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Saturn ION repairs by problem area

Engine (32%)

Transmission and Drivetrain (5%)

Brakes and Traction Control (4%)

Suspension and Steering (30%)

Electrical and Air Conditioning (17%)

Paint, Rust, Leaks, Rattles, and Trim (8%)

Other (5%)

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Chart based on 736 repairs.

See TSBs and recalls for the Saturn ION.

Saturn ION engine repair cost distribution

$2500+ (2%)

$1000 - $2499 (5%)

$500 - $999 (14%)

$100 - $499 (33%)

< $100 (47%)

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Chart based on 195 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

ALL rocker arms popped off. Bent subsequent parts. Needs new engine now. Nothing replaced.

124000 mi

Bad wire harness to secondary air pump

102000 mi

US $270

Fuel pump replaced because it was spraying fuel under car. GM issued a partial recall for this safety issue, but not for cars in my state! After difficulty obtaining new pump (2 weeks, 2 vendors), successfully completed repair myself.

54000 mi US $185	Diagnosis P0446 Evap Vent Solenoid sticking. Installed new updated solenoid with wiring harness.
62300 mi	recall on ignition switch

52000 mi US $52	Don't have the work order so unable to explain. Emissions and something burned out. Will try to find out and explain
89000 mi	Valve # 3 was replaced - problem was fixed by power train warranty.
126200 mi US $800	needed a new fuel pump - will make another trip to repair fuel gage - not working - faulty pump

14000 mi	RPMs were not dropping while coasting with the engine not in gear. RPMs remained at ~1500 until full stop. Issue appears to be fixed for now after a computer reflash.
62620 mi C $20	p0102 code thrown, MAF sensor malfunction. MAF sensor replaced.

37600 mi C $480	fuel pump leaking gazoline smell
57000 mi C $560	replaced injectors
61880 mi C $430	gazoline leak from the line
64480 mi C $80	Replaced exhaust solenoid
71300 mi C $35	Check engine light p00442, related to fuel vapor in gasoline tank. Replaced fuel cap. It seems to be working so far, no light ever since. The temperatures have been really low this winter, so we'll have to wait for spring to come. We will see then if it's a permanent fix.
78120 mi	p00442 code again, Replaced the gazoline cap, but the code came back after a while, Watched videos on youtube. I though that the end of the gazoline pipe might be leeking just a little after ten years. It shows signs of wear, scratches, etc. I USED SOME SWIMMING POOL PUMP GASKET LUBRICANT to lube the end of the pipe taht comes in contact with the gaz cap. Almost 2 months without a code. I will lubricate the end of the pipe from time to time

114000 mi US $820	Heater core strangely started leaking one day. Very unusual to happen on these cars, which is why the part cost so much (no one carries it in stock, even dealer)! Had it fixed in 1 day; however, it is a 5 hr labor rate.
182000 mi US $1200	Camshaft Position Solenoids and Timing Chain Replacement
193000 mi	Emissions Purge Valve replaced.
196000 mi US $880	Rear fuel line replacement, both High and Low Pressure lines. Fuel Filter included.
198000 mi US $150	Knock Sensor

104000 mi	Replaced fuel tank heat shield retaining screw(s).
109000 mi US $232	Electronic Control Module (ECM) had to be reprogrammed due to throttle body cleaning.

64460 mi C $175	Needed to change the tumbler (key started to get stuck at times) and have original key coded.
90820 mi C $120	Fuel line from tank leaking due to corrosion. Replaced a portion of the fuel line.

