| 1 | 0 | 3 | 4 | 3 | 4 |
2006 Saturn ION repairs by problem area
Engine (33%)
Transmission and Drivetrain (2%)
Brakes and Traction Control (2%)
Suspension and Steering (30%)
Electrical and Air Conditioning (17%)
Paint, Rust, Leaks, Rattles, and Trim (12%)
Other (4%)
Chart based on 248 repairs.
2006 Saturn ION engine repair cost distribution
$2500+ (3%)
$1000 - $2499 (1%)
$500 - $999 (14%)
$100 - $499 (26%)
< $100 (56%)
Chart based on 72 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.
2006 Saturn ION
Engine not specified
| 39680 mi | dipstick was popping out. Turned out to be a pinched pcv line on the back of the engine |
2006 Saturn ION 4dr Sedan
170-horsepower 2.4L I4 5-speed manual FWD
| 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. |
2006 Saturn ION 4dr Sedan
170-horsepower 2.4L I4 4-speed automatic FWD
| 38440 mi | Engine light was on when turned in, may have been a tiny hole in muffler. |
| 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 |
| 14260 mi | Check engine light showing intermittingly. Fuel injector fault code detected at dealer 4 injectors replaced. |
2006 Saturn ION 4dr Sedan
140-horsepower 2.2L I4 4-speed automatic FWD
| 76000 mi US $230 |
Ignition column needed to be replaced as the key was stuck in the ignition. |
| 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. |
| 61000 mi US $700 |
GM knows there is a problem with the passlock system that causes it to not allow the car to start in cold weather. Still, they won't pay to fix it. I fixed it myself, replacing and reprogramming the ignition switch. |
| 58000 mi US $800 |
Failure of the ECM logic cxircuits. |
| 46000 mi | Connection at the fuel tank hand to be replace per TSB recall. Vehicle had leaking fuel and strong fuel order. |
| 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. |
| 86800 mi US $600 |
I smelled fuel leaking from under the car. The mechanic checked it when they changed the oil, needed a new fuel pump. |
| 133000 mi | Many emissions components required replacement. |
| 139000 mi | Head gasket blown and the car is now junked. |
| 60000 mi US $265 |
Fixed the dreaded passlock issue with a new ignition and also cleaned the injectors. |
2006 Saturn ION 4dr Coupe
supercharged 205hp 2.0L I4 5-speed manual FWD
| 60000 mi US $250 |
Evaporative Control Module... Check Engine Light kept coming on...*** Will need to return because now the light is on again and I am getting "Check Gas Cap" all the time. |
2006 Saturn ION 4dr Coupe
170-horsepower 2.4L I4 5-speed manual FWD
| 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. |
2006 Saturn ION 4dr Coupe
170-horsepower 2.4L I4 4-speed automatic FWD
| 156860 mi C $450 |
Exhaust camshaft actuator causing transmission to turn to |
| 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 |
| 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 |
| 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. |
| 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 |
2006 Saturn ION 4dr Coupe
140-horsepower 2.2L I4 5-speed manual FWD
| 25420 mi | Ignition switch causing no start issue. Replaced ignition. |
2006 Saturn ION 4dr Coupe
140-horsepower 2.2L I4 4-speed automatic FWD
| 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. |
| 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. |
| 27700 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. |
| 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 |
| 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. |
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