IllustrationRAN OUT OF GAS. INSPECTION INDICATES THAT FUEL IS LEAKING FROM RUSTED FUEL LINE IN FRONT OF LEFT (DRIVER'S SIDE) REAR TIRE. FURTHER INSPECTION SHOWS HEAVY/EXTENSIVE RUST ON THE FUEL LINES ALONG THE ENTIRE LENGTH OF THE UNDERCARRIAGE. PROBLEM APPEARS IDENTICAL TO ANOTHER INCIDENT PREVIOUSLY REPORTED AS #10668929.
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 →How this year compares
Owner complaints by model year
Compare all Ion years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
870–25K
8425–50K
12650–75K
8575–100K
114100–150K
57150K+
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
Fuel/propulsion System complaints
19 reportsTHE FUEL LINES BETWEEN THE GAS TANK AND ENGINE HAVE RUSTED OUT. THEY ARE RUSTED DUE TO THE BRACKETS HOLDING THEM TO THE FRAME AS WELL AS A WATER SOAKED INSULATING BLANKET THAT HAD BEEN PUT AROUND THE FUEL LINES TO PROTECT THEM FROM THE EXHAUST PIPES HEAT. THIS ONLY SPED UP THE RUSTING PROCESS. THEY ARE RUSTED TO THE POINT THAT T…
Read full complaint
THE FUEL LINES BETWEEN THE GAS TANK AND ENGINE HAVE RUSTED OUT. THEY ARE RUSTED DUE TO THE BRACKETS HOLDING THEM TO THE FRAME AS WELL AS A WATER SOAKED INSULATING BLANKET THAT HAD BEEN PUT AROUND THE FUEL LINES TO PROTECT THEM FROM THE EXHAUST PIPES HEAT. THIS ONLY SPED UP THE RUSTING PROCESS. THEY ARE RUSTED TO THE POINT THAT THE GAS IS SPRAYING ON THE EXHAUST PIPES CAUSING A POSSIBLE FIRE OR EXPLOSION. THE LEAK IS ONLY WITHIN A FOOT FROM THE GAS TANK MAKING IT EVEN MORE DANGEROUS. UPON MY RESEARCH I HAVE FOUND THAT SATURN HAS ADDRESSED THIS SAME PROBLEM WITH THEIR 2004 MODELS BUT NOT THE 2003 MODEL. (GM RECALL NO. 04053) THE DIFFERENCE IN THE MODEL YEARS HAS NOT MADE THIS ANY LESS OF A HAZARD. IN A CALL TO SATURN THEY TOLD ME THAT NOTHING CAN BE DONE WITH MY 2003 BUT IF I OWNED A 2004 THIS WOULD BE COVERED ON A SAFETY RECALL. THIS REASONING SOUNDS RATHER FOOLISH TO ME AND THE HAZARD SHOULD BE FIXED REGARDLESS OF THE YEAR VEHICLE. A FIRE OR EXPLOSION DOESN'T KNOW WHAT THE MODEL YEAR IT IS. WHY DID SATURN NOT MAKE THESE FUEL LINES OUT OF STAINLESS STEEL, A MATERIAL THAT WOULD NOT HAVE RUSTED AND BECOME A SAFETY HAZARD? I WOULD APPRECIATE ANY UPDATES ON THIS MATTER. THANK YOU *TR
VEHICLE WAS IN FOR RECALL ON IGNITION SWITCH, AT THE DEALERSHIP CHANGED OIL AND CONDUCTED MULTIPOINT INSPECTION OF VEHICLE. EIGHT WEEKS LATER VEHICLE WAS RETURNED FOR SERVICE FOR SMELL OF GAS, DEALERSHIP REPORTED ALL GAS LINES CORRODED AND LEAKING GAS AND NEED TO BE REPLACED, DEALERSHIP STATES NOT RELEATED TO FUEL FILTER CORROSI…
Read full complaint
VEHICLE WAS IN FOR RECALL ON IGNITION SWITCH, AT THE DEALERSHIP CHANGED OIL AND CONDUCTED MULTIPOINT INSPECTION OF VEHICLE. EIGHT WEEKS LATER VEHICLE WAS RETURNED FOR SERVICE FOR SMELL OF GAS, DEALERSHIP REPORTED ALL GAS LINES CORRODED AND LEAKING GAS AND NEED TO BE REPLACED, DEALERSHIP STATES NOT RELEATED TO FUEL FILTER CORROSION RECALL (NTHSA 04V003000) EVEN THOUGH RECALL SERVICE NOT PERFORMED. CORRODED, LEAKING GAS LINES MAKE VEHICLE UNSAFE TO OPERATE AND HAVE THE POTENTIAL FOR FIRE. BELIEVE THIS SHOULD BE A RECALL AS OPERATING THE VEHICLE WITH LEAKING GAS LINES PUT ME AND MY FAMILY IN DANGER. NOT MENTION THE $1000 PLUS REPAIRS VEHICLE. *TR
TL* THE CONTACT OWNS A 2003 SATURN ION. THE CONTACT STATED AFTER DRIVING THE VEHICLE FOR A FEW MILES THERE WAS A FUEL ODOR THROUGHOUT THE VEHICLE. THE CONTACT STATED THAT AFTER THE VEHICLE WAS PARKED, THE FUEL ODOR INCREASED. THE FAILURE RECURRED ON A REGULAR BASIS. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS N…
Read full complaint
TL* THE CONTACT OWNS A 2003 SATURN ION. THE CONTACT STATED AFTER DRIVING THE VEHICLE FOR A FEW MILES THERE WAS A FUEL ODOR THROUGHOUT THE VEHICLE. THE CONTACT STATED THAT AFTER THE VEHICLE WAS PARKED, THE FUEL ODOR INCREASED. THE FAILURE RECURRED ON A REGULAR BASIS. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE AND CURRENT MILEAGE WAS 165,000.