44000 mi US $680	check engine light and low power engine light, car ran poorly. Had to track down problem since it was intermittent. rewired wiring harness's
91000 mi US $550	fuel line leaks
94000 mi US $623	fuel line replace

3300 mi	SES light activated again, same code stored as before. Tech cleared the codes, claims unit works as designed.
5800 mi	Fuel sending unit shorted, replaced. SES light on again. LF & RF windows rattled when open. Not fixed. Repaired chip in LF rocker panel, repainted rear bumper where trunk meets, installed 3 rubber stops, repainted, adjusted fuel filler door.
8700 mi	Foam emerged from LF roof driprail. Removed and repositioned foam. SES light again - no codes found. Installed latest PCM calibration, lubed clutch pedal hinge and push rod.
13500 mi	Brake lamp lit during extremely cold weather. System checked - no problems found. SES light on again - new clutch switch ordered. Replaced uppermost clutch switch. Front pass. seat cover partially loose, r&r seat, secured cover, fasteners.
16300 mi	Brake lamp lit again during very cold weather - no issues. SES light on again. If PCM sees 8 or more changes in vehicle speed w/o pedal depressed, it will set code..."cannot be helped."
22000 mi	Dash crack appeared near auto headlight sensor. Replaced center dash trim. Rental car. Left fuel tank strap loose and dangling. Bolt fell out. Replaced. Car towed to retailer, key stuck in ignition. Lock cylinder binding in housing. Replaced cylinder. Ren
56900 mi	Replaced intake camshaft position sensor. Replaced exhaust camshaft position sensor. Worn CPS units caused revs to stay up between shifts. Engine revs failed to drop between 1st and 2nd and 2nd and 3rd gears, SES light activated. Problem traced to failed camshaft position sensors. Retailer removed and replaced intake and exhaust sets under extended warranty.
70000 mi	I smelled gasoline while outside the car. Called retailer. Verified there is a TSB on replacing fuel pump module. Local Chevrolet dealer did the work as Saturn no longer exists.
75000 mi	Catalytic converter broke internally at ~73,500 miles, replaced and covered under 8/80,000 mile emissions system warranty.
102000 mi US $587	Car leaked coolant; water pump leaked at weep hole. Replaced water pump.
102000 mi US $387	Front crankcase seal leaked and needed replacement.
120000 mi US $803	Fuel lines corroded, leaked due to age/rust, causing starter to crank longer than usual. Car became harder to start when cold.
120200 mi US $414	Muffler had hole and began to crumble internally.

79360 mi	Check engine light was on. Flashed ecm with new firmware. Made car worse. Will be bringing it in again soon.
102300 mi C $230	Flex pipe rusted through

17000 mi US $45	intermittently, check engine will come on as well as abs, brake, no codes are stored, so nothing gets done about it
33000 mi US $100	When fueling, pump keeps stopping. Bad tank purge solenoid.
34200 mi US $100	check engine light, gas tank needed to be replaced has a built in valve that is defective, wheel hub bearings also no good, making loud noise.

29000 mi	Car would not start a few times. Dealer found no error codes, so dealer did nothing. As an aside, dealer updated engine software.
31000 mi	Car would not start again. Dealer found error codes. Dealer replaced ignition switch at no charge, since car is still under warranty, and this is a known issue. As an aside, dealer performed 30,000-mile maintenance.
55000 mi US $500	Check engine light came on. Diagnosis result: engine thermostat was 'barely functional'. Actions taken: Replaced thermostat and flushed radiator. Problem fixed.
93000 mi US $500	Problem: Engine light flashing and rough acceleration. Error code diagnosed as misfire in cylinder. Coil pack replaced. Repair completed successfully.

128340 mi	Recall for ignition switch and cylinder. But before they called me in to change it over, the ignition cylinder locked up with the car running and I could not turn it off(had to remove the ignition relay to turn the car off and disconnect the battery).
130140 mi C $50	Variable valve timing sensor on intake side failed. Replaced.
138880 mi C $40	Ignition coil cylinder one failed
153840 mi C $35	Thermostat failed.
176700 mi C $5000	New clutch etc. installed Gaskets replaced.

21000 mi	Car shuts off unexpectantly making right hand turns at slow speeds.
29000 mi	Fuel pump in tank had to be replaced leaking fuel externally

22940 mi	Check engine light was on for a few days, however by the time I was able to bring my vehicle in, the light had already been off for a week and the computer showed no history.
23560 mi	Injectors out of balance, installed 4 new updated injectors and performed reprogramming.

