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2004 Saturn Ion: problems, recalls and fuel economy
The 2004 Saturn Ion has 898 owner complaints on file with NHTSA, and steering and the electrical system are the largest groups[1][2][3]. It also has eight recalls on file, the most of any Ion year from 2003 to 2007[4].
Most reported problems
NHTSA lists 898 owner complaints for this model year[1]. Of those, 51 mention a crash, 4 a fire, 35 injuries and 3 deaths[1]. These are unverified reports from owners, and one complaint can name more than one part of the car. The counts are not adjusted for how many cars were sold.
Here are the biggest complaint groups:
| Component group | Complaints | Crashes | Median mileage at failure |
|---|---|---|---|
| Steering[2] | 345 | 16 | 86,000 |
| Electrical system[3] | 331 | 10 | 52,000 |
| Power train[6] | 60 | 2 | 64,000 |
| Engine[7] | 56 | 0 | 82,000 |
| Air bags[8] | 52 | 30 | 55,000 |
| Fuel/propulsion system[9] | 36 | 0 | 105,000 |
| Speed control[10] | 27 | 3 | 93,000 |
| Exterior lighting[11] | 25 | 1 | 51,200 |
Steering. In a sample of complaints we read, owners describe the power steering assist cutting out while driving, leaving the wheel stiff, sometimes with a warning light. Some say it came back after they restarted the engine. A few say they paid for the repair after the warranty ended[2]. The steering group also has 4 injuries[2].
Electrical system. In the sample, owners describe the engine dying while driving, with the dealer finding nothing wrong. Others describe a car that would not start, often in cold weather[3]. The group has 3 fires and 8 injuries[3].
Engine and power train. The engine sample describes stalling, hard starting in cold or damp weather and a couple of cracked cylinder heads[7]. The power train sample describes odd shifting, such as downshifting while braking, slipping or hesitating. Several texts say the dealer could not reproduce the problem[6].
Air bags. This group is small at 52 complaints, but it has 30 crashes and 22 injuries[8]. All 3 deaths in the model year's complaint total are listed under air bags[8][1]. Read this together with the ignition switch recall below, which says the air bags may not deploy if the switch moves out of the run position[12].
Recalls
NHTSA lists eight recalls for this model year[4]. Newest first:
- Ignition cylinder (14V171, April 2014). The key can be removed from the ignition when it is not in Off. The car could then roll away, which raises the risk of a crash and injuries to people in or near the car. Dealers replace the ignition cylinder if it is the original design and cut and re-learn two keys. The recall also covers other GM models[13].
- Remedy pending
Power steering (14V153, March 2014). Electric power steering assist can suddenly stop at any time while driving. The driver then needs more effort to steer at low speeds, which raises crash risk. The remedy for the Ion is a new power steering motor. When the recall was recorded, parts were not yet available and owners were to get a second letter when they were. Our data does not show whether parts are available now[14]. - Ignition switch (14V047, February 2014). The switch can slip out of the run position because of weight on the key ring or road conditions, which turns the engine off. If that happens, the air bags may not deploy in a crash. Dealers replace the switch at no charge. Owners were told to keep only the ignition key on the ring until the repair, and were to get another letter when parts were available. Our data does not show whether parts are available now[12].
- Turn signal (04V547, November 2004). A front turn signal and daytime running lamp can stop working when the bulb loses contact with the socket. Other drivers may react more slowly to a turning car. Dealers replace the bulbs on both sides and add a jumper kit if needed[15].
- Fuel feed pipe (04V281, June 2004). This one applies to 670 cars with the supercharged 2.0L (LSJ) engine[16]. The fuel feed pipe could crack and leak near the fuel rail, with a fire risk. Dealers replace the pipe assembly[16].
- Bumper welds (04V002, January 2004). On 344 cars[17], some welds between the passenger side motor rail and the front bumper bracket did not meet specifications. The bumper could separate from the frame and raise crash risk. The record says all of these vehicles were still in dealers' hands[17].
- Fuel filter (04V003, January 2004). On 127,285 cars with the 2.2L (L61) engine[18], the fuel filter could rust through on the outside. Fuel could drip, and a fire could result if something ignited it. Dealers replace the filter assembly[18].