SMELLED GAS FUMES. NOTICED LEAKING GAS ON GROUND. UPON FURTHER INSPECTION, NOTICED THE FUEL LINES ARE COMPLETELY RUSTED OUT, CAUSING GAS TO LEAK OUT ONTO THE GROUND. THERE IS NO OTHER AREA ON THE CAR WITH RUST. RESEARCHING THIS ISSUE, I CAME ACROSS MANY OTHERS EXPERIENCING THE SAME PROBLEM WITH FUEL LINES RUSTING OUT. THE FUEL L…
Read full complaint
SMELLED GAS FUMES. NOTICED LEAKING GAS ON GROUND. UPON FURTHER INSPECTION, NOTICED THE FUEL LINES ARE COMPLETELY RUSTED OUT, CAUSING GAS TO LEAK OUT ONTO THE GROUND. THERE IS NO OTHER AREA ON THE CAR WITH RUST. RESEARCHING THIS ISSUE, I CAME ACROSS MANY OTHERS EXPERIENCING THE SAME PROBLEM WITH FUEL LINES RUSTING OUT. THE FUEL LINES THAT WERE PUT IN WERE WRAPPED WITH A HEAT RESISTANT COVERING WHICH CAUSED WATER TO STAY AND MOISTURE TO BUILD UP, EVENTUALLY RESULTING IN CORROSION. FURTHERMORE, THE GASOLINE LEAKAGE OCCURRED WITHIN CLOSE PROXIMITY OF THE EXHAUST SYSTEM, WHICH COULD CAUSE FIRE OR EXPLOSION. THE FUEL LINES ARE INADEQUATE, AND DANGEROUS. POTENTIAL FIRE HAZARD. THIS ISSUE NEEDS TO BE ADDRESSED IMMEDIATELY AS IT IS VERY DANGEROUS LEFT UNATTENDED. COULD CAUSE SERIOUS BODILY HARM OR DEATH. *TR
TL* THE CONTACT OWNS A 2003 SATURN ION. THE CONTACT STATED THAT A FUEL LEAK WAS PRESENT FROM THE DRIVER'S SIDE REAR WHEEL AREA. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO DIAGNOSED THAT THE FUEL SUPPLY LINE WAS DEFECTIVE AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE …
Read full complaint
TL* THE CONTACT OWNS A 2003 SATURN ION. THE CONTACT STATED THAT A FUEL LEAK WAS PRESENT FROM THE DRIVER'S SIDE REAR WHEEL AREA. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO DIAGNOSED THAT THE FUEL SUPPLY LINE WAS DEFECTIVE AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 178,000.
SIGNIFICANT RUST AND STRESS FRACTURES ON FUEL LINE RESULTING IN NOTICEABLE FUEL LEAKAGE WITH THE POTENTIAL OF INCENDIARY INCIDENT IN THE CASE OF COLLISION. AFTER VEHICLE MESSAGE BOARD QUERIES THIS PROBLEM SEEMS TO OCCUR WITH UNUSUAL FREQUENCY IN SATURN IONS SPANNING 2003-2007. PAID OUT OF POCKET TO HAVE THE FUEL LINE REPLACED;…
Read full complaint
SIGNIFICANT RUST AND STRESS FRACTURES ON FUEL LINE RESULTING IN NOTICEABLE FUEL LEAKAGE WITH THE POTENTIAL OF INCENDIARY INCIDENT IN THE CASE OF COLLISION. AFTER VEHICLE MESSAGE BOARD QUERIES THIS PROBLEM SEEMS TO OCCUR WITH UNUSUAL FREQUENCY IN SATURN IONS SPANNING 2003-2007. PAID OUT OF POCKET TO HAVE THE FUEL LINE REPLACED; WAS TOLD THAT NO RECALL EXISTS FOR THIS PROBLEM SO I WANTED TO REPORT IT. *TR
DETECTED SMELL OF GASOLINE. CHECKED RECALLS. THERE ARE SOME RECALLS FOR THIS CAR BUT NOT THIS VIN. TOOK TO DEALERSHIP AND HAD RUSTY GAS LINE REPLACED. PAID FOR PARTS AND WORK DONE. *TR
CAR WAS PARKED WHEN STRONG GASOLINE ODOR WAS NOTICED. MOVED CAR TO HARD SURFACE AND DISCOVERED VEHICLE WAS LEAKING RATHER LARGE AMOUNT OF FUEL FROM AREA BEHIND DRIVER SIDE REAR DOOR. TOOK CAR TO DEALER WHERE IT WAS DIAGNOSED AS A CRACKED FUEL PUMP HOUSING. NOTICED 2007 MODEL HAS BEEN RECALLED FOR FUEL PUMP ISSUE. FURTHER STUDY S…
Read full complaint
CAR WAS PARKED WHEN STRONG GASOLINE ODOR WAS NOTICED. MOVED CAR TO HARD SURFACE AND DISCOVERED VEHICLE WAS LEAKING RATHER LARGE AMOUNT OF FUEL FROM AREA BEHIND DRIVER SIDE REAR DOOR. TOOK CAR TO DEALER WHERE IT WAS DIAGNOSED AS A CRACKED FUEL PUMP HOUSING. NOTICED 2007 MODEL HAS BEEN RECALLED FOR FUEL PUMP ISSUE. FURTHER STUDY SHOULD PROBABLY BE DONE TO DETERMINE IF THIS IS A WIDESPREAD PROBLEM IN THE ENTIRE ION LINE. THE AMOUNT OF FUEL RELEASED AFTER PART FAILURE IS A SIGNIFICANT FIRE HAZARD. *TR
Official recalls
514V171000 · 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. 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.
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
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.