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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

Steering complaints

139 reports
Clear category filter
152,000 miles · Jan 14, 2019
Steering

TL* THE CONTACT OWNS A 2003 SATURN ION. WHILE DRIVING 65 MPH, THE STEERING SEIZED AND THE STEERING WHEEL COULD NOT BE TURNED AT ALL. THE CONTACT PULLED THE VEHICLE OVER AND WAITED FOR AWHILE. AFTERWARD, THE STEERING RETURNED TO NORMAL. THERE WERE NO WARNING INDICATORS ILLUMINATED. AN INDEPENDENT MECHANIC WAS CONTACTED, BUT COULD…

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TL* THE CONTACT OWNS A 2003 SATURN ION. WHILE DRIVING 65 MPH, THE STEERING SEIZED AND THE STEERING WHEEL COULD NOT BE TURNED AT ALL. THE CONTACT PULLED THE VEHICLE OVER AND WAITED FOR AWHILE. AFTERWARD, THE STEERING RETURNED TO NORMAL. THERE WERE NO WARNING INDICATORS ILLUMINATED. AN INDEPENDENT MECHANIC WAS CONTACTED, BUT COULD NOT REPAIR THE VEHICLE BECAUSE THEY DID NOT HAVE THE EQUIPMENT TO REPAIR ELECTRIC VEHICLES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER AND DEALER WERE NOT NOTIFIED. THE FAILURE MILEAGE WAS 152,000.

NHTSA ODI #11169983

Mileage unknown · Apr 4, 2018
Electrical SystemSteering

2003 SATURN ION. CONSUMER WRITES IN REGARDS TO IGNITION SWITCH AND POWER STEERING RECALL NOTICES ISSUES. *SMD *CN

NHTSA ODI #10725028

Mileage unknown · Mar 4, 2018
Steering

POWER STEERING GOES IN AND OUT WHEN DRIVING

NHTSA ODI #11076141

Mileage unknown · Dec 13, 2017
Electrical SystemElectronic Stability Control (esc)Steering

CAR JUST RECENTLY POPPED UP POWER STEERING ONLY HAPPENS WHEN ITS SITS OVER NIGHT AND WHEN I START IT UP IN THE MORNING IT'S VERY STIFF TO TURN BUT IF I DRIVE IT LIKE THAT FOR A LITTLE AND SHUT THE CAR OFF THE STEERING IS FINE. THE DASH LIGHTS FLICKER OFF AND ON AND WHEN DOING SO CAUSES HEAT OR A/C TO CUT OUT AFTER DRIVING IT FOR…

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CAR JUST RECENTLY POPPED UP POWER STEERING ONLY HAPPENS WHEN ITS SITS OVER NIGHT AND WHEN I START IT UP IN THE MORNING IT'S VERY STIFF TO TURN BUT IF I DRIVE IT LIKE THAT FOR A LITTLE AND SHUT THE CAR OFF THE STEERING IS FINE. THE DASH LIGHTS FLICKER OFF AND ON AND WHEN DOING SO CAUSES HEAT OR A/C TO CUT OUT AFTER DRIVING IT FOR ALITTLE BIT. THE KEY LOCKS IN THE IGNITION SWITCH WHEN I GO TO SHUT OFF THE CAR AND I HAVE TO PRESS THE PLUNGER FOR IT TO RELEASE. KEEPS SAYING COOLANT WHEN GOING DOWN THE ROAD EVEN THOUGH THE COOLANT IS WHERE IT NEEDS TO BE. *TR

NHTSA ODI #11054619

227,478 miles · Oct 5, 2017
Steering

SEVERAL TIMES THESE LAST FEW MONTHS MY VEHICLE PWR STR LIGHT HAS COME ON. THE STEERING WHEEL IS HARD TO TURN LEFT OR RIGHT. THE FIRST TIME THIS HAPPENED I TURNED THE CAR OFF AND WENT IN THE HOUSE AND GOT MY HUSBAND. WHEN HE TURNED IT ON AND PUT IT IN REVERSE NOTHING HAPPENED, IT WAS OK. THE NEXT TIME I WAS BACKING INTO A PARKING…

