NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
33 reportsClear category filterMileage unknown · Jan 9, 2014
Electrical SystemEngine And Engine CoolingSteering
2004 SATURN ION. CONSUMER WRITES IN REGARDS TO ELECTRONIC POWER STEERING FAILURE. *SMD THE CONSUMER STATED SHE FIRST STARTED HAVING FRONT SUSPENSION PROBLEMS, WHICH THE DEALER FIXED FREE OF CHARGE. THE EXHAUST WAS LEAKING AND SHE PAID TO HAVE IT REPLACED, ALONG WITH THE CATALYTIC CONVERTER. ALSO, THE HORN STOPPED WORKING. THE…
Read full complaint
2004 SATURN ION. CONSUMER WRITES IN REGARDS TO ELECTRONIC POWER STEERING FAILURE. *SMD THE CONSUMER STATED SHE FIRST STARTED HAVING FRONT SUSPENSION PROBLEMS, WHICH THE DEALER FIXED FREE OF CHARGE. THE EXHAUST WAS LEAKING AND SHE PAID TO HAVE IT REPLACED, ALONG WITH THE CATALYTIC CONVERTER. ALSO, THE HORN STOPPED WORKING. THE CONSUMER RECEIVED A LETTER IN JULY 2012, FROM GM STATING THE WARRANTY WAS BEING EXTENDED BECAUSE THE ELECTRIC POWER STEERING COULD FAIL. ON DECEMBER 16, 2013, THE POWER STEERING FAILED, AS THE CONSUMER WAS LEAVING A PARKING LOT. SHE HAD TO USE EXTRA FORCE TO TURN THE STEERING WHEEL. AFTER A COUPLE OF MINUTES, IT WAS BACK TO NORMAL. A TEST REVEALED, THERE WAS INDEED A FAILURE. WHEN THE CONSUMER CALLED GM, SHE WAS INFORMED THE EXTENDED WARRANTY HAD EXPIRED ON 11/28/13 THE CONSUMER NO LONGER OWNS THE VEHICLE. UPDATED 02/5/14
NHTSA ODI #10558808
58,000 miles · May 18, 2011
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2004 SATURN ION. THE CONTACT STATED WHEN THE VEHICLE WAS TURNED ON IT FAILED TO START. THE FAILURE OCCURRED INTERMITTENTLY, AND ON ONE OCCASION THE VEHICLE STALLED WITHOUT WARNING. THE MANUFACTURER TOOK FILED REPORT 71948037911 AND ADVISED THAT THEY WERE NOT AWARE OF THE FAILURE, AND THERE WERE NO RELATED …
Read full complaint
TL*THE CONTACT OWNS A 2004 SATURN ION. THE CONTACT STATED WHEN THE VEHICLE WAS TURNED ON IT FAILED TO START. THE FAILURE OCCURRED INTERMITTENTLY, AND ON ONE OCCASION THE VEHICLE STALLED WITHOUT WARNING. THE MANUFACTURER TOOK FILED REPORT 71948037911 AND ADVISED THAT THEY WERE NOT AWARE OF THE FAILURE, AND THERE WERE NO RELATED RECALLS. THE VEHICLE WILL BE TAKEN TO THE LOCAL MECHANIC FOR DIAGNOSTIC TESTING. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILES WERE 58,000.
NHTSA ODI #10401415
88,000 miles · Mar 14, 2011
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2004 SATURN ION 3 COUPE. THE CONTACT WAS APPROACHING A TRAFFIC STOP WHEN THE VEHICLE BEGAN TO IDLE HARD AND DISPLAYED SEVERAL ATTEMPTS TO STALL. THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC WHERE A DIAGNOSTIC WAS PERFORMED AND THE CONTACT WAS ADVISED THAT THE CATALYTIC CONVERTER WOULD NEED REPLACEMENT. HE TH…
Read full complaint
TL* THE CONTACT OWNS A 2004 SATURN ION 3 COUPE. THE CONTACT WAS APPROACHING A TRAFFIC STOP WHEN THE VEHICLE BEGAN TO IDLE HARD AND DISPLAYED SEVERAL ATTEMPTS TO STALL. THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC WHERE A DIAGNOSTIC WAS PERFORMED AND THE CONTACT WAS ADVISED THAT THE CATALYTIC CONVERTER WOULD NEED REPLACEMENT. HE THEN CONTACTED THE MANUFACTURER AND WAS ADVISED TO TAKE THE VEHICLE TO AN AUTHORIZED DEALER. THE DEALER ADVISED THERE WERE NO RECALLS ON THE VEHICLE AND THE VEHICLE WAS NOT DIAGNOSED BY THE DEALER. THE VEHICLE WAS NOT REPAIRED AND THE FAILURE BECAME PROGRESSIVELY WORSE TO THE POINT WHERE IT WOULD STALL SPORADICALLY AND WITHOUT WARNING. THE FAILURE MILEAGE WAS 88,000 AND THE CURRENT MILEAGE WAS 93,640.
