One problem related to gas recirculation valve (egr valve) has been reported for the 2004 Saturn ION. The most recently reported issues are listed below.
I tried to start my 2004 Saturn Ion at about 11 pm last night and it took fifteen minutes for it to turn over. The temperature was about 28 degrees (f). This has happened several dozen times over the past few years, always when the temperature is below freezing. I know that Saturn is aware of this problem and that it is acknowledged to be a problem with the ignition. I have found reports of hundreds of other Ion owners who have experienced this problem. I think this needs to be recalled and fixed by Saturn as sitting for 10-20 minutes or more in freezing temperatures waiting for one's car to start is not safe, especially at night. Please make this a recall issue!!.