Two problems related to engine clicking and tapping noises have been reported for the 2006 Saturn ION. The most recently reported issues are listed below.
Vehicle doesn't turn on in below freezing temperatures. Has happened on multiple occasions. Electrical works, but engine won't turn over, just makes a clicking noise. After temperature warms, vehicle will start.
I bought my 2006 Ion brand new with only 10 miles on it now the car is at 27k miles and now it has a clunking noise in the front suspension, I have taken in to dealer many times they have replaced 1) intermediate shaft 2) lower control arm rear bushing 3) catalytic converter 4) steering rack: and on top of all this it has been 8 months and my car is still not fixed. The dealer told me they don't know what it is. I have done some research found TSB's for this both of which they have supposedly already done.