NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
382 reportsClear category filter70,000 miles · Jan 16, 2009
Electrical System
MY CAR WILL NOT START WHEN IT IS COLD. IT IS DUE TO THE FAULTY DESIGN OF THE IGNITION SWITCH/PASSLOCK ERROR. IT HAPPENS AT LEAST THREE OR FOUR TIMES A WEEK, END EVERY MORNING IT IS BELOW 34 DEGREES. I HAVE HAD A NEW BATTERY, FUEL FILTER AND STARTER REPLACED IN THE PAST WEEK. AFTER TEN TO FIFTEEN MINUTES IT STARTS, BUT TODAY AFTE…
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MY CAR WILL NOT START WHEN IT IS COLD. IT IS DUE TO THE FAULTY DESIGN OF THE IGNITION SWITCH/PASSLOCK ERROR. IT HAPPENS AT LEAST THREE OR FOUR TIMES A WEEK, END EVERY MORNING IT IS BELOW 34 DEGREES. I HAVE HAD A NEW BATTERY, FUEL FILTER AND STARTER REPLACED IN THE PAST WEEK. AFTER TEN TO FIFTEEN MINUTES IT STARTS, BUT TODAY AFTER FORTY FIVE MINUTES IT STILL DID NOT START. I WENT ONLINE AND FOUND THAT THOUSANDS OF OTHER SATURN OWNERS HAVE THE SAME PROBLEM. THIS PART NEEDS TO BE RECALLED. *TR
NHTSA ODI #10255289
93,000 miles · Jan 14, 2009
Electrical System
WE HAVE A 2003 SATURN ION THAT WONT START IN COLD WEATHER DUE TO IGNITION SWITCH PROBLEMS. SATURN DEALER WANTS $100 JUST TO DIAGNOSE IT ON A COMPUTER BUT MANY FORUMS HAVE INFORMATION STATING THAT THE DEALER ALREADY KNOWS THAT THE IGNITION SWITCH IS FAULTY. *TR
NHTSA ODI #10255055
36,000 miles · Jan 13, 2009
Electrical System
TL*THE CONTACT OWNS A 2003 SATURN ION. IN COLD WEATHER CONDITIONS, THE VEHICLE WOULD NOT START. USUALLY AFTER REPEATED ATTEMPTS OF TURNING THE KEY IN THE IGNITION, THE VEHICLE WILL START. THE VEHICLE HAS NOT BEEN TAKEN TO THE DEALER FOR INSPECTION TO DETERMINE THE CAUSE OF THE FAILURE. THE FAILURE MILEAGE WAS 36,000 AND CURR…
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TL*THE CONTACT OWNS A 2003 SATURN ION. IN COLD WEATHER CONDITIONS, THE VEHICLE WOULD NOT START. USUALLY AFTER REPEATED ATTEMPTS OF TURNING THE KEY IN THE IGNITION, THE VEHICLE WILL START. THE VEHICLE HAS NOT BEEN TAKEN TO THE DEALER FOR INSPECTION TO DETERMINE THE CAUSE OF THE FAILURE. THE FAILURE MILEAGE WAS 36,000 AND CURRENT MILEAGE WAS 48,000.
NHTSA ODI #10254877
60,000 miles · Jan 10, 2009
Electrical System
I DRIVE A 2003 SATURN ION 3 - AND EVERY WINTER I GO THROUGH THE SAME ISSUE. THE CAR WILL RANDOMLY NOT START. AFTER ABOUT 10-20 MINUTES OF ATTEMPTING TO START THE VEHICLE WILL FINALLY TURN OVER AND START JUST FINE. I BEGAN TO RESEARCH THIS ISSUE LAST WINTER AND FOUND THIS: HTTP://WWW.CARSURVEY.ORG/VIEWMORECOMMENTS_REVIEW_97727_6.…
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I DRIVE A 2003 SATURN ION 3 - AND EVERY WINTER I GO THROUGH THE SAME ISSUE. THE CAR WILL RANDOMLY NOT START. AFTER ABOUT 10-20 MINUTES OF ATTEMPTING TO START THE VEHICLE WILL FINALLY TURN OVER AND START JUST FINE. I BEGAN TO RESEARCH THIS ISSUE LAST WINTER AND FOUND THIS: HTTP://WWW.CARSURVEY.ORG/VIEWMORECOMMENTS_REVIEW_97727_6.HTML THIS WEBSITE HAS PAGES AND PAGES OF PEOPLE OWNING THE SAME CAR AND HAVING THE SAME PROBLEM. THE PROBLEM HAPPENS ONLY WHEN IT'S COLD OUT AND IT STARTED OFF HAPPENING ONCE IN A GREAT WHILE...UP UNTIL THIS WINTER. I