17360 mi	Power steering went out.
18600 mi	Engine light came on. Took it too shop. Apparently I had a fuel line partly freeze up during very cold -30 Celcius weather. That caused engine light to come on had thawed by the time I got it to the shop.
32240 mi C $55	Would not turn over happened in January. Replaced battery. Happened again, but this time battery fine. Could not replicate problem. Has not happened since that time.
53860 mi C $150	Engine warning light was on it, appears that it was a false warning caused by a sensor problem.
37920 mi C $300	Had to replace carburateur
55800 mi	Saturn ion ignition recall my key got stuck in the ignition so I got a loaner until the parts came in
73020 mi C $2500	Timing chain needed to be replaced

7000 mi	Could not start due to ignition/key interlock
56000 mi US $431	Ignition frozen with key stuck, could not turn car off.
64000 mi US $80	Dealer serviced coolant which had air pockets causing occasional coolant low warning.
81000 mi US $210	O2 sensor 1 was the code, in reality my wiring harness was damaged by rodents. O2 sensor was fine.
86000 mi US $200	Coolant filter tank reservoir was replaced. The sensor was bad but they had to replace the whole unit, Not just the sensor.
93000 mi US $90	Exhaust VVT sensor

30200 mi	Fuel pump module leaking. Replaced free of charge by dealer as part of special recall by General Motors.
26000 mi US $280	Check engine light came on. Air pump had failed and was replaced. Check valve had to be replaced
34000 mi US $400	Oxygen sensor replaced.

61000 mi	Ignition switch and key cylinder replaced as per recall. The key cylinder would occasionally not fully rotate back to the off position, leaving the key stuck in the cylinder and necessitating the use of the manual release button under the steering column.
65300 mi US $1000	Significant fuel leak developed at the fuel pump assembly. Unit replaced.
83000 mi US $500	Radiator fan failed and required replacement.
116000 mi US $230	Large emissions system leak reported by check engine light. Inspected and replaced failing evap purge and vent solenoids.

101640 mi	Car in for new Ignition Switch based on recent Recall.
108500 mi	The spark plugs need to be replaced in the ION but all 4 are seized in the head (original plugs). This car is still drivable but not as fuel efficient as it could be.
139500 mi	Exhaust hangers broke due to rust and flange bolts. New hangers welded and flange bolts added to exhaust which is still in good shape and the original system.

110660 mi C $80	Engine light on and car hard to start after refueling but always started. Parts changed so far: Fuel Cap & Exhaust Gas Recirculation Valve - problem still there so changed valve assembly, which fixed problem.
114700 mi C $195	Car need a new key cylinder - key got stuck and car would not shut off.
127720 mi C $60	Upper stream O2 sensor replaced
139500 mi	This car has developed a serious fuel economy issue. There is fuel smell present at start up and rough idle. To date the following parts have been replaced: MAF Sensor, Spark Plugs, Coil Pack/Ignition Module, Gas Cap. Car still has issue. A used Engine has been purchased for this car due to a fuel economy issue. The engine has not been installed yet.
112220 mi	Car had serious fuel consumption issues and has been permanently taken off the road.

76000 mi US $800	O2 sensor had been causing a CEL, replaced. (planned) Confirmed suspected exhaust/muffler leaks, putting that maintenance off until spring.
78000 mi US $120	Repaired exhaust leak, simple exhaust piping replacement using generic tubing and old heat shields

