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2003 Saturn Ion

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2003 Saturn Ion do not stand out strongly from the model-year median of 816.5.

About this comparison →

When problems were reported

Mileage at the reported incident

553 reports with mileage · 204 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Electrical System. Review the 382 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Steering. Review the 139 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 58 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

43 crash reports4 fire reports22 injury reports

Electrical System complaints

382 reports
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74,000 miles · Dec 21, 2008
Electrical System

WE HAVE A 2003 SATURN ION THAT HAS EXPERIENCED IGNITION PROBLEMS OVER THE LAST 2 YEARS. WE HAD THE STARTER REPLACED BY OUR MECHANIC WHEN THE PROBLEM FIRST OCCURRED IN 2006 BUT HAVE EXPERIENCED THE PROBLEM 12-15 TIMES SINCE THEN. WE HAVE FOUND OUT THAT THE CAR WILL START IF YOU WAIT FOR 15 MINUTES OR SO BUT IT IS NOT ALWAYS CON…

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WE HAVE A 2003 SATURN ION THAT HAS EXPERIENCED IGNITION PROBLEMS OVER THE LAST 2 YEARS. WE HAD THE STARTER REPLACED BY OUR MECHANIC WHEN THE PROBLEM FIRST OCCURRED IN 2006 BUT HAVE EXPERIENCED THE PROBLEM 12-15 TIMES SINCE THEN. WE HAVE FOUND OUT THAT THE CAR WILL START IF YOU WAIT FOR 15 MINUTES OR SO BUT IT IS NOT ALWAYS CONVENIENT TO DO SO. AN INTERNET SEARCH REVEALS NUMEROUS SATURN OWNERS WITH THE SAME PROBLEM WHICH HAS NOT BEEN ACKNOWLEDGED BY SATURN AS A DESIGN OR MANUFACTURING DEFECT. MY LOCAL DEALERSHIP IS AWARE OF THE PROBLEM WITH THE PASSLOCK IGNITION SYSTEM BUT CAN ONLY REPAIR IT FOR A FEE. *TR

NHTSA ODI #10252472

Mileage unknown · Dec 18, 2008
Electrical System

I WANT TO FILE A COMPLAINT ABOUT MY SATURN ION 2003 IN HOPES THAT WE CAN RECALL THE CAR. MY CAR IS OUTSIDE UNCOVERED ALL NIGHT. RIGHT NOW IT IS 27.1 DEGREES OUTSIDE. MY SATURN ION 2003 HAS A HARD TIME STARTING WHEN IT IS BELOW 32 DEGREES. I READ ON THIS WEBSITE HTTP://WWW.CARSURVEY.ORG/VIEWCOMMENTS_REVIEW_97727.HTML THAT I A…

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I WANT TO FILE A COMPLAINT ABOUT MY SATURN ION 2003 IN HOPES THAT WE CAN RECALL THE CAR. MY CAR IS OUTSIDE UNCOVERED ALL NIGHT. RIGHT NOW IT IS 27.1 DEGREES OUTSIDE. MY SATURN ION 2003 HAS A HARD TIME STARTING WHEN IT IS BELOW 32 DEGREES. I READ ON THIS WEBSITE HTTP://WWW.CARSURVEY.ORG/VIEWCOMMENTS_REVIEW_97727.HTML THAT I AM NOT THE ONLY ONE THAT IS HAVING THIS ISSUE. IT SEEMS TO BE AN ISSUE WITH THE IGNITION SWITCH. THIS HAS HAPPENED TO ME 2 TIMES THIS WEEK, 3 TIMES THIS YEAR, A TOTAL OF 6 TO 8 TIMES IN THE 5 YEARS THAT I'VE HAD IT. IT SOUNDS LIKE THE IGNITION REVS, BUT THEN IT DIES AND MY CAR HAS A MESSAGE "SERVICE SOON". IF I GIVE IT A FEW MINUTES TO SIT, THEN I TRY IT AGAIN, SOMETIMES IT DOES THE EXACT SAME THING, SOMETIMES IT GETS A LITTLE BETTER, BUT THE ENGINE WON'T TURN OVER COMPLETELY. THEN, WHEN THE IGNITION SWITCH IS A LITTLE WARMER, IT WILL ACTUALLY START. I USUALLY STAY IN MY CAR FOR AN AVERAGE OF 15 MINUTES. LONGEST I'VE WAITED FOR MY CAR TO START WAS AN HOUR. I HAVE TALKED TO SATURN ONCE ABOUT THIS, BUT THEY STATED THAT THEY WILL HAVE TO REPRODUCE THE ISSUE BEFORE THEY CAN FIND OUT WHAT IS WRONG. IF I CAN GET MY CAR TO SATURN, OBVIOUSLY THEY WILL NOT BE ABLE TO REPRODUCE THE ISSUE. THIS IS SOMETHING THAT SATURN REALLY NEEDS TO ACKNOWLEDGE SINCE IT IS MORE OF A SAFETY ISSUE. WE DON'T WANT TO BE STRANDED IN THE COLD WITH NO PHONE SERVICE WAITING FOR THE GREASE OR IGNITION SWITCH TO WARM UP. IT'S RIDICULOUS. THANK YOU FOR YOUR ATTENTION. *TR