NHTSA ODI #10390057
86,000 miles · Aug 21, 2010
Engine And Engine Cooling
MY 2004 SATURN ION WILL NOT START ON COLD DAYS. I LIVE IN VERMONT SO THERE ARE PLENTY OF COLD DAYS. IT USUALLY TAKES ME ABOUT 10 MINUTES TO1/2 HOUR TO GET IT STARTED, IF IT STARTS. WHEN IT FINALLY STARTS I HAVE TO LEAVE IT RUNNING SO THE ENGINE WILL WARM UP BECAUSE IF I DON'T I HAVE TO START THE PROCESS OVER AGAIN. THIS IS A…
Read full complaint
MY 2004 SATURN ION WILL NOT START ON COLD DAYS. I LIVE IN VERMONT SO THERE ARE PLENTY OF COLD DAYS. IT USUALLY TAKES ME ABOUT 10 MINUTES TO1/2 HOUR TO GET IT STARTED, IF IT STARTS. WHEN IT FINALLY STARTS I HAVE TO LEAVE IT RUNNING SO THE ENGINE WILL WARM UP BECAUSE IF I DON'T I HAVE TO START THE PROCESS OVER AGAIN. THIS IS A HUGE INCONVENIENCE! EVERYONE I'VE BROUGHT IT TO DOESN'T SEEM TO KNOW WHAT THE PROBLEM IS. I LOVE MY CAR BUT COULD DEFINITELY DO WITHOUT THIS PROBLEM! *TR
NHTSA ODI #10351077
Mileage unknown · Jul 29, 2010
Engine And Engine Cooling
WHEN THE WEATHER GETS TOO COLD, MY CAR DOES NOT START. I EITHER HAVE TO KEEP TRYING TO START THE IGNITION EVERY 5 MINUTES AND THEN IN HALF AN HOUR IT STARTS OR I HAVE TO WAIT UNTIL THE SUN COMES OUT FOR MY CAR TO START. I'VE HAD THIS CAR FOR A COUPLE OF YEARS NOW AND I ONLY HAVE THIS PROBLEM FROM NOVEMBER-FEBRUARY. THESE ARE THE…
Read full complaint
WHEN THE WEATHER GETS TOO COLD, MY CAR DOES NOT START. I EITHER HAVE TO KEEP TRYING TO START THE IGNITION EVERY 5 MINUTES AND THEN IN HALF AN HOUR IT STARTS OR I HAVE TO WAIT UNTIL THE SUN COMES OUT FOR MY CAR TO START. I'VE HAD THIS CAR FOR A COUPLE OF YEARS NOW AND I ONLY HAVE THIS PROBLEM FROM NOVEMBER-FEBRUARY. THESE ARE THE COLDEST MONTHS AND EVERY MORNING DURING THESE MONTHS I HAVE THIS PROBLEM OF NOT BEING ABLE TO START MY VEHICLE. *TR
NHTSA ODI #10346057
123,000 miles · Apr 21, 2010
Engine And Engine Cooling
DRIVING DOWN THE ROAD CAR SHUTS OFF, I WAS GOING 20MHP THE ROAD WAS STRAIGHT CAME TO A RIGHT HAND BEND IN THE ROAD AND CAR WAS OFF NO ABS, NO PWR STER, THERE WERE CARS SITTING AT THE STOP SIGN. LUCKILY I WAS ABLE TO GET THE CAR STOPPED. TO GET THE CAR STARTED I HAD TO PUT IN PARK TURN KEY OFF THEN TURN KEY OVER AND IT STARTS RIG…
Read full complaint
DRIVING DOWN THE ROAD CAR SHUTS OFF, I WAS GOING 20MHP THE ROAD WAS STRAIGHT CAME TO A RIGHT HAND BEND IN THE ROAD AND CAR WAS OFF NO ABS, NO PWR STER, THERE WERE CARS SITTING AT THE STOP SIGN. LUCKILY I WAS ABLE TO GET THE CAR STOPPED. TO GET THE CAR STARTED I HAD TO PUT IN PARK TURN KEY OFF THEN TURN KEY OVER AND IT STARTS RIGHT UP. THIS IS NOW THE 2ND TIME THIS HAS HAPPENED. FIRST TIME SITTING AT A RED LIGHT CAR WAS RUNNING LIGHT TURNED GREEN GAVE IT THE GAS MID WAY THROUGH INTERSECTION CAR SHUT OFF AGAIN AND DRIFTED TO SIDE OF THE ROAD WITH A BUNCH OF CARS HONKING. I THOUGHT I NEEDED A TUNE UP AND THAT WAS 3MONTHS AGO. THAT HAPPENED UNTIL TWO DAYS AGO. CAR SHUTS OFF WHILE DRIVING WITH WARNING, IF I WAS GOING ANY FASTER I WOULD HAVE HIT THE BACK END OF THE CAR THAT WAS STOPPED @ A STOP SIGN. 2004 SATURN ION 2.2L I HAVE NOT DONE ANYTHING WITH THIS PART DO TO NO INCOME RIGHT NOW. *TR
NHTSA ODI #10326880
82,000 miles · Mar 8, 2010
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2004 SATURN ION. THE CONTACT STARTED THE IGNITION; HOWEVER, THE ENGINE FAILED TO START AFTER SEVERAL ATTEMPTS. THE PREVIOUS DAY THE VEHICLE WAS USED TO JUMP START ANOTHER VEHICLE. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER FOR DIAGNOSTIC TESTING. THE TECHNICIAN STATED THAT THE ENGINE NEEDED TO BE REPLAC…
Read full complaint
TL*THE CONTACT OWNS A 2004 SATURN ION. THE CONTACT STARTED THE IGNITION; HOWEVER, THE ENGINE FAILED TO START AFTER SEVERAL ATTEMPTS. THE PREVIOUS DAY THE VEHICLE WAS USED TO JUMP START ANOTHER VEHICLE. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER FOR DIAGNOSTIC TESTING. THE TECHNICIAN STATED THAT THE ENGINE NEEDED TO BE REPLACED. THE VEHICLE HAS NOT BEEN REPAIRED AT THIS TIME. THE BATTERY HAS BEEN REPLACED ON THREE SEPARATE OCCASIONS. THE FAILURE MILEAGE WAS 82,000.
