2004 Saturn Ion Recalls
NHTSA lists 8 recall campaigns for the 2004 Saturn Ion. A recall applies only to vehicles built within the affected range, so check your own VIN at nhtsa.gov/recalls. Repairs for recalls are free at a franchised dealer.
- Electrical system › IgnitionCovers: Saturn Ion 2003–2007, Chevrolet Cobalt 2005–2010, HHR 2006–2011 +3 more
Reported issue: 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.
Possible 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…
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…
- Steering › Electric power assist systemCovers: Saturn Ion 2004–2007, Chevrolet Malibu 2004–2006, 2008–2009, Pontiac G6 2005–2006, 2008–2009 +4 more
Reported issue: 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.
Possible 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…
- Air bagsCovers: Saturn Ion 2003–2007, Chevrolet Cobalt 2005–2010, HHR 2006–2011 +3 more
Reported issue: 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…
Possible 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…
- Exterior lighting › Turn signalCovers: Saturn Ion 2003–2004
Reported issue: 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.
Possible 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.
- Fuel system, other › Delivery › Fuel pumpCovers: Saturn Ion 2004
Reported issue: 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.
Possible 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.
- Structure › Body › BumpersCovers: Saturn Ion 2004
Reported issue: On certain passenger vehicles, some welds between the passenger's side motor rail and the front bumper bracket do not meet engineering specifications.
Possible 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.
- Fuel system, gasolineCovers: Saturn Ion 2003–2004
Reported issue: 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.
Possible 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.
- Visibility › Power window devices and controlsCovers: Saturn Ion 2003–2004
Reported issue: 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.
Possible 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.
NHTSA investigations
- EA11014Electric Power Steering FailureClosed · Sep 29, 2011
- RQ10004Electric Power Steering FailureClosed · Dec 15, 2010
- EA04035Front turn signal/drl failureClosed · Dec 22, 2004
- PE04061Front turn signal/drl failureClosed · Aug 17, 2004
← All problems reported for the 2004 Saturn Ion
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 29, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.