NHTSA ODI #10252174

48,000 miles · Dec 16, 2008
Electrical System

2003 SATURN ION IGNITION SWITCH PROBLEM. CAR WON'T START, THEN INTERLOCK PREVENTS CAR FROM BEING STARTED FOR 8-10 MINUTES. THIS HAS OCCURRED APPROXIMATELY A DOZEN TIMES AT VARIOUS TEMPERATURES.*TR

NHTSA ODI #10251967

Mileage unknown · Dec 16, 2008
Electrical System

MY 2003 SATURN ION 2 WILL NOT START IN THE WINTER WHEN THE TEMPERATURE IS BELOW 32 DEGREES. THIS CAN HAPPEN AT LEAST ONCE A WEEK ALL WINTER LONG. IT CAN TAKE ANYWHERE FROM 10 MINUTES TO ONE HOUR FOR MY CAR TO START AGAIN. I TOOK IT TO A MECHANIC WHO COULD NOT FIND WHAT THE PROBLEM WAS AND CHARGED ME $80 FOR NOTHING. THIS HAS BEE…

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MY 2003 SATURN ION 2 WILL NOT START IN THE WINTER WHEN THE TEMPERATURE IS BELOW 32 DEGREES. THIS CAN HAPPEN AT LEAST ONCE A WEEK ALL WINTER LONG. IT CAN TAKE ANYWHERE FROM 10 MINUTES TO ONE HOUR FOR MY CAR TO START AGAIN. I TOOK IT TO A MECHANIC WHO COULD NOT FIND WHAT THE PROBLEM WAS AND CHARGED ME $80 FOR NOTHING. THIS HAS BEEN HAPPENING FOR THREE WINTERS AND HAS GOTTEN WORSE EACH WINTER. IT HAS CAUSED ME TO MISS WORK AND BE LATE FOR WORK SEVERAL TIMES. *TR

NHTSA ODI #10251921

86,000 miles · Dec 14, 2008
Electrical System

FAULTY IGNITION SWITCH. CAR WILL NOT START FOR 10-15 MINUTES WHEN ITS COLD OUTSIDE. BATTERY REPLACED AND IT DID NOT HELP. *TR

NHTSA ODI #10251765

50,000 miles · Dec 13, 2008
Electrical System

2003 SATURN ION FAILS TO START. THIS IS LEAVING MY WIFE AND KIDS STRANDED IN THE COLD A COUPLE OF TIMES A DAY NOW. DETAILS CAN BE FOUND AT THIS WEBSITE AS WELL AS MANY OTHERS. THIS IS THE PERFECT DESCRIPTION. HTTP://WWW.CARSURVEY.ORG/VIEWCOMMENTS_REVIEW_97727.HTML. *TR

NHTSA ODI #10251677

30,000 miles · Dec 12, 2008
Electrical System

FAULTY DESIGN IN THE IGNITION SWITCH. THE SWITCH LEAKS LUBRICANT ONTO THE WIRES OF THE IGNITION SYSTEM. IN COLD TEMPERATURES THIS LUBRICANT FREEZES AND PREVENTS THE ELECTRICAL SIGNAL NEEDED BY THE PASSLOCK ANTI-THEFT SYSTEM FROM BEING RECEIVED BY THE BCM (BODY CONTROL MODULE). WHEN THIS SIGNAL ISN'T RECEIVED THE ANTI-THEFT SYS…