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SEVERAL TIMES THESE LAST FEW MONTHS MY VEHICLE PWR STR LIGHT HAS COME ON. THE STEERING WHEEL IS HARD TO TURN LEFT OR RIGHT. THE FIRST TIME THIS HAPPENED I TURNED THE CAR OFF AND WENT IN THE HOUSE AND GOT MY HUSBAND. WHEN HE TURNED IT ON AND PUT IT IN REVERSE NOTHING HAPPENED, IT WAS OK. THE NEXT TIME I WAS BACKING INTO A PARKING SPOT, IT LOCKED UP AND WAS HARD TO TURN. I TURNED THE IGNITION OFF AND RESTARTED IT, THEN IT WORKED AGAIN. THEN AGAIN IN THE DRIVE POSITION. THIS HAS HAPPENED SEVERAL TIMES. MY DAUGHTER WAS DRIVING THE CAR NOT LONG AGO ON A CITY STREET AND HAD TO STOP IN THE MIDDLE OF THE STREET, TURN THE CAR OFF AND ON AGAIN, THEN IT WAS OK. TODAY I WAS DRIVING ON THE ROAD (A CITY STREET) AND THE STEERING WHEEL LOCKED. I FOUGHT WITH THE WHEEL TO GET OVER. TURNED THE CAR OFF AND ON AGAIN BUT THE STEERING WHEEL WAS STILL HARD TO TURN AND THE PWR STR LIGHT REMAINED ON. I DID THIS SEVERAL TIMES TO NO AVAIL.THE WHEEL STAYED HARD TO TURN. I FOUGHT WITH THE WHEEL, TURNING CORNERS, PRAYING NO ONE WOULD BE IN MY WAY AS I HAD TO MAKE WIDE TURNS BECAUSE OF THE HARD STEERING WHEEL. WHEN I GOT TO MY DRIVEWAY I HAD TO TURN AND BACKUP SEVERAL TIMES TO GET INTO MY DRIVEWAY. I TURNED THE CAR OFF AND ON AGAIN SEVERAL TIMES AND THE LIGHT HAS NOT GONE OUT. I WILL NOT BE ABLE TO DRIVE MY CAR IN THIS CONDITION.

NHTSA ODI #11031976

69,000 miles · Aug 25, 2017
Electrical SystemSteering

SEVERAL TIMES WHEN I HAVE GONE TO TURN OFF MY CAR THE IGNITION SWITCH WILL NOT RELEASE THE KEY. WHEN THIS HAPPENS I HAVE TO PLACE MY FOOT BACK ON THE BRAKE AND RUN THROUGH THE GEARS WITH MY GEAR STICK. THE IGNITION SWITCH THAT IS CURRENTLY IN MY CAR IS ONE THAT WAS USED TO REPLACE THE FACTORY ONE WHEN THE IGNITION SWITCH RECALL …

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SEVERAL TIMES WHEN I HAVE GONE TO TURN OFF MY CAR THE IGNITION SWITCH WILL NOT RELEASE THE KEY. WHEN THIS HAPPENS I HAVE TO PLACE MY FOOT BACK ON THE BRAKE AND RUN THROUGH THE GEARS WITH MY GEAR STICK. THE IGNITION SWITCH THAT IS CURRENTLY IN MY CAR IS ONE THAT WAS USED TO REPLACE THE FACTORY ONE WHEN THE IGNITION SWITCH RECALL WAS ISSUED. ALSO, RECENTLY MY CAR HAS BEEN SHOWING PROBLEMS WITH THE POWER STEERING. IT HAS GONE OUT MULTIPLE TIMES ON MY SON WHILE HE WAS DRIVING RESULTING IN HIM HAVING TO FIGHT THE CAR TO GET IT TO TURN. I HAVE NEVER HAD A PROBLEM BEFORE AND I HEAR THAT THERE ARE RECALLS FOR BOTH. THESE PROBLEMS HAVE HAPPENED MULTIPLE TIMES AND I DO NOT HAVE EXACT DATES.