LIVE IN WISCONSIN AND IT'S COLD FOR A GOOD 4 OR 5 MONTHS. THIS WEEK MY CAR HAS NOT STARTED 5 TIMES RESULTING IN ME BEING LATE FOR WORK AND LATE FOR SCHEDULED EVENTS....5 TIMES. I WORK FOR A HIGHLY RESPECTED COMPANY AND AM AN OFFICE MANAGER. I AM EXPECTED TO BE ON TIME TO OPEN THE OFFICE AND GET THINGS GOING IN THE MORNING. I'M HOPING THAT WITH THE MILLIONS OF SATURN CUSTOMERS WHO ARE NOT SATISFIED THAT A RECALL WILL BE ISSUED AND I CAN HAVE THIS PROBLEM FIXED. I CAN NOT JUSTIFY PAYING FOR A PROBLEM THAT A MULTI MILLION DOLLAR CAR COMPANY IS AWARE OF AND IS CHOOSING TO DO NOTHING ABOUT. *TR
NHTSA ODI #10254483
60,000 miles · Jan 9, 2009
Electrical System
ONLY WHEN IT'S COLD OUTSIDE, MY CAR WON'T START. I'VE REPLACED THE STARTER AND FOUND OUT THAT IT WAS NOT THE PROBLEM. AFTER RESEARCHING MY ISSUE ON THE INTERNET, I FOUND THAT THOUSANDS OF OTHER PEOPLE HAVE THE EXACT SAME PROBLEM AS ME. SINCE THE PROBLEM IS THE IGNITION SWITCH, AND EVERYONE THAT REPLACES IT SAYS THE PROBLEM PERSI…
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ONLY WHEN IT'S COLD OUTSIDE, MY CAR WON'T START. I'VE REPLACED THE STARTER AND FOUND OUT THAT IT WAS NOT THE PROBLEM. AFTER RESEARCHING MY ISSUE ON THE INTERNET, I FOUND THAT THOUSANDS OF OTHER PEOPLE HAVE THE EXACT SAME PROBLEM AS ME. SINCE THE PROBLEM IS THE IGNITION SWITCH, AND EVERYONE THAT REPLACES IT SAYS THE PROBLEM PERSISTS, I'M NOT GOING TO WASTE MONEY ON AN ISSUE THAT CAN'T BE RESOLVED UNLESS YOUR ORGANIZATION PUTS A RECALL ON THAT PART. I'M SURE YOU'VE RECEIVED NUMEROUS OF EMAILS REGARDING THIS PROBLEM, SO THE ONLY SOLUTION WOULD BE TO RECALL THAT ITEM. SINCE WE HAVE GIVEN YOU BUSINESS BY PURCHASING YOUR VEHICLES, THE ONLY THING TO DO IS TO HELP OUT YOUR LOYAL CUSTOMERS. *TR
NHTSA ODI #10254404
40,000 miles · Jan 9, 2009
Electrical SystemSteering
TL*THE CONTACT OWNS A 2003 SATURN ION. THE CONTACT WAS ABLE TO REMOVE THE KEY FROM THE IGNITION WHILE THE VEHICLE WAS IN ANY GEAR, INCLUDING DRIVE OR REVERSE. SHE TOOK THE VEHICLE TO THE DEALER AT LEAST TWICE AND EACH TIME THEY STATED THAT THERE WAS A DIFFERENT FAILURE. THE DEALER WANTS TO REPLACE THE STEERING COLUMN ALL THE …
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TL*THE CONTACT OWNS A 2003 SATURN ION. THE CONTACT WAS ABLE TO REMOVE THE KEY FROM THE IGNITION WHILE THE VEHICLE WAS IN ANY GEAR, INCLUDING DRIVE OR REVERSE. SHE TOOK THE VEHICLE TO THE DEALER AT LEAST TWICE AND EACH TIME THEY STATED THAT THERE WAS A DIFFERENT FAILURE. THE DEALER WANTS TO REPLACE THE STEERING COLUMN ALL THE WAY THROUGH THE ENGINE TO DETERMINE THE CAUSE OF THE FAILURE. THE KEY WOULD NOT TURN ALL THE WAY BACK TO THE ACC POSITION UNLESS THE VEHICLE HAD BEEN IDLING FOR AT LEAST 3-5 MINUTES. THE CONTACT FOUND NHTSA CAMPAIGN ID NUMBER 97V055000 (ELECTRICAL SYSTEM:IGNITION:SWITCH) FOR THE SAME MAKE, BUT A DIFFERENT MODEL AND THE PREVIOUS YEAR. THE CONTACT FEELS THAT THE RECALL SHOULD BE EXPANDED FOR HER YEAR, MAKE, AND MODEL VEHICLE. SHE FOUND HUNDREDS OF COMPLAINTS ONLINE REGARDING THIS FAILURE. THE FAILURE BEGAN WITHIN A WEEK OF PURCHASING THE VEHICLE. THE FAILURE MILEAGE WAS 40,000 AND CURRENT MILEAGE WAS 41,000.