NHTSA ODI #10317625
17,000 miles · Feb 25, 2010
Engine And Engine CoolingVehicle Speed Control
OUR 4 CYLINDER 2004 SATURN ION HAS HAD UNINTENDED SUDDEN ACCELERATION PROBLEMS FOR SEVERAL YEARS. I AM A PATENT HOLDING SOFTWARE AND HARDWARE ENGINEER AND I CAN STATE ABSOLUTELY AFTER OBSERVING THE BEHAVIOR OVER AT LEAST 4 YEARS THAT THIS IS A SOFTWARE ISSUE AND/OR A SENSOR ISSUE AND NOT A STICKING MECHANICAL CONTROL. IT IS NO…
Read full complaint
OUR 4 CYLINDER 2004 SATURN ION HAS HAD UNINTENDED SUDDEN ACCELERATION PROBLEMS FOR SEVERAL YEARS. I AM A PATENT HOLDING SOFTWARE AND HARDWARE ENGINEER AND I CAN STATE ABSOLUTELY AFTER OBSERVING THE BEHAVIOR OVER AT LEAST 4 YEARS THAT THIS IS A SOFTWARE ISSUE AND/OR A SENSOR ISSUE AND NOT A STICKING MECHANICAL CONTROL. IT IS NOT NECESSARY TO EVEN TOUCH OR MOVE THE ACCELERATOR PEDAL IN ORDER FOR THIS TO OCCUR. UNDER CERTAIN CONDITIONS OF TEMPERATURE AND HUMIDITY, EITHER SOME SENSOR MALFUNCTIONS OR SOME CONNECTOR BECOMES INTERMITTENT OR THE SOFTWARE MISREADS SOMETHING. AT STARTUP THE ENGINE RUNS AT AN UNUSUALLY HIGH IDLE (~800 RPM), AND AS SOON AS YOU PUT IT IN GEAR, THE CAR LUNGES FORWARD OR BACKWARD HARD AND YOU HAVE TO PUT IT IN NEUTRAL TO AVOID HAVING IT RUN AWAY WITH YOU - ALL THIS WITHOUT TOUCHING THE ACCELERATOR PEDAL. WHEN YOU PUT THE CAR IN NEUTRAL THE ENGINE RUNS AT BETWEEN 3,000 AND 4,000 RPM ON THE TACHOMETER FOR A FEW SECONDS AND THEN SLOWLY DROPS BACK TO AN IDLE (~800RPM). AS SOON AS YOU PUT IT IN GEAR AGAIN, THE CAR LUNGES ONCE AGAIN - THROW IT IN NEUTRAL - 3,000 - 4,000 RPM, SLOWLY RECOVERS. AFTER TWO - THREE MINUTES THE ENGINE STABILIZES AND THE PROBLEM IS GONE. PLEASE NOTE THIS IS ALL WITHOUT TOUCHING THE ACCELERATOR - EVER! THIS HAPPENS WHEN THE VEHICLE IS COLD AND USUALLY DURING HIGH HUMIDITY OR RAINY CONDITIONS. IT IS SO UNPREDICTABLE THAT I HAVE NEVER SOUGHT HELP FROM A DEALER. IT IS NOT REPEATABLE IN A WAY THAT THE DEALER WOULD BE ABLE TO DIAGNOSE SINCE IT HAPPENS FAIRLY RARELY (SOMETIMES A COUPLE OF TIMES A WEEK - SOMETIMES ONCE A MONTH) AND INCONSISTENTLY. IF I WAS AN INEXPERIENCED DRIVER AND IF THIS WAS A MORE POWERFUL CAR, I WOULD NO DOUBT HAVE HAD A SERIOUS ACCIDENT BY NOW. I HAVE LEARNED TO PAY ATTENTION TO THE MOTOR WHEN I FIRST START THE VEHICLE. IF IT SOUNDS LIKE IT IS IDLING A BIT FAST THEN I KNOW IT WILL TRY TO RUN AWAY WITH ME WHEN I PUT IT IN GEAR SO I JUST WAIT FOR IT TO IDLE DOWN TO NORMAL BEFORE PUTTING IT IN GEAR. *TR
NHTSA ODI #10314087
63,270 miles · Jan 4, 2010
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2004 SATURN ION. THE VEHICLE WOULD NOT START WHENEVER THE TEMPERATURES OUTSIDE WERE LOW. THE VEHICLE HAS NOT BEEN DIAGNOSED BY THE DEALER AND THERE WERE NO PRIOR WARNINGS. THE CURRENT AND FAILURE MILEAGES WERE 63270.
NHTSA ODI #10298132
55,000 miles · Oct 28, 2009
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2004 SATURN ION. AFTER DRIVING FOR APPROXIMATELY TEN MINUTES THE VEHICLE INTERMITTENTLY STALLS. THE VEHICLE WAS IN THE PROCESS OF BEING TAKEN TO THE DEALER FOR INSPECTION. HOWEVER ON THE INTERNET SHE DISCOVERED MANY COMPLAINTS DESCRIBING THE FAILURE. THE FAILURE MILEAGE WAS 55,000 . THE VEHICLE IDENTIFICA…
Read full complaint
TL* THE CONTACT OWNS A 2004 SATURN ION. AFTER DRIVING FOR APPROXIMATELY TEN MINUTES THE VEHICLE INTERMITTENTLY STALLS. THE VEHICLE WAS IN THE PROCESS OF BEING TAKEN TO THE DEALER FOR INSPECTION. HOWEVER ON THE INTERNET SHE DISCOVERED MANY COMPLAINTS DESCRIBING THE FAILURE. THE FAILURE MILEAGE WAS 55,000 . THE VEHICLE IDENTIFICATION NUMBER WAS UNAVAILABLE.