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FAULTY DESIGN IN THE IGNITION SWITCH. THE SWITCH LEAKS LUBRICANT ONTO THE WIRES OF THE IGNITION SYSTEM. IN COLD TEMPERATURES THIS LUBRICANT FREEZES AND PREVENTS THE ELECTRICAL SIGNAL NEEDED BY THE PASSLOCK ANTI-THEFT SYSTEM FROM BEING RECEIVED BY THE BCM (BODY CONTROL MODULE). WHEN THIS SIGNAL ISN'T RECEIVED THE ANTI-THEFT SYSTEM KICKS IN. IT THEN SHUTS OFF THE FUEL DELIVERY SYSTEM FOR A DEFAULT PERIOD OF 10 MINUTES OR SOMETIMES LONGER FOR UP TO AN HOUR. THIS HAS CAUSED NUMEROUS FAILURES WITH THE DRIVER BEING STRANDED IN COLD TEMPERATURES. THERE'S NUMEROUS DOCUMENTATION IN REGARDS TO THIS PROBLEM ONLINE FOR SEVERAL YEARS AND SATURN IS TAKING NO RESPONSIBILITY TO TRY AND REMEDY THIS PROBLEM, EXCEPT TO CHARGE UNREASONABLE PRICES TO FIX. IN ADDITION, ACCORDING TO MANY REVIEWS ONLINE THIS PROBLEM RESURFACES AT A LATER DATE... *TR

NHTSA ODI #10251607

Mileage unknown · Dec 5, 2008
Electrical System

IF THE SATURN VEHICLE IS EXPOSED TO TEMPERATURES AT OR APPROACHING 32 DEGREES F FOR SEVERAL HOURS WHEN THE ENGINE IS NOT RUNNING (USUALLY 6-10 HOURS), THEN WHEN YOU ATTEMPT TO START THE VEHICLE, THE IGNITION SWITCH CLICKS AND THE CAR STALLS. THE SECURITY SYSTEM KICKS IN. THE SECURITY LIGHT BLINKS AND THE ODOMETER SCREEN READS…

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IF THE SATURN VEHICLE IS EXPOSED TO TEMPERATURES AT OR APPROACHING 32 DEGREES F FOR SEVERAL HOURS WHEN THE ENGINE IS NOT RUNNING (USUALLY 6-10 HOURS), THEN WHEN YOU ATTEMPT TO START THE VEHICLE, THE IGNITION SWITCH CLICKS AND THE CAR STALLS. THE SECURITY SYSTEM KICKS IN. THE SECURITY LIGHT BLINKS AND THE ODOMETER SCREEN READS: 'SERVICE ENGINE SOON.' FUEL WILL NOT BE SENT TO THE ENGINE. THE VEHICLE WILL NOW NOT START FOR ABOUT 8-10 MINUTES AS THE SECURITY SYSTEM RESETS. AFTER 8-10 MINUTES, THE SECURITY LIGHT WILL STOP BLINKING AND THEN GO OUT. 'THE SERVICE ENGINE SOON' SCROLL LIGHT WILL STOP AND ALSO GO OUT. NOW, YOU MAY ATTEMPT TO START THE VEHICLE AGAIN. .HOWEVER, IF THE IGNITION SWITCH GREASE HAS NOT ADEQUATELY WARMED, THEN THE PROCESS WILL BEGIN AGAIN. A SIGNAL THAT THE VEHICLE WILL LIKELY START AFTER THE PRESENT 'LOCK-OUT' WILL BE WHEN THE IGNITION SEEMS TO CRANK A BIT MORE THAN JUST A CLICK, BEFORE LOCKING OUT AGAIN. REMEDY:1. THE GREASE IN THE IGNITION SWITCH IS FREEZING AND/OR HARDENING SO THAT THE IGNITION SWITCH CAN NOT ENGAGE. THE DEALER MUST RECALL ALL OF THESE VEHICLES AND REPLACE THE IGNITION SWITCH AND GREASE. THEY APPARENTLY HAVE A REDESIGNED SWITCH, WHICH CERTAINLY CAN BE CONSTRUED AS AN ADMISSION TO THE FAULTY DESIGN. OF COURSE, THIS TYPE OF REMEDIAL MEASURE CANNOT BE USED IN COURT, BUT IS CERTAINLY HELPFUL TO THOSE OF US CONSUMERS WHO ARE THE VICTIMS OF THE FAULTY DESIGN. SATURN MUST OPENLY ACKNOWLEDGE THE MISTAKE AND FIX IT, BEFORE SOMEONE IS STRANDED IN THE COLD, IN AN AREA WITH NO CELL PHONE SERVICE. SERVICE BULLETIN:040845005 NHTSA ITEM NUMBER:10007431 MFG BULLETIN DATE: 20060301 COMPONENT: ELECTRICAL SYSTEM:IGNITION:SWITCH BULLETIN SUMMARY: NO CRANK, NO START WHEN AMBIENT TEMPERATURES IS COLD - DIAGNOSTIC TROUBLE CODES (DTCS) B2960 AND OR B3033 ARE SET. *TR

