Problems owners report
Complaints filed with NHTSA about the 2004 Saturn ION, by the system named in each complaint. One complaint can name several.
- Steering345
- Electrical system331
- Power train60
- Air bags52
- Fuel/propulsion system36
- Engine and engine cooling33
- Vehicle speed control27
- Exterior lighting25
- Engine23
- Unknown or other20
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 35 injuries and 3 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 39 2004 ION vehicles were involved in crashes on US public roads in which someone died; 34 people died inside them, and 4 of the vehicles rolled over. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 2004 Saturn ION failed the safety check 2.59% of the time — 17% more often than the average 2004 passenger car (2.21%). Median odometer at inspection: 118,404 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
Fuel consumption
Official Canadian test results for 3 variants: combined 9.2–10.0 L/100 km (about 24–26 mpg US), CO₂ 212–230 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| Ion · Subcompact · Regular gasoline | 10.8 | 7.2 | 9.2 |
| Ion · Subcompact · Regular gasoline | 10.9 | 8.1 | 9.6 |
| Ion · Subcompact · Regular gasoline | 11.6 | 8.0 | 10.0 |
Litres per 100 km. Natural Resources Canada, Fuel consumption ratings (open.canada.ca) · Open Government Licence – Canada
Recalls in Canada
8 Transport Canada recalls for the 2004 Saturn ION.
| 2014126 10 Apr 2014 | Other On certain vehicles, a defect may allow the ignition key to be removed from the ignition switch when the key is not in the "Off" position. This could result in … |
| 2014104 1 Apr 2014 | Steering Certain vehicles equipped with electric power steering may experience a sudden loss of power steering assist that could occur at any time while driving. If the… |
| 2014060 26 Feb 2014 | Electrical On certain vehicles, a defect in the ignition switch could allow the switch to move out of the "run" position if the key ring is carrying added weight and the v… |
| 2010447 16 Dec 2010 | Steering Certain vehicles equipped with electric power steering may experience a sudden loss of power steering assist that could occur at any time while driving. If the… |
| 2004401 17 Nov 2004 | Lights And Instruments On certain vehicles, the turn signal/daytime running lamp (DRL) bulb on either front side can become inoperative because of inadequate contact between the bulb … |
| 2004191 9 Jun 2004 | Fuel System On certain Saturn Ion Red Line vehicles equipped with the supercharged 2.0L engine, the fuel feed pipe may crack near the fuel rail, which would result in a fue… |
| 2003344 23 Dec 2003 | Electrical Certain vehicles do not comply with the requirements of CMVSS 118. The power windows and/or sunroof may be operable after the ignition has been turned to the "… |
| 2003345 23 Dec 2003 | Fuel System On certain vehicles, the fuel filter assembly may corrode prematurely on the exterior surface. If corrosion on the exterior surface of the fuel filter assembly… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
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.
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.
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.
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.
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.
ON CERTAIN PASSENGER VEHICLES, SOME WELDS BETWEEN THE PASSENGER'S SIDE MOTOR RAIL AND THE FRONT BUMPER BRACKET DO NOT MEET ENGINEERING SPECIFICATIONS.
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.
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.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Saturn told its dealers about the 2004 Saturn ION: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 11009156 | This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and Vehicle Data Recorder tools, giving website address and step by step instructions to complete the update. |
| 11007744 | This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature. |
| 11007743 | This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature. |
| 11007208 | This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection. |
| 11006621 | Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers. |
| 11004557 | This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim. |
| 11002312 | This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information. |
| 11000576 | This Warranty Administration bulletin provides retail and wholesale service personnel with the policies/procedures and the warranty transaction submission procedures that support the Personal Property Damage process. |
| 10252735 | This bulletin provides information for electrical ground repairs using new General Motors replacement fasteners with conductive finish. |
| 10252163 | XM Audio Traffic And Travel Link Availability And Operation. |
| 10251890 | This technical bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up. |
| 10250775 | This service bulletin provides service information to technicians on guidelines to replace Oil Cooler, Oil Cooler Lines and Oil Tank if the engine was replaced where large amounts of debris has flowed throughout the oiling system. |
| 10250094 | Special Coverage Adjustment ? Power Steering Assist |
| 10249980 | This Preliminary Information communication provides information to the technician about vibration complaints that are one of the most challenging complaints to accurately diagnose and repair. Technician will need to use Pico Oscilloscope Diagnostic Kit to effectively diagnosis vehicles. Technician should drive the vehicle will using the Pico Oscilloscope to record data. After the data is recorded it should be reviewed to determine the root cause of the concern. If a repair attempt made the concern better but not eliminated or had no affect at all, and are requesting assistance from General Mot |
| 10249579 | This PI bulletin advises the technician on the proper way to install the pistons in an engine. |
| 10249011 | This informational bulletin provides information for dealers/technicians on Headlamp, Tail Lamp, License Lamp or Fog/Driving Lamp Damage. |
| 10248444 | Vehicle Recalls |
| 10247780 | This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature. |
| 10247681 | Information On Requests To Add OnStar Bluetooth Option. |
| 10247336 | Replace Ignition Key |
| 10247335 | Replace Ignition Key |
| 10247334 | Replace Ignition Key |
| 10247333 | Replace Ignition Key |
| 10247332 | Replace Ignition Key |
| 10247317 | Electric Power Steering Assist |
NHTSA manufacturer communications (public domain)
NHTSA investigations
Electric Power Steering Failure
Electric Power Steering Failure
FRONT TURN SIGNAL/DRL FAILURE
FRONT TURN SIGNAL/DRL FAILURE
NHTSA Office of Defects Investigation