Sign inCreate free garage
Research · Compact Cars

2004 Saturn IonRecalls, problems, MPG & safety

NHTSA lists 10 safety recalls and 898 owner complaints for the 2004 Saturn Ion. Most complaints involve steering (345) and electrical system (331). The EPA rates it 23–26 mpg combined.

Check a VINAdd to my garage
Combined MPG
23–26mpg
EPA · 4 versions
NHTSA overall
—
Not rated by NCAP
Safety recalls
10campaigns
Latest Apr 2014
Owner complaints
898
Top: steering
Fuel cost / yr
$2,400est.
EPA estimate, best version
01 —Recalls

Safety recalls

10 NHTSA campaigns · applies to some vehicles, check your VIN

Electrical system: switch

Free remedy

UCI-FRAM Group is recalling certain LS1328 ignition Switches sold as Wells LS1328, Duralast LS1328, Airtex 1S6097, and Carquest 53-27479, and LS1497 Ignition Switches sold as Wells LS1497, Duralast LS1497, Airtex 1S10961, and Carquest 53-27967, for use on various General Motors model and model year vehicles during repair and replacement of the original ignition switch. The weight on the key ring and/or road conditions or some other jarring event may cause the affected ignition switches to move out of the run position, turning off the engine and disabling the air bags.

Electrical systemReported Apr 30, 2014NHTSA 14E021000

Electrical system: ignition

Free remedy

General Motors LLC (GM) is recalling certain model year 2005-2010 Chevrolet Cobalt, 2006-2011 Chevrolet HHR, 2007-2010 Pontiac G5, 2006-2010 Pontiac Solstice, 2003-2007 Saturn Ion, and 2007-2010 Saturn Sky vehicles. In the affected vehicles, the key can be removed from the ignition when the ignition is not in the "Off" position.

Electrical systemReported Apr 10, 2014NHTSA 14V171000

Steering: electric power assist system

Remedy pending

General Motors LLC (GM) is recalling certain model year 2004-2006 and 2008-2009 Chevrolet Malibu, 2004-2006 Malibu Maxx, 2009-2010 HHR (non-turbo), 2010 Cobalt, 2008-2009 Saturn Aura and 2004-2007 Ion, and 2005-2009 Pontiac G6. In the affected vehicles, there may be a sudden loss of electric power steering (EPS) assist that could occur at any time while driving.

SteeringReported Mar 31, 2014NHTSA 14V153000
See all 10 recalls with remedies
Data from NHTSA Recalls API · synced Nov 9, 2026 · All recall detailsNHTSA vehicle page
02 —Complaints

Owner complaints by component

898 complaints filed with NHTSA · Jan 2004 – Nov 2025
  1. Steering345
  2. Electrical system331
  3. Power train60
  4. Air bags52
  5. Fuel/propulsion system36
  6. Engine and engine cooling33
  7. Vehicle speed control27
  8. Exterior lighting25
  9. Engine23

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.

By model year

Complaints for each Ion model year we’ve synced.

View as table
Model yearNHTSA complaints
2003768
2004898
2005573
20061,235
2007876
Crashes reported
51
Fires reported
4
Injuries reported
35
Deaths reported
3
Data from NHTSA Complaints API · synced Nov 9, 2026 · Full problem breakdownNHTSA vehicle page
03 —Common problems

What owners report most

Verbatim excerpts from NHTSA complaints, by component

Steering

345 reports16 crashes1 fire
“The car doesn't always want to release the key. I have to stick my finger up in the column to push the little button to release it which is not convenient at all. It seems to do it if the wheels aren't completely straight. But still even with the steering wheel straight, sometimes it wont come out if its on a slight hill. Ive had a new key made and it makes no difference, no check engine light and auto technician said the ignition looks fine. Ive read tons of reports like this on the 2004 saturn ion 2-why isn't this being addressed?”
Owner complaint to NHTSAFiled Nov 2, 2025SteeringODI 11696981

Electrical system

331 reports10 crashes3 fires
“The contact owns a 2004 Saturn Ion. The contact stated that while driving at an undisclosed speed, the vehicle stalled. Additionally, the contact stated that the key was stuck in the ignition. The failure was intermittent. The vehicle was taken to the dealer, who replaced the ignition switch and the ignition lock cylinder; however, the failure recurred. The contact stated that while driving at an undisclosed speed, the vehicle stalled. The contact related the failure to NHTSA Campaign Numbers: 14V047000 (Air Bags, Electrical System) and 14V171000 (Electrical System). The manufacturer was made aware of the failure. The failure mileage was approximately 230,000.”
Owner complaint to NHTSAFiled Jul 6, 2023Electrical system, Air bagsODI 11530643