NHTSA ODI #10254339
Mileage unknown · Jan 1, 2009
Electrical System
MY SATURN 2003 ION CONTINUES TO HAVE INTERMITTENT STARTING PROBLEMS(NOT RELATED TO THE BATTERY), AND PROBLEMS WITH THE KEY GETTING STUCK IN THE IGNITION CYLINDER, EVEN AFTER THE IGNITION CYLINDER WAS REPLACED. THEY CANNOT DETECT A PROBLEM YET IT STILL KEEPS HAPPENING! *TR
NHTSA ODI #10253525
26,000 miles · Dec 23, 2008
Electrical System
2003 SATURN ION HAS PROBLEMS STARTING IN THE COLD. MULTIPLE WEBSITES DOCUMENT DOZENS OF CASES OF PEOPLE WITH THE EXACT SAME ISSUE ALL RELATING TO A FAULTY IGNITION SWITCH SYSTEM. PROBLEM OCCURRED SPORADICALLY THE FIRST COUPLE YEARS BUT HAS BECOME MORE AND MORE COMMON. SATURN IS WILLING TO REPLACE THE IGNITION SWITCH BUT AT MY EX…
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2003 SATURN ION HAS PROBLEMS STARTING IN THE COLD. MULTIPLE WEBSITES DOCUMENT DOZENS OF CASES OF PEOPLE WITH THE EXACT SAME ISSUE ALL RELATING TO A FAULTY IGNITION SWITCH SYSTEM. PROBLEM OCCURRED SPORADICALLY THE FIRST COUPLE YEARS BUT HAS BECOME MORE AND MORE COMMON. SATURN IS WILLING TO REPLACE THE IGNITION SWITCH BUT AT MY EXPENSE FOR SOMETHING THAT IS AN OBVIOUS DEFECT OF THE CAR. *TR
NHTSA ODI #10252669
Mileage unknown · Dec 23, 2008
Electrical SystemEngine And Engine Cooling
CAR WILL NOT START IN TEMPERATURES NEAR 32 DEGREES OR LESS. IGNITION SWITCH AND BATTERY HAVE ALREADY BEEN REPLACED. CAR STARTS TO CRANK THEN STALLS OUT AND SERVICE LIGHT COMES ON. MUST WAIT 10-15 MINUTES TO TRY AGAIN. IF LUCKY IT WILL START ON 2ND TRY, OTHERWISE 3RD. THIS HAS BEEN GOING ON FOR PAST 3 WEEKS WHEN TEMPS DROPPE…
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CAR WILL NOT START IN TEMPERATURES NEAR 32 DEGREES OR LESS. IGNITION SWITCH AND BATTERY HAVE ALREADY BEEN REPLACED. CAR STARTS TO CRANK THEN STALLS OUT AND SERVICE LIGHT COMES ON. MUST WAIT 10-15 MINUTES TO TRY AGAIN. IF LUCKY IT WILL START ON 2ND TRY, OTHERWISE 3RD. THIS HAS BEEN GOING ON FOR PAST 3 WEEKS WHEN TEMPS DROPPED. *TR
NHTSA ODI #10252638
12,030 miles · Dec 22, 2008
Electrical System
BOUGHT VEHICLE IN APR. 05, DEC 06 PROBLEM STARTING CAR IN COLD WEATHER LATE FOR WORK, DEALER REPLACED PASSLOCK2 SYSTEM DEC 06, VEHICLE FINE UNTIL DEC 07, PROBLEM CAME ABOUT AGAIN, JAN 08 CALLED DEALER SAID TO BRING IN FOR DIAGNOSTIC, DID SO DEALER SAID IT'S THE BODY CONTROL MODULE (BCM FOR SHORT), PRIOR TO FINDING THAT OUT REPLA…
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BOUGHT VEHICLE IN APR. 05, DEC 06 PROBLEM STARTING CAR IN COLD WEATHER LATE FOR WORK, DEALER REPLACED PASSLOCK2 SYSTEM DEC 06, VEHICLE FINE UNTIL DEC 07, PROBLEM CAME ABOUT AGAIN, JAN 08 CALLED DEALER SAID TO BRING IN FOR DIAGNOSTIC, DID SO DEALER SAID IT'S THE BODY CONTROL MODULE (BCM FOR SHORT), PRIOR TO FINDING THAT OUT REPLACED STARTER AND BATTERY TO TRY AND FIX PROBLEM. CALLED SATURN CUSTOMER SUPPORT JAN OR FEB, THEY SAID THE ELECTRONIC FAILING WAS MY FAULT AND I HAD TO FIX PROBLEM. SITTING IN THE COLD WAITING TO START MY CAR HAS RESULTED IN LOSE OF DEXTERITY AND FEELING IN FINGER TIPS DUE TO PROLONGED EXPOSURE TO SUB-ZERO TEMPS TRYING TO START CAR. SATURN HAS A BULLETIN #1787659 SAYING THAT IF OWNERS COME IN REFERRING TO THEIR CAR NOT STARTING IN COLD WEATHER "NO CRANK, NO START WITH COMPLETE POWER". SATURN KNOWS OF THE PROBLEM AND WONT FIX IT CAUSE THEY DEEM IT "A NON-SAFETY ISSUE". *TR
NHTSA ODI #10252601
Official recalls
5Apr 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.
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. GMs 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. GMs 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. GMs 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.
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.
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.
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
5PE07011 · 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.
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