Saturn ION repairs by problem area

Saturn ION engine repair cost distribution

2007 Saturn ION

2007 Saturn ION 4dr Sedan

2007 Saturn ION 4dr Sedan

2007 Saturn ION 4dr Sedan

2007 Saturn ION 4dr Sedan

2007 Saturn ION 4dr Coupe

2007 Saturn ION 4dr Coupe

2007 Saturn ION 4dr Coupe

2007 Saturn ION 4dr Coupe

2007 Saturn ION 4dr Coupe

2006 Saturn ION 4dr Sedan

2006 Saturn ION 4dr Sedan

2006 Saturn ION 4dr Sedan

2006 Saturn ION 4dr Coupe

2006 Saturn ION 4dr Coupe

2006 Saturn ION 4dr Coupe

2006 Saturn ION 4dr Coupe

2006 Saturn ION 4dr Coupe

2005 Saturn ION 4dr Sedan

2005 Saturn ION 4dr Sedan

2005 Saturn ION 4dr Coupe

2005 Saturn ION 4dr Coupe

2005 Saturn ION 4dr Coupe

2004 Saturn ION

2004 Saturn ION 4dr Sedan

2004 Saturn ION 4dr Sedan

2004 Saturn ION 4dr Coupe

2004 Saturn ION 4dr Coupe

2004 Saturn ION 4dr Coupe

2004 Saturn ION 4dr Coupe

2003 Saturn ION

2003 Saturn ION 4dr Sedan

2003 Saturn ION 4dr Sedan

2003 Saturn ION 4dr Sedan

2003 Saturn ION 4dr Coupe

2003 Saturn ION 4dr Coupe

Saturn ION Engine Problems

130000 mi US $60	random multiple misfires. Replaced coil pack
130000 mi US $60	Ignition cylinder failed. Key would not turn. Had to replace

68300 mi US $78	Radiator fan needed to be replaced.
73000 mi US $100	Replaced Front Oxygen Sensor and coolant sensor

17000 mi	Gauges starting "lagging". Speedometer in particular. Also cruise control occasionally not working. ECU update fixed it.
23000 mi	Head was cracked on the motor. Check engine light tipped us off that something was wrong - but car ran pretty well like this for a year. It explained the mysterious dissapearing coolant. Warranty covered $1400 cost.

14000 mi	Ignition Switch Replacement, Car locked key in ignition, no start no electrical
49000 mi US $236	I paid for the ignition switch replacement though it was replaced not 20,000 miles ago under warranty. The BTSI sensor [$400.00] was covered by GM as it had been replaced 20,000 miles before as well. Update: GM later refunded the rest.
61200 mi	Recall ignition switch and cylinder. The 2011 repair lasted a little over a year and 3000 miles. I've been diddling a little tab under the steering wheel to get the key to release.
69000 mi US $988	Fuel filler neck and vapor recovery system

75500 mi US $45	Bad oxygen sensor "upstream", means before catalytic converter. Replaced sensor.
78000 mi	engine coolant light comes on. Needs new coolant surge tank.

59000 mi	Took car in for yearly PA. state inspection. Car would not pass state emissions test due to bad gas cap. Dealer service replaced gas cap.
75000 mi US $8	Car was running a tiny bit hot according to temp gauge. Checked to find upper radiator hose was collapsing due to negative pressure in cooling system. Replaced screw on cap on overflow reservoir. Problem solved.
99000 mi US $65	Replaced the coolant recovery tank and hose engine supply hose from the tank to the engine. Old one was leaking from the bottom near the sensor. New one came with sensor and cap.
113000 mi US $266	Emission light on dash was related to a faulty valve from gas tank that traps and hold fumes. Valve replaced and light cleared.

91000 mi US $475	ignition switch lock cylinder replaced during GM recall failed (key will not turn). Found dealer recall 'repair' damaged switch housing to where lock cylinder replacement ineffective, need to replace the entire switch and housing
102000 mi US $320	Engine light, code 102; thermostat replacement

59000 mi US $150	p0455 error, can't solve it, put new gas caps still happens. can't find parts that need attention on the car, don't know where to look
70000 mi US $291	emissions problems

63000 mi US $100	Slow coolant leak. Dealer replaced water pump.
75000 mi	Cat convertor flex pipe cracked. Replaced under Federal Emmissions requirement
115000 mi US $300	Crankshaft position sensor failure
118000 mi US $680	Check engine light was still on after I replaced the crankshaft position sensor myself. Code said I needed to do a CASE relearn. The dealer also found another code indicating the coolant temp was too low. Also replace a failing thermostat.

97000 mi US $1400	fuel and return line replaced - rusted from factory heat shield holding water
106000 mi US $88	replaced water pump