NHTSA ODI #10290119
Official recalls
8Apr 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.
Mar 31, 2014
General Motors LLC (GM) is recalling certain model year 2004-2006 and 2008-2009 Chevrolet Malibu, 2004-2006 Malibu Maxx, 2009-2010 HHR (non-turbo), 2010 Cobalt, 2008-2009 Saturn Aura and 2004-2007 Ion, and 2005-2009 Pontiac G6. In the affected vehicles, there may be a sudden loss of electric power steering (EPS) assist that could occur at any time while driving.
Consequence & remedy
Consequence: If power steering assist is lost, greater driver effort would be required to steer the vehicle at low speeds, increasing the risk of a crash.
Remedy: GM will notify owners, and dealers will perform one of four bulletins. Parts are not currently available. GM expects to send an interim notification around May 28, 2014. When parts are available, owners will be mailed a second letter to come in to have the applicable bulletin applied. Bulletin 14115 covers model year 2004-2007 Saturn Ion, 2009-2010 Chevrolet HHR and 2010 Chevrolet Cobalts. Dealers will replace the EPS motor. Bulletin 14116 covers model year 2004-2006 Chevrolet Malibu and Malibu Maxx, 2005-2006 Pontiac G6 and 2008-2009 Chevrolet Malibu, Pontiac G6 and Saturn Aura built from March 1, 2008, through June 27, 2008. Dealers will replace the torque sensor assembly. Bulletin 14117 covers model year 2008 Chevrolet Malibu, Pontiac G6 and Saturn Aura built from February 1, 2008, through February 28, 2008. Dealers will replace the torque sensor assembly and EPS motor controller unit. Bulletin 14118 covers model year 2008 Chevrolet Malibu, Pontiac G6 and Saturn Aura built from October 1, 2007, through January 31, 2008. Dealers will replace the EPS motor controller unit. The recall began on July 17, 2014. Owners may contact Chevrolet at 1-800-630-2438, Saturn at 1-800-553-6000, and Pontiac at 1-800-620-7668. GM's number for this recall is N140115. Note: GM bulletin number 14119 will be implemented for model year 2006-2008 and early production of 2009 Chevrolet HHR (non-turbo) and model year 2003 Saturn ION to provide EPS Motor replacement for the life of the vehicle.
Feb 10, 2014
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring. General Motors LLC (GM) notified the agency on February 10, 2014 that they are recalling 619,122 model year 2005-2007 Chevrolet Cobalt, and 2007 Pontiac G5 vehicles. On February 25, 2014, GM increased the recall to include an additional 748,024 model year 2006-2007 Chevrolet HHR and Pontiac Solstice vehicles and 2003-2007 Saturn Ion vehicles and 2007 Saturn Sky vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine. On March 27, 2014, GM notified the agency that the defective ignition switches may have been used as service replacement parts on other vehicles, and as a result GM will be recalling certain model year 2008-2010 Chevrolet Cobalt, Saturn Sky, and Pontiac G5 and Solstice, and 2008-2011 Chevrolet HHR vehicles. The part numbers for the service parts are 10392423 (a/k/a ACDelco D1461F), 10392737, 15857948, 15854953, 15896640, and 25846762. This expansion represents an additional 823,788 vehicles.
Consequence & remedy
Consequence: If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a crash, increasing the risk of injury.
Remedy: GM will notify owners, and dealers will replace the ignition switch, free of charge. An interim notification was issued to owners of 2007 and earlier models on March 10, 2014, informing them of the safety defect. Owners of 2008 and later vehicles will be mailed an interim letter on April 21, 2014. All affected owners will receive another letter once parts are available. The recall began on April 18, 2014. Owners may contact Chevrolet at 1-800-222-1020, Pontiac at 1-800-762-2737 or Saturn at 1-800-553-6000. GM's number for the initial recall is 13454 and 14063 for the expansion. GMs recall number for the vehicles that may have received the replacement parts is 14092. Note: Until the recall repairs have been performed, it is very important that customers remove all items from their key rings, leaving only the vehicle key. The key fob (if applicable), should also be removed from the key ring. Always wear your seatbelt.
Additional source detail variants (2)
Air Bags
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring. General Motors LLC (GM) notified the agency on February 10, 2014 that they are recalling 619,122 model year 2005-2007 Chevrolet Cobalt, and 2007 Pontiac G5 vehicles. On February 25, 2014, GM increased the recall to include an additional 748,024 model year 2006-2007 Chevrolet HHR and Pontiac Solstice vehicles and 2003-2007 Saturn Ion vehicles and 2007 Saturn Sky vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine. On March 27, 2014, GM notified the agency that the defective ignition switches may have been used as service replacement parts on other vehicles, and as a result GM will be recalling certain model year 2008-2010 Chevrolet Cobalt, Saturn Sky, and Pontiac G5 and Solstice, and 2008-2011 Chevrolet HHR vehicles. The part numbers for the service parts are 10392423 (a/k/a ACDelco D1461F), 10392737, 15857948, 15854953, 15896640, and 25846762. This expansion represents an additional 823,788 vehicles.
Consequence: If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a crash, increasing the risk of injury.
