One problem related to loud engine noise has been reported for the 2006 Saturn ION. The most recently reported issues are listed below.
I purchased my 2006 Saturn Ion 3 in 2008 from a dealership. I have had all the recall issues happen to my vehicle. 1) I have replaced the ignition switch and cylinder twice due to the car being unable to shut off. This happened in 2008 and again in 2012. Both times it was covered under warranty and repairs were done by gm dealership. Even though these have been replaced I was told they need to be replaced again under the recall because those parts are faulty as well. I have been in contact with the dealership and was told they do not have the parts yet and will let me know when they are available. 2) in November 2013 my vehicle smelled of gas and was making me and my children sick. I had it checked out at the dealership and it was the fuel module. This was covered by a ntsb warranty extension. 3) my vehicle will intermittently shut off or lose power steering. When I took it into the dealership in 2013 they told me they would not touch it if they could not replicate the problem. It has not been fixed. 4) this issue is not mentioned in any of the complaints I have read here, but I have seen others complain on the internet. Beginning in January of 2014 there is a strong odor of exhaust fumes in my vehicle. My personal mechanic said there is a leak that is going into the cabin. My vehicle is slow to accelerate and feels shakey. There is also a loud noise coming from the engine compartment. I have to drive with the windows down at all times. I have had nothing but problems with this vehicle since right after I purchased it. I do not have a second vehicle nor the means to buy one. I rely on it to get me to work and to transport my family. It is very disappointing to have to deal with these issues over and over again.