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.

• 10043015Nov 1, 2011Brakes. Saturn: low brake fluid warning and/or red brake light on due to possible brake fluid reservoir or fluid switch being replaced. Brake and brake pedal operation not affected. *pe updated 2/8/12.
• 10037184Oct 1, 2011Seat belts. Gm: service bulletin explaining when the safety belts are supposed to lock. *rm updated 12/6/11.
• 10038759Apr 1, 2011Electrical system. Gm: onstar is making incomplete calls without the driver knowing. When have a data connection.
• 10038510Mar 1, 2011Engine cooling. Gm: there may be noise coming from the cylinder head, because of low oil pressure which is caused by debris.
• 10019478Jun 1, 2010Steering. Normal operating characteristics of electric power steering (eps) system during extended lock-to-lock (maximum steering wheel rotation) usage. *tt updated 3/30/11.
• 10033034Jan 1, 2010Engine cooling. Saturn chevrolet service campaign: see document search button for owner letter. Some 2004-07 saturn ion red line and 2005-07 chevrolet cobalt ss vehicles, equipped with 2.0l 4 cylinder (rpo lsj) engine, may have illumination of the malfunction indicator lamp (mal) and/or lack of engine power. This may be caused by failure of the catalytic converter.
• 10022958Aug 1, 2009Steering. Diagnostic tips for power steering inoperative/steering wheel hard to turn, power steering message displayed on dic, dtc's c0176, c0176, c0475, c0476, c0550, u2105, u2107 set. *nj updated 2/17/10. *pe updated 3/01/10.
• 10033184Jul 1, 2009Transmission and drivetrain. Chevrolet/pontiac/saturn: blocked shift, gear hop out 1st, 3rd, 5th gear or difficulty shifting. The shift lever on the manual transmissions roll pin can back out and contact the shift cover during a shift event. This can cause an incomplete, blocked shift or difficulty shifting the transmission.
• 10020740Jun 1, 2009Steering. Power steering inoperative/steering wheel hard to turn, pwr str displayed on driver information center (dic). After jump starting the vehicle. *kb (replace fuse and instruct owner how to jump start vehicle). Updated 2/17/10.
• 10021115Dec 1, 2008Suspension. Information on tire radial force variation (rfv). 2008 and prior gm passenger cars and light duty trucks including 2008 and prior hummer h2, h3 and 2005-08 saab 9-7x and 2000-05 saturn l series and 2003-07 saturn ion. *kb updated 4/11/08. *nj updated 5/27/09.
• 10021114Feb 1, 2008Other or unknown. Trailer, recreational and disabled vehicle towing information. *kb updated 08-15-07. *kb updated 10/09/07. *nj updated 4/3/08.
• 10032850Jan 1, 2008Tires, Equipment. General motors: information on tire radial force variation. Vehicle must be driven before measuring tires on equipment hunter gsp9700 toensure removal of any flatspotting. Models include all gm passenger cars and light trucks, as well as certain hummers, saabs, and saturns.
• 10022484Dec 31, 2007Engine cooling. Intermittent ses light due to dtc's p060e, p2135, and/or p2138. *kb updated 2/27/08.
• 10023942Oct 1, 2007Transmission and drivetrain. Information on 4t40-e (mn4) and 4t45-e (mn5) front wheel drive automatic transmission valve body reconditioning, dtc p0741, p0742, p0751, p0752, p0756, p0757, p1811, harsh shifts, slips, no drive, no reverse.
• 10017497Sep 1, 2007Steering. Ei05093 - clunk noise in steering system at slow speeds while turning and/or driving over bumps. *tt (replace intermediate shaft). Updated 10/05/07. *nj updated 11/02/07
• 10021919Apr 1, 2007Electrical system. Floor plan corrosion (rust) perforation in battery compartment.
• 10021453Apr 1, 2007Transmission and drivetrain. Mg3, m86 transaxle grinding/whining noise in 3rd or 4th gear, excessive engagement or disengagement effort while shifting into 3rd or 4th gear, will not shift into either 3rd or 4th gear. (replace complete output shaft assembly).
• 10021074Mar 1, 2007Other or unknown. Parts update - timing chain tensioner design change.
• 10020923Jan 30, 2007Engine cooling. Low oil pressure - inspect oil filter for damage. *kb updated 10/18/07.
• 10021121Jan 1, 2007Engine cooling. Lsj, l61, lk5, l52, ll8 engine - reduced engine power, mil/ses light, dtc p1516, p2135, p2138.