Remedy: GM will notify owners, and dealers will replace the ignition switch, free of charge. An interim notification was issued to owners of 2007 and earlier models on March 10, 2014, informing them of the safety defect. Owners of 2008 and later vehicles will be mailed an interim letter on April 21, 2014. All affected owners will receive another letter once parts are available. The recall began on April 18, 2014. Owners may contact Chevrolet at 1-800-222-1020, Pontiac at 1-800-762-2737 or Saturn at 1-800-553-6000. GM's number for the initial recall is 13454 and 14063 for the expansion. GMs recall number for the vehicles that may have received the replacement parts is 14092. Note: Until the recall repairs have been performed, it is very important that customers remove all items from their key rings, leaving only the vehicle key. The key fob (if applicable), should also be removed from the key ring. Always wear your seatbelt.
Electrical System:ignition:switch
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring. General Motors LLC (GM) notified the agency on February 10, 2014 that they are recalling 619,122 model year 2005-2007 Chevrolet Cobalt, and 2007 Pontiac G5 vehicles. On February 25, 2014, GM increased the recall to include an additional 748,024 model year 2006-2007 Chevrolet HHR and Pontiac Solstice vehicles and 2003-2007 Saturn Ion vehicles and 2007 Saturn Sky vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine. On March 27, 2014, GM notified the agency that the defective ignition switches may have been used as service replacement parts on other vehicles, and as a result GM will be recalling certain model year 2008-2010 Chevrolet Cobalt, Saturn Sky, and Pontiac G5 and Solstice, and 2008-2011 Chevrolet HHR vehicles. The part numbers for the service parts are 10392423 (a/k/a ACDelco D1461F), 10392737, 15857948, 15854953, 15896640, and 25846762. This expansion represents an additional 823,788 vehicles.
Consequence: If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a crash, increasing the risk of injury.
Remedy: GM will notify owners, and dealers will replace the ignition switch, free of charge. An interim notification was issued to owners of 2007 and earlier models on March 10, 2014, informing them of the safety defect. Owners of 2008 and later vehicles will be mailed an interim letter on April 21, 2014. All affected owners will receive another letter once parts are available. The recall began on April 18, 2014. Owners may contact Chevrolet at 1-800-222-1020, Pontiac at 1-800-762-2737 or Saturn at 1-800-553-6000. GM's number for the initial recall is 13454 and 14063 for the expansion. GMs recall number for the vehicles that may have received the replacement parts is 14092. Note: Until the recall repairs have been performed, it is very important that customers remove all items from their key rings, leaving only the vehicle key. The key fob (if applicable), should also be removed from the key ring. Always wear your seatbelt.
Nov 16, 2004
CERTAIN PASSENGER VEHICLES HAVE A CONDITION IN WHICH THE TURN SIGNAL LAMP AND DAYTIME RUNNING LAMP (DRL) ON EITHER FRONT SIDE CAN STOP WORKING BECAUSE OF LOSS OF CONTACT BETWEEN THE BULB AND SOCKET.
Consequence & remedy
Consequence: IF A FRONT TURN SIGNAL LAMP IS INOPERATIVE, OTHERS MAY REACT MORE SLOWLY TO A TURNING VEHICLE AND A CRASH COULD OCCUR.
Remedy: DEALERS WILL REPLACE THE DRL/TURN SIGNAL BULB ON BOTH THE LEFT AND RIGHT FRONT SIDE AND INSPECT FOR AND ADD A DRL JUMPER KIT IF NOT PRESENT. THE RECALL BEGAN NOVEMBER 17, 2004. OWNERS SHOULD CONTACT SATURN AT 1-800-972-8876.
Jun 8, 2004
CERTAIN VEHICLES EQUIPPED WITH SUPERCHARGED 2.0L 4-CYLINDER (LSJ) ENGINE WERE BUILT WITH A FUEL FEED PIPE THAT COULD CRACK AND LEAK FUEL NEAR THE FUEL RAIL. IF FUEL LEAKS FROM THE FUEL FEED PIPE, THERE WOULD BE A NOTICEABLE FUEL ODOR AROUND THE VEHICLE.
Consequence & remedy
Consequence: FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: DEALERS WILL REPLACE THE FUEL FEED PIPE ASSEMBLY. OWNER NOTIFICATION BEGAN ON JUNE 9, 2004. OWNERS SHOULD CONTACT SATURN AT 1-800-972-8876.
Jan 6, 2004
ON CERTAIN PASSENGER VEHICLES, SOME WELDS BETWEEN THE PASSENGER'S SIDE MOTOR RAIL AND THE FRONT BUMPER BRACKET DO NOT MEET ENGINEERING SPECIFICATIONS.
Consequence & remedy
Consequence: LONG TERM DURABILITY OF THE JOINT MAY BE REDUCED AND SEPARATION OF THE BUMPER FROM THE FRAME ON THE PASSENGER'S SIDE OF THE VEHICLE MAY RESULT, INCREASING THE RISK OF A CRASH.
Remedy: ALL VEHICLES ARE STILL IN DEALER'S POSSESSIONS.
Jan 5, 2004
CERTAIN PASSENGER VEHICLES EQUIPPED WITH 2.2L 4-CYLINDER (L61) ENGINES WERE BUILT WITH A FUEL FILTER THAT COULD CORRODE PREMATURELY ON THE EXTERIOR SURFACE.
Consequence & remedy
Consequence: IF CORROSION ON THE EXTERIOR SURFACE OF THE FUEL FILTER PROGRESSES TO THE POINT OF CREATING A HOLE IN THE SHELL, FUEL DROPLETS COULD FORM AND DROP TO THE GROUND. IF AN IGNITION SOURCE IS PRESENT, A FIRE COULD RESULT.