Power train

60 reports2 crashes
“1. THE IGNITION SWITCH WILL NOT DISENGAGE...SOMETIMES AFTER MOTOR IS TURNED OFF AND CAR IS IN PARK THE CAR MUST BE TURNED BACK ON FOUR OR FIVE TIMES BEFORE THE IGNITION WILL ENGAGE CORRECTLY. THE VEHICLE IS STATIONARY...IN THE PARK POSITION....KEY WILL LOCK INSELF AND NOT DISENGAGE. THE CAR WAS ON A CITY STREET WHEN THIS OCCURRED. IT BEGAN TO OCCUR FIVE MONTHS AGO...NOW IT HAPPENS AT LEAST TEN TIMES A WEEK. 2. ALL ELECTRICAL SYMBOLS ON DASHBOARD SAY: COOLANT...BUT WHEN CHECKED THE COOLANT IS FINE.”
Owner complaint to NHTSAFiled Aug 22, 2017Power train, Electrical systemODI 11018943
All 2004 Ion problemsSend a problem to a mechanic on findmechanic.ai
Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 9, 2026
04 —Key specs

Engines, transmissions & drive

4 versions rated by the EPA
EPA class
Compact Cars
Engines
2.2L 4-cyl · 2.0L 4-cyl supercharged
Transmissions
Manual 5-spd · Automatic (variable gear ratios) · Automatic 5-spd
Drive
Front-Wheel Drive
Fuel
Regular Gasoline · Premium Gasoline

Towing, payload and dimensions aren’t in the EPA or NHTSA data, so we don’t list them.

Data from EPA fueleconomy.gov · synced Nov 9, 2026EPA listing
05 —Fuel economy

EPA fuel economy by version

City / highway / combined, annual fuel cost and CO₂
EPA
VersionCityHwyComb.Fuel / yrCO₂ g/mi
Ion
Man 5-spd, 4 cyl, 2.2 L · Front-Wheel Drive
233226$2,400342
Ion
Auto (variable gear ratios), 4 cyl, 2.2 L · Front-Wheel Drive
222924$2,600370
Ion
Auto 5-spd, 4 cyl, 2.2 L · Front-Wheel Drive
203024$2,600370
Ion
Man 5-spd, 4 cyl, 2.0 L, Sup Charg · Front-Wheel Drive
202623$3,350386
  • Ion
    Man 5-spd, 4 cyl, 2.2 L
    23 city · 32 hwy · $2,400/yr
    26
    mpg comb.
  • Ion
    Auto (variable gear ratios), 4 cyl, 2.2 L
    22 city · 29 hwy · $2,600/yr
    24
    mpg comb.
  • Ion
    Auto 5-spd, 4 cyl, 2.2 L
    20 city · 30 hwy · $2,600/yr
    24
    mpg comb.
  • Ion
    Man 5-spd, 4 cyl, 2.0 L, Sup Charg
    20 city · 26 hwy · $3,350/yr
    23
    mpg comb.
Estimate your fuel costCost of ownership
Data from EPA fueleconomy.gov · synced Nov 9, 2026 · Fuel cost is EPA’s annual estimate (15,000 mi, 55% city)
06 —Safety

NHTSA 5-Star Safety Ratings

2 tested variants
NHTSA has not published 5-Star Safety Ratings for the 2004 Saturn Ion as of Nov 9, 2026.
Data from NHTSA NCAP Safety Ratings API · synced Nov 9, 2026Vehicle 1268Vehicle 1267
07 —Maintenance

Maintenance basics

General guidance, not the OEM schedule. Check your owner’s manual.
General guidance
ItemMilesTimeNote
Engine oil & filter5,000–10,000 mi6–12 monthsFollow the oil-life monitor if fitted
Tire rotation5,000–7,500 miEvery oil changeCheck pressure monthly
Engine air filter15,000–30,000 mi1–2 yearsSooner in dusty areas
Cabin air filter15,000–25,000 mi1–2 years
Brake fluid—2–3 yearsAbsorbs moisture over time
Coolant60,000–100,000 mi5–10 yearsLong-life coolants last longer
Spark plugs60,000–100,000 mi—Iridium/platinum plugs at the long end
12V battery—3–5 yearsHeat shortens battery life
  • Engine oil & filter5,000–10,000 mi
    6–12 months
  • Tire rotation5,000–7,500 mi
    Every oil change
  • Engine air filter15,000–30,000 mi
    1–2 years
  • Cabin air filter15,000–25,000 mi
    1–2 years
  • Brake fluid—
    2–3 years
  • Coolant60,000–100,000 mi
    5–10 years
  • Spark plugs60,000–100,000 mi
    —
  • 12V battery—
    3–5 years
Typical intervals for modern cars. Severe service (towing, short trips, extreme heat or cold) shortens them.
09 —FAQ

2004 Ion questions

How many recalls does the 2004 Saturn Ion have?

10 safety recalls as of Nov 9, 2026, according to NHTSA. Recall repairs are free at a dealer. Check your VIN to see whether your car is included and whether the repair was done.

What are the most common 2004 Saturn Ion problems?

Owners filed 898 complaints with NHTSA. The most-cited components are steering (345), electrical system (331), power train (60). Complaints are unverified owner reports and aren't adjusted for how many cars were sold.

What MPG does the 2004 Saturn Ion get?

The EPA rates the 2004 Saturn Ion at 23–26 mpg combined, depending on engine and drivetrain (4 versions rated).

Data from NHTSA & EPA · synced Nov 9, 2026