NHTSA ODI #11019790

143,000 miles · Jul 21, 2017
Steering

THE POWER STEERING WENT OUT ON MY CAR TWICE SO FAR, BOTH TIMES I WAS DRIVING THE CAR AT THE TIME IT WENT OUT. THIS HAPPENED ONE WEEK APART AND BOTH TIMES THE POWER STEERING CAM BACK AFTER THE IGNITION WAS TURNED OFF AND THEN RESTARTED. THE FIRST TIME IT WENT OUT I WAS DRIVING ON AN INTERSTATE HIGHWAY AND THE SECOND IN THE CITY.

NHTSA ODI #11010014

170,000 miles · Apr 10, 2017
Air BagsSteeringVehicle Speed ControlCrashInjury

DRIVING ON STAIGHT ON THE HIGHWAY HIT A BUMP IN THE ROAD MY CAR STARTED SPINNING OUT OF CONTROL STEERING WHEEL LOCKED UP WHICH MADE MY DRIVER SIDE CRASH INTO A CEMENT WALL, MY AIRBAGS DID NOT DEPLOY EVEN THOUGHT THE CAR HIT THE WALL SO HARD THAT IT CRACKED MY RADIATOR, MY CAR THEN SHUT OFF THEN TURNED BACK ON

NHTSA ODI #10971606

134,000 miles · Sep 18, 2016
Steering

IN JUNE OF 2016 AT A SPEED OF APPROX. 70 MPH MY 2003 SATURN ION LOST POWER STEERING ON THE E-WAY. I HAD TO PULL OFF E-WAY. PARK AND RESTART. AFTER RESTART POWER STEERING WAS BACK BUT ONLY FOR SHORT PERIODS OF TIME. HAS BEEN AN OFF AND ON REOCCURING PROBLEM SINCE.

NHTSA ODI #10907471

141,000 miles · Aug 15, 2016
Air BagsElectrical SystemEngine

TL* THE CONTACT OWNS A 2003 SATURN ION. WHILE DRIVING AT VARIOUS SPEEDS, THE STEERING WHEEL BECAME DIFFICULT TO TURN. THE CONTACT HAD TO APPLY FORCE TO THE STEERING WHEEL IN ORDER TO STEER THE VEHICLE. THE FAILURE RECURRED ON NUMEROUS OCCASIONS. THE VEHICLE WAS TAKEN TO A DEALER AND REPAIRED PER A RECALL. AFTER THE REPAIRS, WHIL…

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TL* THE CONTACT OWNS A 2003 SATURN ION. WHILE DRIVING AT VARIOUS SPEEDS, THE STEERING WHEEL BECAME DIFFICULT TO TURN. THE CONTACT HAD TO APPLY FORCE TO THE STEERING WHEEL IN ORDER TO STEER THE VEHICLE. THE FAILURE RECURRED ON NUMEROUS OCCASIONS. THE VEHICLE WAS TAKEN TO A DEALER AND REPAIRED PER A RECALL. AFTER THE REPAIRS, WHILE DRIVING AT VARIOUS SPEEDS, THE ACCELERATOR PEDAL WAS DEPRESSED, BUT THE VEHICLE FAILED TO ACCELERATE. THE AIR BAG AND CHECK ENGINE WARNING LIGHTS ILLUMINATED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURES. THE RECALL SPECIFICS WERE UNKNOWN. THE FAILURE MILEAGE WAS 141,000. UPDATED 10/19/16*LJ *TR

NHTSA ODI #10895916

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.