Remedy: DEALERS WILL REPLACE THE FUEL FILTER ASSEMBLY. OWNER NOTIFICATION BEGAN ON DECEMBER 30, 2003. OWNERS SHOULD CONTACT SATURN AT 1-800-972-8876.
Jan 5, 2004
CERTAIN PASSENGER VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 118, "POWER-OPERATED WINDOW, PARTITION, AND ROOF PANEL SYSTEMS." THE POWER WINDOWS AND/OR SUNROOF MAY BE OPERABLE AFTER THE IGNITION HAS BEEN TURNED TO THE "OFF" POSITION AND THE FRONT PASSENGER DOOR IS OPENED.
Consequence & remedy
Consequence: IF UNSUPERVISED CHILDREN ARE LEFT UNATTENDED IN THE VEHICLE AND OPERATE THE POWER WINDOWS OR SUNROOF, THERE IS AN INCREASED RISK OF INJURY TO THE CHILD.
Remedy: DEALERS WILL UPGRADE THE BODY CONTROL MODULE (BCM) CALIBRATION. OWNER NOTIFICATION BEGAN ON DECEMBER 30, 2003. OWNERS SHOULD CONTACT SATURN AT 1-800-972-8876.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
4EA11014 · Electric Power Steering Failure
Opened Sep 29, 2011 · Closed Apr 15, 2014
Status: closed (inferred from source dates) · Steering:electric Power Assist System
On March 31, 2014, General Motors Company (GM) submitted a Defect Information Report (DIR) to NHTSA describing a safety defect that may result in a sudden loss of power steering assist in approximately 1,340,447 model year (MY) 2004 through 2010 vehicles equipped with electric power steering (EPS), including 334,728 MY 2004 through 2007 Saturn ION vehicles that are the subject of EA11-014.GM has assigned the recall number N140115.The NHTSA recall number is 14V-153.According to the DIR, if power steering assist is lost, a message is displayed on the Driver Information Center and a chime sounds to inform the driver.GM indicated that steering control can be maintained in manual (unassisted) steering mode, but would require greater driver effort at low vehicle speeds, which could increase the risk of a crash.Sudden loss of power steering assist can occur in the subject vehicles if the system loses electrical power or whenever the system detects a fault that requires it to enter fail-safe operation mode, removing power from the EPS motor.GM?s DIR identifies three basic conditions that may result in loss of power steering assist in the recalled vehicles:power steering motor faults, torque sensor assembly faults, and power steering motor controller unit faults.GM will issue four service bulletins providing different repair procedures for recalled vehicles.Bulletin 14115 will provide repair instructions for replacing the power steering motor in MY 2004-2007 Saturn ION, 2009-2010 Chevrolet HHR (non-turbo), 2010 Chevrolet Cobalt and vehicles repaired in recall 10V-073 that received repairs prior to May 31, 2010.Bulletin 14116 will provide repair instructions for replacing the torque sensor assembly in MY 2004-2006 Chevrolet Malibu and Malibu Maxx, 2005-2006 Pontiac G6 and 2008-2009 Malibu, Pontiac G6 and Saturn Aura vehicles built from March 1, 2008 through June 27, 2008.Bulletin 14117 will provide repair instructions for replacing the torque sensor assembly and power steering motor controller unit in MY 2008 Malibu, G6 and Aura vehicles built from February 1, 2008 through February 28, 2008.Bulletin 14118 will provide repair instructions for replacing the power steering motor controller unit in MY 2008 Malibu, G6 and Aura vehicles built from October 1, 2007 through January 31, 2008.Analysis of information from all sources identified a total of 4,787 complaints and 30,560 warranty claims related to loss of power steering assist while driving in the MY 2004 through 2007 Saturn ION vehicles, resulting in a complaint rate of 14.3 incidents per thousand vehicles and a warranty claim rate of 9.1 percent.ODI?s analysis of alleged steering related crashes identified 12 with evidence indicating the incident was related to a loss of power steering assist. Two of the crash allegations involved low-speed curb impacts and are excluded from the resume crash count.Three incidents occurred in parking lots, six occurred while turning at street intersections, and one occurred on a highway exit ramp.The crashes in parking lots or intersections all occurred at speeds less than 30 mph.The crash on the highway exit ramp involved impact into a guard rail at approximately 35 mph.Two of the crashes resulted in injuries to the drivers.This investigation is closed.All ODI complaints associated with this closing resume are listed in the attachment pages.