NHTSA ODI #10250882

58,000 miles · Dec 5, 2008
Electrical System

I JUST BOUGHT A 2003 SATURN ION 2 ABOUT 2 WEEKS AGO. MY WIFE WOKE UP THIS MORNING TO START HER CAR AND IT WOULD NOT START. I TRIED JUMPING THE CAR AND STILL NO LUCK. THE PASSLOCK LIGHT CAME ON AND SAID SERVICE VEHICLE. SO I TOLD MY WIFE TO GET IN THE CAR AND SHIFT IT TO NEUTRAL SO WE COULD PUSH IT INTO A DIFFERENT SPOT SO SH…

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I JUST BOUGHT A 2003 SATURN ION 2 ABOUT 2 WEEKS AGO. MY WIFE WOKE UP THIS MORNING TO START HER CAR AND IT WOULD NOT START. I TRIED JUMPING THE CAR AND STILL NO LUCK. THE PASSLOCK LIGHT CAME ON AND SAID SERVICE VEHICLE. SO I TOLD MY WIFE TO GET IN THE CAR AND SHIFT IT TO NEUTRAL SO WE COULD PUSH IT INTO A DIFFERENT SPOT SO SHE COULD TAKE MY TRUCK TO WORK. SHE DECIDED TO TRY AND START IT ONE LAST TIME AND IT THEN STARTED. FRUSTRATED, I WENT ON TO THE INTERNET AND SEARCH FOR ION PROBLEMS AND HAVE FOUND ABOUT 200 COMPLAINTS ABOUT THE SAME PROBLEM. THIS IS A PROBLEM THAT SATURN NEEDS TO ADDRESS AND TAKE CARE!! *TR

NHTSA ODI #10250830

26,235 miles · Dec 3, 2008
Electrical System

WE OWN A 2003 SATURN ION AND THE KEY GETS STUCK IN THE IGNITION. YOU HAVE TO PRESS A RELEASE BUTTON IN THE STEERING COLUMN TO GET THE KEY OUT. IN ADDITION, THIS APPEARS TO CREATE AN ELECTRICAL ISSUE AS SOMETIMES THE CAR WON'T START. WE PURCHASED THIS VEHICLE USED AND TOOK IT BACK TO THE DEALERSHIP WITHIN THE 30 DAY WARRANTY PERI…

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WE OWN A 2003 SATURN ION AND THE KEY GETS STUCK IN THE IGNITION. YOU HAVE TO PRESS A RELEASE BUTTON IN THE STEERING COLUMN TO GET THE KEY OUT. IN ADDITION, THIS APPEARS TO CREATE AN ELECTRICAL ISSUE AS SOMETIMES THE CAR WON'T START. WE PURCHASED THIS VEHICLE USED AND TOOK IT BACK TO THE DEALERSHIP WITHIN THE 30 DAY WARRANTY PERIOD. THEY SAID THEY WERE "UNABLE TO REPLICATE" PROBLEM, UNBEKNOWNST TO US THIS WAS AN ONGOING ISSUE WITH SATURN IONS. THE "TEMPORARY FIX" IS EVEN IN THE OWNERS MANUAL. THAT'S JUST WRONG! HOW CAN A COMPANY GET AWAY WITH SELLING SUCH A DEFECTIVE PRODUCT -- AND ESPECIALLY A CAR!!! I FEEL RIPPED OFF AND SATURN SHOULD STAND BEHIND SUCH A DEFECTIVE VEHICLE ISSUE. THIS DOES CREATE A SAFETY ISSUE BECAUSE SOMETIMES THE CAR WON'T START LEAVING YOU STRANDED. THE DEALERSHIP WON'T EVEN OFFER TO GIVE A "FREE ESTIMATE" -- AND NOW THEY TELL ME THERE ARE VARIOUS POSSIBLE FIXES -- IT DEPENDS ON WHICH PART IS BROKEN. SO I HAVE TO GIVE THEM $85 FOR THEM TO TELL ME HOW MUCH IT WILL COST TO FIX. I AM A SINGLE PARENT, I PURCHASED THIS VEHICLE BECAUSE IT WAS AFFORDABLE AND I CERTAINLY DON'T SEE WHY I HAVE TO PAY FOR A MANUFACTURING DEFECT. SATURN NEEDS TO STEP UP AND FIX THE PROBLEM!!! THERE ARE HUNDREDS OF STORIES LIKE MINE ONLINE. I HOPE YOU CAN HELP! *TR

NHTSA ODI #10250573

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.