Four problems related to wiring 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 that during cold weather the vehicle intermittently failed to start. During the failure, the engine rpms would momentarily increase and the security warning light would illuminate. The contact stated that the security light indicated that the vehicle did not recognize the key. The vehicle was taken to an authorized dealer where the contact was told that the failure may be due to a wiring issue. The vehicle was not repaired. The failure and current mileage was 88,000.
Failure of a wiring harness in a front door that controls windows, mirrors and door lock. A 2004 Saturn Ion with 25, 106 miles had 5 broken wires in the drivers door. The left rear door has no power at the window switch. This failure is due to an inherent design flaw that forces tiny wires to bend 2 times at 90 degrees and be slammed by a door!! think of the safety of unlocking a door in a panic situation or driving with a window down in rain, sleet, cold, etc. , and a fuse is not the problem.
In 2005 a recall was issued for the 2004 Saturn Ion front headlamps. I had the recalled parts replaced. For the past few months my left blinker has gone out about five times. I have replaced bulbs, had the dealer replace the sockets, and am now about to have the wiring harness replaced. The dealer said that no one else has had this problem. However, I have been researching the problem and have found hundreds of the same occurrences online and have seen other Saturn Ions around town with the same blinker out. I believe this problem is not normal wear and tear. I believe it is directly related to the 2005 recall.
Car will randomly not start and will only start again with new spark plugs.