Additional source detail variants (2)
Steering:electric Power Assist System
On March 31, 2014, General Motors Company (GM) submitted a Defect Information Report (DIR) to NHTSA describing a safety defect that may result in a sudden loss of power steering assist in approximately 1,340,447 model year (MY) 2004 through 2010 vehicles equipped with electric power steering (EPS), including 334,728 MY 2004 through 2007 Saturn ION vehicles that are the subject of EA11-014.GM has assigned the recall number N140115.The NHTSA recall number is 14V-153.According to the DIR, if power steering assist is lost, a message is displayed on the Driver Information Center and a chime sounds to inform the driver.GM indicated that steering control can be maintained in manual (unassisted) steering mode, but would require greater driver effort at low vehicle speeds, which could increase the risk of a crash.Sudden loss of power steering assist can occur in the subject vehicles if the system loses electrical power or whenever the system detects a fault that requires it to enter fail-safe operation mode, removing power from the EPS motor.GM?s DIR identifies three basic conditions that may result in loss of power steering assist in the recalled vehicles:power steering motor faults, torque sensor assembly faults, and power steering motor controller unit faults.GM will issue four service bulletins providing different repair procedures for recalled vehicles.Bulletin 14115 will provide repair instructions for replacing the power steering motor in MY 2004-2007 Saturn ION, 2009-2010 Chevrolet HHR (non-turbo), 2010 Chevrolet Cobalt and vehicles repaired in recall 10V-073 that received repairs prior to May 31, 2010.Bulletin 14116 will provide repair instructions for replacing the torque sensor assembly in MY 2004-2006 Chevrolet Malibu and Malibu Maxx, 2005-2006 Pontiac G6 and 2008-2009 Malibu, Pontiac G6 and Saturn Aura vehicles built from March 1, 2008 through June 27, 2008.Bulletin 14117 will provide repair instructions for replacing the torque sensor assembly and power steering motor controller unit in MY 2008 Malibu, G6 and Aura vehicles built from February 1, 2008 through February 28, 2008.Bulletin 14118 will provide repair instructions for replacing the power steering motor controller unit in MY 2008 Malibu, G6 and Aura vehicles built from October 1, 2007 through January 31, 2008.Analysis of information from all sources identified a total of 4,787 complaints and 30,560 warranty claims related to loss of power steering assist while driving in the MY 2004 through 2007 Saturn ION vehicles, resulting in a complaint rate of 14.3 incidents per thousand vehicles and a warranty claim rate of 9.1 percent.ODI?s analysis of alleged steering related crashes identified 12 with evidence indicating the incident was related to a loss of power steering assist. Two of the crash allegations involved low-speed curb impacts and are excluded from the resume crash count.Three incidents occurred in parking lots, six occurred while turning at street intersections, and one occurred on a highway exit ramp.The crashes in parking lots or intersections all occurred at speeds less than 30 mph.The crash on the highway exit ramp involved impact into a guard rail at approximately 35 mph.Two of the crashes resulted in injuries to the drivers.This investigation is closed.All ODI complaints associated with this closing resume are listed in the attachment pages.
Steering:electric Power Assist System
On March 31, 2014, General Motors Company (GM) submitted a Defect Information Report (DIR) to NHTSA describing a safety defect that may result in a sudden loss of power steering assist in approximately 1,340,447 model year (MY) 2004 through 2010 vehicles equipped with electric power steering (EPS), including 334,728 MY 2004 through 2007 Saturn ION vehicles that are the subject of EA11-014.GM has assigned the recall number N140115.The NHTSA recall number is 14V-153.According to the DIR, if power steering assist is lost, a message is displayed on the Driver Information Center and a chime sounds to inform the driver.GM indicated that steering control can be maintained in manual (unassisted) steering mode, but would require greater driver effort at low vehicle speeds, which could increase the risk of a crash.Sudden loss of power steering assist can occur in the subject vehicles if the system loses electrical power or whenever the system detects a fault that requires it to enter fail-safe operation mode, removing power from the EPS motor.GM?s DIR identifies three basic conditions that may result in loss of power steering assist in the recalled vehicles:power steering motor faults, torque sensor assembly faults, and power steering motor controller unit faults.GM will issue four service bulletins providing different repair procedures for recalled vehicles.Bulletin 14115 will provide repair instructions for replacing the power steering motor in MY 2004-2007 Saturn ION, 2009-2010 Chevrolet HHR (non-turbo), 2010 Chevrolet Cobalt and vehicles repaired in recall 10V-073 that received repairs prior to May 31, 2010.Bulletin 14116 will provide repair instructions for replacing the torque sensor assembly in MY 2004-2006 Chevrolet Malibu and Malibu Maxx, 2005-2006 Pontiac G6 and 2008-2009 Malibu, Pontiac G6 and Saturn Aura vehicles built from March 1, 2008 through June 27, 2008.Bulletin 14117 will provide repair instructions for replacing the torque sensor assembly and power steering motor controller unit in MY 2008 Malibu, G6 and Aura vehicles built from February 1, 2008 through February 28, 2008.Bulletin 14118 will provide repair instructions for replacing the power steering motor controller unit in MY 2008 Malibu, G6 and Aura vehicles built from October 1, 2007 through January 31, 2008.Analysis of information from all sources identified a total of 4,787 complaints and 30,560 warranty claims related to loss of power steering assist while driving in the MY 2004 through 2007 Saturn ION vehicles, resulting in a complaint rate of 14.3 incidents per thousand vehicles and a warranty claim rate of 9.1 percent.ODI?s analysis of alleged steering related crashes identified 12 with evidence indicating the incident was related to a loss of power steering assist. Two of the crash allegations involved low-speed curb impacts and are excluded from the resume crash count.Three incidents occurred in parking lots, six occurred while turning at street intersections, and one occurred on a highway exit ramp.The crashes in parking lots or intersections all occurred at speeds less than 30 mph.The crash on the highway exit ramp involved impact into a guard rail at approximately 35 mph.Two of the crashes resulted in injuries to the drivers.This investigation is closed.All ODI complaints associated with this closing resume are listed in the attachment pages.
