Summary
The Saturn Ion has 11 recalls spanning the 2003–2011 production run, with the most serious being a fuel feed pipe crack on 2004 Red Line models equipped with the supercharged 2.0L engine that can leak fuel and, if an ignition source is nearby, cause a fire.
The 2003 model year also carries a fuel system fire risk: the exterior of the fuel filter assembly can corrode through, allowing fuel to drip onto the ground and ignite if an ignition source is present. A separate but related concern runs through 2003–2007 models: the ignition key can be removed from the switch before it reaches the "Off" position, which on automatic-transmission vehicles means the transmission may not be in Park, allowing the vehicle to roll away unattended. The 2003 model year also has a version of this problem where a weighted key ring combined with rough road conditions can cause the ignition to slip out of the "run" position while driving, cutting power to the engine and disabling safety systems mid-trip.
On the steering side, 2003–2007 models equipped with electric power steering can experience a sudden loss of power assist while driving. When this happens, a dashboard message and chime alert the driver, but steering the vehicle at low speeds requires noticeably more effort, raising the risk of a crash.
The 2003 model year has two additional lower-severity issues: front turn signal or daytime running lamp bulbs can lose contact with their sockets and go dark, making the vehicle harder for other drivers to read at intersections, and the power windows and sunroof can remain operable after the ignition is switched off and the front passenger door is opened, posing a risk to children left unattended in the vehicle.
Going further back in trim-specific territory, 2006 Ion Quad Coupe Red Line models have a lighting compliance issue where turning on the fog lamps does not automatically activate the parking lamps, tail lamps, license plate lamp, and side marker lamps as required.
