2005 Saturn Ion Technical Service Bulletins

569 technical service bulletins (TSBs) are on record for the 2005 Saturn Ion. TSBs are notes manufacturers send to dealers about repair procedures for issues seen in the field. They are not recalls and do not by themselves mean a vehicle has a fault.

• 11020816Jul 18, 2025Other or unknown. This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.
• 11019074May 30, 2025Other or unknown. This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.
• 11019073May 30, 2025Other or unknown. This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.
• 11019072May 30, 2025Other or unknown. This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.
• 11014455Feb 20, 2025Other or unknown. This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the noise for assessment by engineering. Technician will need to call General Motors Technical Assistance Center for further assistance.
• 11011782Dec 7, 2024Other or unknown. This Preliminary Information communication provides information to the technician about the use of J-35616-64B terminal test probe, replacement terminals, and terminated leads. The J-35616-64B is the latest test probe released for checking tension or probing the .64 series terminals. The test probe terminal has been released in the terminal repair kit (J-38125-620H) located in Lear Tray 7 part number 963716-2.
• 11009156Oct 25, 2024Electrical system. 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.
• 11007744Sep 12, 2024Other or unknown. 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.
• 11007743Sep 12, 2024Other or unknown. 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.
• 11008956Sep 9, 2024Other or unknown. This service bulletin provides information for dealers/technicians on When and How to Submit a Field Product Report (FPR) (U.S. and Canada Dealers Only).
• 11007208Sep 6, 2024Other or unknown. 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.
• 11006621Aug 26, 2024Electrical system. 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…
• 11007091Aug 5, 2024Engine. This service bulletin provides guidelines and diagnostic/repair information to technicians regarding vehicle engine oil consumption.
• 11004557Jun 17, 2024Other or unknown. This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.
• 11002312Jun 6, 2024Electrical system. 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.
• 11001321May 16, 2024Transmission and drivetrain. This bulletin provides information on the harmful effects of water or ethylene glycol in transmission fluid.
• 11000576May 7, 2024Other or unknown. 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.
• 11000162Apr 30, 2024Electrical system. The intent of this service bulletin is to identify aftermarket ALDL or DLC interface devices as potential sources for causing multiple customer concerns that do not have other diagnostic methods to identify them.
• 10252735Mar 28, 2024Electrical system. This bulletin provides information for electrical ground repairs using new General Motors replacement fasteners with conductive finish.
• 10251890Mar 13, 2024Engine cooling. 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.
• 10250775Feb 22, 2024Engine cooling. 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.
• 10249980Jan 12, 2024Equipment. 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…
• 10249579Jan 12, 2024Engine cooling, Transmission and drivetrain. This PI bulletin advises the technician on the proper way to install the pistons in an engine.
• 10249011Jan 12, 2024Exterior lighting. This informational bulletin provides information for dealers/technicians on Headlamp, Tail Lamp, License Lamp or Fog/Driving Lamp Damage.
• 10249295Dec 18, 2023Equipment. This Preliminary Information communication provides information to the technician about the use of J-35616-64B terminal test probe, replacement terminals, and terminated leads. The J-35616-64B is the latest test probe released for checking tension or probing the .64 series terminals. The test probe terminal has been released in the terminal repair kit (J-38125-620H) located in Lear Tray 7 part number 963716-2.
• 10245395Nov 6, 2023Wheels, Transmission and drivetrain, Steering, Suspension, Engine cooling. This service bulletin provides a vibration analysis worksheet the technician can use in conjunction with the appropriate Vibration Analysis-Road testing procedure when diagnosing vibration concerns.
• 10244274Oct 6, 2023Wheels. This service bulletin provides information about the Hunter wheel Road Force balancers that should be utilized for all repairs requiring balance and Road Force measurement.
• 10244273Oct 6, 2023Engine cooling. This service bulletin provides guidelines and diagnostic/repair information to technicians regarding vehicle engine oil consumption.
• 10247780Sep 26, 2023Visibility (wipers, defrost, mirrors). 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.
• 10244201Sep 26, 2023Equipment. This service bulletin provides information for dealers on how to submit a product information report (PIR) (Canada Only).
• 10244200Sep 26, 2023Equipment. This service bulletin provides information for dealers/technicians on When and How to Submit a Field Product Report (FPR) (U.S. and Canada Dealers Only).
• 10244214Sep 21, 2023Equipment, Electrical system. This informational bulletin provides information for the IPC odometer programming method quick reference guide.
• 10242262Aug 24, 2023Engine cooling. This service bulletin provides graphics, information and guidelines for engine component wear to assist service personnel as a guideline to perform necessary engine repairs and prevent unnecessary engine replacement.
• 10242298Aug 10, 2023Engine. This Preliminary information communicates information that will need to be provided to TAC to aid in diagnosing if a vehicle comes in with misfire and DTC Codes P0300 - P0308 and/or P050D
• 10240793Jul 18, 2023Equipment. This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the noise for assessment by engineering. Technician will need to call General Motors Technical Assistance Center for further assistance.
• 10239101Jun 30, 2023Engine cooling. This service bulletin provides guidelines and diagnostic/repair information to technicians regarding vehicle engine oil consumption.
• 10239102Jun 29, 2023Electrical system. The intent of this service bulletin is to identify aftermarket ALDL or DLC interface devices as potential sources for causing multiple customer concerns that do not have other diagnostic methods to identify them.
• 10237841Jun 1, 2023Equipment. This service bulletin provides information for dealers/technicians on When and How to Submit a Field Product Report (FPR) (U.S. Dealers Only).
• 10235799Apr 27, 2023Wheels. This service bulletin provides information about the Hunter wheel Road Force balancers that should be utilized for all repairs requiring balance and Road Force measurement.
• 10236164Apr 24, 2023Engine cooling. This Preliminary information communicates information that will need to be provided to TAC to aid in diagnosing if a vehicle comes in with misfire and DTC Codes P0300 - P0308 and/or P050D
• 10235802Apr 24, 2023Engine cooling. This diagnostic tip bulletin provides additional information on how to diagnose a possible valve, lifter or camshaft issue.
• 10234619Apr 6, 2023Transmission and drivetrain. This bulletin provides information on the harmful effects of water or ethylene glycol in transmission fluid.
• 10234141Mar 23, 2023Engine cooling. This diagnostic tip bulletin provides additional information on how to diagnose a possible valve, lifter or camshaft issue.
• 10234110Mar 17, 2023Engine cooling. This service bulletin provides service information on new torque specification and installation procedure for ACDelco Spin-On Oil Filters.
• 10232287Feb 21, 2023Equipment. This warranty administration bulletin provides information regarding the field action courtesy transportation policy.
• 10232136Feb 15, 2023Exterior lighting. This service bulletin provides information for dealers/technicians on Exterior Lamp Condensation and Water Leaks and Replacement Guidelines.
• 10232811Feb 10, 2023Equipment. This Preliminary information communicates information that will need to be provided to TAC to aid in diagnosing if a vehicle comes in with misfire and DTC Codes P0300 - P0308 and/or P050D
• 10231302Jan 20, 2023Equipment. This service bulletin provides information for dealers/technicians on When and How to Submit a Field Product Report (FPR) (U.S. Dealers Only).
• 10228906Dec 21, 2022Equipment. 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.
• 10230697Dec 15, 2022Visibility (wipers, defrost, mirrors). This Preliminary information communicates to the technician the need to inspect the induction system for potential icing issues in very cold ambient temperatures. To allow the ice to melt so that it can be drained from the related components. That any of the listed DTC's may set with or without poor engine performance.

← All problems reported for the 2005 Saturn Ion