- Power windows and sunroof (04V004, January 2004). On 79,204 cars[19], the windows or sunroof could work after the ignition was off and the front passenger door was opened. Unattended children could be hurt. Dealers update the body control module calibration[19].
Before you buy, check the VIN to see which of these are still open on a specific car.
Fuel economy
The EPA lists four versions of the 2004 Ion, all front-wheel drive:
| Engine and transmission | City / highway / combined MPG | Est. annual fuel cost |
|---|---|---|
| 2.0L, manual 5-speed, premium fuel[20] | 20 / 26 / 23 | $3,550 |
| 2.2L, automatic (variable gear ratios), regular[21] | 22 / 29 / 24 | $2,800 |
| 2.2L, automatic 5-speed, regular[22] | 20 / 30 / 24 | $2,800 |
| 2.2L, manual 5-speed, regular[5] | 23 / 32 / 26 | $2,600 |
The annual cost uses the EPA's current fuel price assumptions, not prices when the car was new. The 2.0L needs premium fuel, and its estimated annual fuel cost is the highest of the four[20].
Safety ratings
NHTSA's 5-Star Safety Ratings list this model year as not rated, both for the 2-door[23] and the 4-door[24].
Engine and size
The EPA lists a 2.0L 4-cylinder[20] and a 2.2L 4-cylinder[21]. Recall records also mention a supercharged 2.0L (LSJ) engine[16].
These sizes are Canadian-market specifications from Transport Canada, so they can differ slightly from US cars:
How 2004 compares with other years
Show the numbers
| Model year | Complaints | Recalls |
|---|---|---|
| 2003 | 758 | 5 |
| 2004 | 898 | 8 |
| 2005 | 573 | 3 |
| 2006 | 1,235 | 4 |
| 2007 | 876 | 5 |
Here are the complaints and recalls on file for each Ion model year[4]:
| Model year | Complaints | Recalls |
|---|---|---|
| 2003 | 758 | 5 |
| 2004 | 898 | 8 |
| 2005 | 573 | 3 |
| 2006 | 1,235 | 4 |
| 2007 | 876 | 5 |
The 2004 model year has the most recalls of the five years. Its 898 complaints are the second highest, behind 2006 with 1,235[4]. The 2005 year has the fewest of both. Complaint counts are not adjusted for sales, so treat them as a rough guide.
Should you buy a used 2004 Saturn Ion?
The record for this model year is mixed at best. Steering and electrical complaints are the largest groups, and owners in the sample describe the car losing power steering assist or stalling while driving[2][3]. Eight recalls are on file, including three from 2014 that involve the ignition and power steering[13][14][12]. If you are considering one, check the VIN for open recalls and ask whether the ignition and power steering work was done, and confirm with a dealer whether repair parts are available now, since our data cannot say. The complaint numbers are unverified and not adjusted for sales, so they show where owners reported trouble and not how likely any one car is to fail.
Frequently asked questions
- What are the most common problems with the 2004 Saturn Ion?
- NHTSA lists 898 complaints[1]. Steering has the most (345), followed by the electrical system (331)[1][2][3]. In the sample we read, owners describe lost power steering assist, stalling and hard starting[2][3].
- How many recalls does the 2004 Saturn Ion have?
- NHTSA lists eight recalls, the most of any Ion model year from 2003 to 2007[4]. Three are from 2014 and cover the ignition cylinder, ignition switch and power steering[13][14][12].
- What gas mileage does the 2004 Saturn Ion get?
- The EPA rates it at 23 to 26 mpg combined depending on engine and transmission[20][21][22][5]. The 2.2L manual is the best at 26 combined[20][21][22][5].
- Is the 2004 Saturn Ion safe?
- NHTSA lists its 5-Star Safety Ratings for the 2-door and 4-door as not rated[23][24]. The ignition switch recall warns that the air bags may not deploy if the switch moves out of the run position[12].
- Which Saturn Ion year has the fewest complaints?
- Among 2003 to 2007, the 2005 model year has the fewest complaints (573) and the fewest recalls (3)[4].
