2004 Saturn Ion Recalls
In order to help prevent rollaway type accidents, all late model vehicles are designed so that the transmission must be in park (or reverse for a manual transmission) before the ignition switch can be turned to the "off" position and the key removed. These vehicles are being recalled because the key can be removed when the ignition is not in the "off" position, increasing the risk of a rollaway type accident. Dealers will inspect the vehicle and replace the ignition lock cylinder as necessary. 2 new keys will also be supplied and programmed as required.
The vehicles being recalled are equipped with an electric power steering (EPS) assist system. The EPS can fail unexpectedly while driving. If this were to occur, steering ability would be maintained but much greater effort would be necessary to steer the vehicle, especially at slow speeds. One of four remedies will be applied depending on the model and year. Parts are not yet available so expect a second notification when they are.
These vehicles are being recalled because the weight on the key ring and/or a jarring event while driving may cause the ignition switch to move out of the run position, turning off the engine. If the key is not in the run position, the air bags may not deploy in the event of a crash, increasing the risk of injury. Dealers will replace the ignition switch to correct this concern.
One or both or the front turn signal/daytime running lamps may stop working because of loss of contact between the bulb and the socket. If a turn signal lamp is inoperative, others may react more slowly to a turning vehicle and a crash could occur. Dealers will replace the affected bulbs add add a daytime running light jumper kit as required. The General Motors recall number is 04095.
On some supercharged Ion models, the hard fuel feed pipe to the engine could crack and leak fuel near the fuel rail. If this happens, there would be an noticeable fuel odor. A fuel leak in the presence of an ignition source may result in a fire. Dealers will replace the fuel feed pipe assembly. The recall began June 9, 2004. The GM recall number is 04053.
Some welds between the passenger side motor rail and bumper bracket of the vehicle do not meet the engineering specification. Long term durability of the joint may be reduced and the bumper bracket may separate from the frame, increasing the risk of a crash. The GM recall number is 03067.
A fuel leak may develop on vehicles equipped with a 2.2L 4-cylinder engine. Premature corrosion of the exterior of the filter could lead to a hole, resulting in a fuel leak. Any fuel leak always increases the risk of a fire. Dealers will replace the inline fuel filter to correct this concern. The General Motors recall number is 03068.
The power windows and/or sunroof may operate after the ignition has been turned to the off position and the front passenger door is opened. If children are left unattended and operate the windows or sunroof, there is an increased risk of injury. Dealers will upgrade the body control module (BCM) calibration to correct this concern.