *TR

NHTSA ODI #10299665

122,000 miles · Jan 13, 2010
Electrical System

2003 SATURN ION WILL NOT START DUE TO THE PASSLOCK TIMING ME OUT. IT HAS LEFT ME STRANDED TOO MANY TIMES AND YESTERDAY I HAD TO WAIT 3 HRS FOR MY CAR TO START. I HAVE READ REPORTS OF OTHER CONSUMERS HAVING THE SAME ISSUE AND WANTED TO FILE A WRITTEN COMPLAINT. *TR

NHTSA ODI #10299660

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.