RQ10004 · Electric Power Steering Failure
Opened Dec 15, 2010 · Closed Oct 5, 2011
Status: closed (inferred from source dates) · Steering; Steering:electric Power Assist System
ODI has received 846 complaints and GM identified 3,489 reports alleging sudden loss of steering power assist in model year (MY) 2004 through 2007 Saturn Ion vehicles manufactured and sold by General Motors Corporation (GM).Sixteen of these complaints alleged that the EPS warning lamp had illuminated before or during the loss of steering assist and the increased steering effort contributed to a crash. Two of the GM crash claims indicated that the driver was injured in the crash. In a previous Preliminary Evaluation PE10-005, ODI investigated the sudden loss of power steering assist in MY 2005 through 2010 Chevrolet Cobalt vehicles. In May 2011, in response to an ODI information request letter for RQ10-004, GM provided ODI with complaint, warranty and EPS system information related to EPS loss of assist for the Saturn ION and Peer vehicles Pontiac G6 and Chevrolet Malibu. In that response, GM indicated that the EPS system used in the subject vehicles was the same as that used in the MY2005 to 2010 Chevrolet Cobalt and Pontiac G5. In March 2010, GM recalled approximately 1.05 million Chevrolet Cobalt and Pontiac G5 vehicles (NHTSA recall no. 10V-073) to correct a defect with the EPS assist motor. The defect identified was described as a buildup of brush debris mixed with oily material on the EPS electric motor armature which causes the motor to stop functioning; the same problem identified in the current subject vehicles.ODI has duplicated this failure in both a Chevrolet Cobalt and Saturn Ion previously tested at the Vehicle Research and Test Center (VRTC). In the defect notification letter for the previously recalled Cobalt and G5 vehicles, GM stated that the vehicles may experience a sudden loss of assist that could occur at any time while driving and that if power steering was lost the vehicle would revert to manual steering mode and would require increased steering effort from the driver.ODI believes that, depending on driving circumstances this increase in steering effort could result in some loss of control and a crash.This investigation has been upgraded to an engineering analysis (EA11-014) to further assess the frequency, scope and safety consequences of a sudden loss of steering assist in the subject vehicles.
Additional source detail variants (2)
Steering:electric Power Assist System
ODI has received 846 complaints and GM identified 3,489 reports alleging sudden loss of steering power assist in model year (MY) 2004 through 2007 Saturn Ion vehicles manufactured and sold by General Motors Corporation (GM).Sixteen of these complaints alleged that the EPS warning lamp had illuminated before or during the loss of steering assist and the increased steering effort contributed to a crash. Two of the GM crash claims indicated that the driver was injured in the crash. In a previous Preliminary Evaluation PE10-005, ODI investigated the sudden loss of power steering assist in MY 2005 through 2010 Chevrolet Cobalt vehicles. In May 2011, in response to an ODI information request letter for RQ10-004, GM provided ODI with complaint, warranty and EPS system information related to EPS loss of assist for the Saturn ION and Peer vehicles Pontiac G6 and Chevrolet Malibu. In that response, GM indicated that the EPS system used in the subject vehicles was the same as that used in the MY2005 to 2010 Chevrolet Cobalt and Pontiac G5. In March 2010, GM recalled approximately 1.05 million Chevrolet Cobalt and Pontiac G5 vehicles (NHTSA recall no. 10V-073) to correct a defect with the EPS assist motor. The defect identified was described as a buildup of brush debris mixed with oily material on the EPS electric motor armature which causes the motor to stop functioning; the same problem identified in the current subject vehicles.ODI has duplicated this failure in both a Chevrolet Cobalt and Saturn Ion previously tested at the Vehicle Research and Test Center (VRTC). In the defect notification letter for the previously recalled Cobalt and G5 vehicles, GM stated that the vehicles may experience a sudden loss of assist that could occur at any time while driving and that if power steering was lost the vehicle would revert to manual steering mode and would require increased steering effort from the driver.ODI believes that, depending on driving circumstances this increase in steering effort could result in some loss of control and a crash.This investigation has been upgraded to an engineering analysis (EA11-014) to further assess the frequency, scope and safety consequences of a sudden loss of steering assist in the subject vehicles.
Steering
ODI has received 846 complaints and GM identified 3,489 reports alleging sudden loss of steering power assist in model year (MY) 2004 through 2007 Saturn Ion vehicles manufactured and sold by General Motors Corporation (GM).Sixteen of these complaints alleged that the EPS warning lamp had illuminated before or during the loss of steering assist and the increased steering effort contributed to a crash. Two of the GM crash claims indicated that the driver was injured in the crash. In a previous Preliminary Evaluation PE10-005, ODI investigated the sudden loss of power steering assist in MY 2005 through 2010 Chevrolet Cobalt vehicles. In May 2011, in response to an ODI information request letter for RQ10-004, GM provided ODI with complaint, warranty and EPS system information related to EPS loss of assist for the Saturn ION and Peer vehicles Pontiac G6 and Chevrolet Malibu. In that response, GM indicated that the EPS system used in the subject vehicles was the same as that used in the MY2005 to 2010 Chevrolet Cobalt and Pontiac G5. In March 2010, GM recalled approximately 1.05 million Chevrolet Cobalt and Pontiac G5 vehicles (NHTSA recall no. 10V-073) to correct a defect with the EPS assist motor. The defect identified was described as a buildup of brush debris mixed with oily material on the EPS electric motor armature which causes the motor to stop functioning; the same problem identified in the current subject vehicles.ODI has duplicated this failure in both a Chevrolet Cobalt and Saturn Ion previously tested at the Vehicle Research and Test Center (VRTC). In the defect notification letter for the previously recalled Cobalt and G5 vehicles, GM stated that the vehicles may experience a sudden loss of assist that could occur at any time while driving and that if power steering was lost the vehicle would revert to manual steering mode and would require increased steering effort from the driver.ODI believes that, depending on driving circumstances this increase in steering effort could result in some loss of control and a crash.This investigation has been upgraded to an engineering analysis (EA11-014) to further assess the frequency, scope and safety consequences of a sudden loss of steering assist in the subject vehicles.
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.
Illustration