Four problems related to alternator/generator/regulator have been reported for the 2004 Saturn ION. The most recently reported issues are listed below.
The contact owns a 2004 Saturn Ion. The contact stated she had her vehicle serviced under NHTSA campaign number: 14v171000 (electrical system) and NHTSA campaign number: 14v047000 (air bags, electrical system). The contact mentioned that when she came to pick up the vehicle the exhaust pipe was visibly on the floor. The contact immediately informed the service manager since the vehicle was not in that condition prior to the repairs. The service manager agreed to repair the failure by reattaching one side of the exhaust pipe with a wire hanger. The contact reluctantly took the vehicle home and while on the way home the air bag, alternator and battery light illuminated on the instrumental panel. Shortly after the lights illuminated, the vehicle stalled. The manufacturer was made aware of the failure. The vehicle was not repaired. The approximate failure mileage was 127,000.
The problem began within the first month of the car's purchase. It was cold outside, and the car wouldn't start. After about 30 minutes, it started right up. After visiting several mechanics, I was advised to replace the alternator. Since then, I cannot count the number of times that I go out to the car and it won't start. Now, I am told that it 'may be' a faulty ignition switch. I am a teacher, and cannot be late for class. I have 34 students waiting for me every morning. Now, I have to go out to my car, 30 minutes early, and start it. If it starts, I run out 30 minutes worth of gas for fear that it won't start if I turn it off. If it doesn't start, I waste 20 to 25 minutes in the morning getting it to start. This winter, it has not started no less than 15 times. This car is not dependable.
I bought my 2004 Saturn Ion used with less than 60,000 miles on it, I had it less than a year when one day it wouldn't start, I thought it was the battery or the alternator, but none of that fixed the problem. This problem progressively got worse and started happening very frequently, more often when it got cold out. After about 10-15 minutes the car will start, I have had to wait up to 45 minutes for the car to start sometimes. This problem has made me late for work, left my children waiting for me and left myself after work closing a bar one night at 3:00 in the morning. The more I mentioned this problem to people the more I found out I am not the only one with this problem, it has to do with the security pass lock system and ignition. If this is such a frequent problem for Saturns why hasn't there been a recall ever to had it fixed, and why are dealerships allowed to sell used Saturns without correcting the problem or making buyers aware of this potential problem, it is simply dishonest!.
Car does not start when weather is very cold. Changed battery and had alternator checked. Took it in to etna battery to have checked out. Car started when it gets warmer or the sun warms up the car.