• 10020951Oct 1, 2006Steering. Information on inadvertent turning of key cylinder, loss of electrical system and no dtc's.
• 10020838Jun 1, 2006Engine cooling. Engine malfunction indicator lamp (mil)/service engine soon (ses) lamp illuminated with dtc p0171.
• 10020821Jun 1, 2006Engine cooling. Service engine soon (ses)/malfunction indicator lamp (mil) on and/or engine driveability concerns.
• 10019866May 5, 2006Brakes. Bcm service part not available for tsb 04-08-45-005c.
• 10020711May 1, 2006Body and structure. Water leak, wet or stained carpet in trunk, water or dirt accumulates under the carpet in spare tire well (inspect tail lamp wiring harness and rewrap, if necessary).
• 10019421Mar 15, 2006Engine cooling. Engine rpm limited to 4,000 rpm - monitor tr switch input to tcm.
• 10019228Feb 21, 2006Transmission and drivetrain. M86/m94 transmission information to disassemble third fourth and fifth gear.
• 10018915Jan 25, 2006Electrical system. Hesitation on acceleration after internal engine repairs - check injector harness orientation.
• 10018624Jan 9, 2006Fuel system. Fuel tank is slow to fill and/or dtc p0446 - inspect evap vent pipe. The ses lamp may be illuminated due to a p0466 dtc. *tt updated 08-15-07.
• 10018532Jan 5, 2006Engine cooling. Momentary sag on light to moderate accel when cold - valve deposits.
• 10018530Jan 5, 2006Electrical system. Incorrect mileage displayed after programming a new bcm. Various models including 2005 - 2006 pontiac pursuit (canada only).
• 10015023Jan 1, 2006Electrical system. Service engine soon light illuminated fuel gauges stay on fluctuating speedometer and or tachometer intermittent vehicle theft security telltale lamp on.
• 10018679Nov 1, 2005Suspension. Identifying correct design level of rear axle assembly.
• 10017512Nov 1, 2005Transmission and drivetrain. Transmission control module (tcm) shorted to battery voltage during diagnosis and/or service. *tt updated.
• 10017261Nov 1, 2005Engine cooling. Service engine soon (ses) light due to a p0171 - inspect air intake and oil dipstick.
• 10017248Oct 29, 2005Fuel system, Other or unknown. High fuel pressure - possible fuel filter concern.
• 10017247Oct 29, 2005Vehicle speed control. No throttle response, rough running, and no diagnostic trouble code - possible tcm concern.
• 10017218Oct 28, 2005Transmission and drivetrain. Manual transaxle gear rattle noise heard during cold ambient temperatures with clutch pedal released (up) and engine rpm 1500-2500. Noise will not be present when clutch pedal is pressed to the floor.
• 10017124Oct 25, 2005Electrical system. Running rough, no power, service engine soon (ses) light on and or hesitation that can be intermittent. Engine harness rubbing on the uhjb.
• 10017096Oct 24, 2005Transmission and drivetrain. Vehicle will not move in either direction. Transmission may show over full. P90 4t40e 4t45e no movement drive or reverse. Converter may be empty of fluid.
• 10017086Oct 24, 2005Transmission and drivetrain. 4t40e or 4t45e will not shift no diagnostic trouble codes.
• 10017062Oct 21, 2005Transmission and drivetrain. 4t40e/4t45e hard to shift.
• 10017032Oct 21, 2005Engine cooling. Service engine soon (ses) light and severe engine misfire on cylinders 1 and 4 or cylinders 2 and 3. *tt updated 08-15-07.
• 10017021Oct 21, 2005Electrical system. Service engine soon (ses) light at highway speeds due to a p0171 diagnostic trouble code (dtc).
• 10016948Oct 18, 2005Suspension. Clunk noise from front of vehicle during turning maneuver.
• 10016822Oct 12, 2005Engine cooling. Machining debris on the oil filter element.
• 10017423Oct 1, 2005Steering. Power steering inoperative/steering wheel hard to turn, pwr str message displayed on driver information center (dic) after jump starting vehicle.
• 10016533Sep 20, 2005Electrical system. Service engine soon (ses) light due to a p1182 diagnostic trouble code - potential causes and issues.
• 10016527Sep 20, 2005Electrical system. Crank no start, hard start, or service engine soon (ses) light after campaign 05522.
• 10016524Sep 20, 2005Transmission and drivetrain. Shift control knob loose or detached from shift control lever.

← All problems reported for the 2005 Saturn Ion