Headlights problems of the 2004 Saturn ION

Two problems related to headlights have been reported for the 2004 Saturn ION. The most recently reported issues are listed below.

1 Headlights problem

Failure Date: 08/12/2014

While driving in pre-dawn hours (headlights & defrosters on), started smelling something melting or burning. Then instrument panel lights went out for a few seconds. Instrument panel lights then came back on & started flashing on & off really fast. At that same time, door locks started locking & unlocking repeatedly on their own. Burning & melting smell was getting stronger. As I was pulling over, I entered a more well-lit area and saw smoke accumulating indide car near roof & top of windshield. Shut car off immediately.

2 Headlights problem

Failure Date: 01/01/2009

After 5 years my 2004 Saturn Ion will not start when the temperature is below +10f. There is power ( new battery ) and no fuel issue ( clean fuel system and filter ), but after 10 to 15 minutes and a couple of hesitant engine turns, it starts. No one needs an unreliable vehicle where winter temps last several months. After replacing the anti-sway bar, both headlight assemblies as well as other annoying problems ( instrument lights out, cabin fan noisy ) I will never ever buy another Saturn . I took the problem ( out of warranty of course ) to Saturn of rochester and was told it was a faulty ignition switch, a common problem for this make and model year. Since it is not a safety issue, no recall was issued and I would have to pay at least $275 unless "something else" came up. Being late for work ( public safety and volunteer fireman ) or my wife and children is not an option for me. Please force gm to make the recall on this ignition part for the financially stressed new york consumers. Thank you.


Other Exterior Lighting related problems of the 2004 Saturn ION



Fuel Economy of ION Vehicles
ION Service Bulletins
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ION Defect Investigations