Facts and sources
- NHTSA has 898 owner complaints on file for the 2004 Saturn Ion (51 mention a crash, 4 a fire, 35 injuries, 3 deaths reported). NHTSA vehicle records
- 345 complaints name the steering component group (16 crashes, 1 fires, 4 injuries, median mileage at failure 86,000). NHTSA vehicle records
- 331 complaints name the electrical system component group (10 crashes, 3 fires, 8 injuries, median mileage at failure 52,000). NHTSA vehicle records
- Owner complaints and recalls for every Saturn Ion model year (chart above). NHTSA recall database
- EPA rating for Ion, 2.2L 4-cyl, Manual 5-spd, Regular, Front-Wheel Drive: 23 city / 32 highway / 26 combined MPG; EPA estimated annual fuel cost $2,600. EPA / DOE fueleconomy.gov
- 60 complaints name the power train component group (2 crashes, 0 fires, 0 injuries, median mileage at failure 64,000). NHTSA vehicle records
- 56 complaints name the engine component group (0 crashes, 0 fires, 0 injuries, median mileage at failure 82,000). NHTSA vehicle records
- 52 complaints name the air bags component group (30 crashes, 0 fires, 22 injuries, median mileage at failure 55,000). NHTSA vehicle records
- 36 complaints name the fuel/propulsion system component group (0 crashes, 1 fires, 0 injuries, median mileage at failure 105,000). NHTSA vehicle records
- 27 complaints name the speed control component group (3 crashes, 0 fires, 1 injuries, median mileage at failure 93,000). NHTSA vehicle records
- 25 complaints name the exterior lighting component group (1 crashes, 1 fires, 0 injuries, median mileage at failure 51,200). NHTSA vehicle records
- Recall 14V047, filed February 10, 2014: Air Bags. NHTSA recall database
- Recall 14V171, filed April 10, 2014: Electrical System › Ignition. NHTSA recall database
- Recall 14V153, filed March 31, 2014: Steering › Electric Power Assist System. NHTSA recall database
- Recall 04V547, filed November 16, 2004: Exterior Lighting › Turn Signal. NHTSA recall database
- Recall 04V281, filed June 8, 2004: Fuel System, Other › Delivery › Fuel Pump. NHTSA recall database
- Recall 04V002, filed January 6, 2004: Structure › Body › Bumpers. NHTSA recall database
- Recall 04V003, filed January 5, 2004: Fuel System, Gasoline. NHTSA recall database
- Recall 04V004, filed January 5, 2004: Visibility › Power Window Devices And Controls. NHTSA recall database
- EPA rating for Ion, 2.0L 4-cyl, Manual 5-spd, Premium, Front-Wheel Drive: 20 city / 26 highway / 23 combined MPG; EPA estimated annual fuel cost $3,550. EPA / DOE fueleconomy.gov
- EPA rating for Ion, 2.2L 4-cyl, Automatic (variable gear ratios), Regular, Front-Wheel Drive: 22 city / 29 highway / 24 combined MPG; EPA estimated annual fuel cost $2,800. EPA / DOE fueleconomy.gov
- EPA rating for Ion, 2.2L 4-cyl, Automatic 5-spd, Regular, Front-Wheel Drive: 20 city / 30 highway / 24 combined MPG; EPA estimated annual fuel cost $2,800. EPA / DOE fueleconomy.gov
- NHTSA 5-Star Safety Ratings, 2 DR None: not rated. NHTSA vehicle records
- NHTSA 5-Star Safety Ratings, 4 DR None: not rated. NHTSA vehicle records
- Transport Canada specifications via NHTSA vPIC, ION 4DR QUAD COUPE FWD /2/3/RED LINE: length 185 in, width 68 in, height 56 in, wheelbase 103 in, curb weight 2,751 lb (converted from centimeters and kilograms). vpic.nhtsa.dot.gov
- Transport Canada specifications via NHTSA vPIC, ION 4DR SEDAN FWD 1/2/3: length 185 in, width 67 in, height 57 in, wheelbase 103 in, curb weight 2,692 lb (converted from centimeters and kilograms). vpic.nhtsa.dot.gov