Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2005 Saturn Ion owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl* the contact owned a 2005 Saturn Ion. The contact's son observed an orange glare coming from the back of their house. The family ran outside together and discovered that the son's vehicle was on fire. The fire department was down the street, but took twenty minutes to arrive at the scene. The contact's nineteen year old son extinguished the fire with water from the house. A police report was filed and there were no injuries. The vehicle was totaled. The dealer and manufacturer were not made aware of the failure. The failure mileage was 217,000.
Tl* the contact owns a 2005 Saturn Ion. The contact stated that while driving approximately 55 MPH, the loss motive power without warning. The contact stated that steering assist and gauges were in operable. The contact coasted to the side of the road and restarted the vehicle. The contact stated that several of the electrical functions returned however, the electrical functions failed intermittently. The power steering assist warning light illuminated intermittently when the power steering assist was inoperable. Ocean crest Chevrolet Buick GMC Cadillac (855 alternate hwy 101, warrenton, or 97146, [phone]) was contacted and informed of the failure. The dealer suggested that the vehicle be taken in to be diagnosed which was still pending. The vehicle was not yet repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 110,000.
I have had issues with my car even after I have had some recalls done to it. The biggest issue is when I am driving or stationary with my car on, the car rumbles and feels like it is tugging backwards. The cylinder 2 keeps misfiring (p0302). I have seen several Saturn ions that are having the same issue. Over the past four years this has been a problem consistently. There are periods where it doesn't happen much and sometimes it happens every time I drive. Furthermore, my car still doesn't turn on/off all the way sometimes and the ignition switch messes up.
Tl* the contact owns a 2005 Saturn Ion. The vehicle was repaired under special policy 10187 at the dealer. While driving approximately 35 MPH, the vehicle completely shut off and the power steering warning indicator illuminated. The failure recurred on multiple occasions. The vehicle was taken to a dealer who diagnosed that the electronic power steering control module failed, the vehicle was not repaired and the manufacturer was notified. The approximate failure mileage was 118,000. Updated 4/13/15 updated 9/20/2017
Tl* the contact owns a 2005 Saturn Ion. The contact stated that while driving approximately 40 MPH, the driver made a sudden turn when the engine stalled and caused a loss of steering control. The driver then traveled down and crashed into an embankment. There were no injuries and a police report was filed at the scene. The vehicle was not diagnosed or repaired. The manufacturer was not notified. The failure mileage was 165,000.
Tl* the contact owns a 2005 Saturn Ion. While driving at various speeds, the steering wheel became hard to maneuver. The power steering and check engine warning lights illuminated. The contact pulled over to the side of the road and restarted the vehicle, but the failure occurred once more. The vehicle was not diagnosed nor repaired. The manufacturer was made aware of the failure. The failure mileage was 97,200.
Tl contact owns a 2005 Saturn Ion. The contact stated that while driving at approximately 25 MPH, the vehicle stalled without warning. The vehicle was able to restart. The failure occurred on three occasions. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 124,000. The VIN was not available.
Engine failed at 125,000 miles. Engine specialist determined cylinder #4 oil starvation as the cause. Oil change intervals have always been approximately 7500 miles. Engine stalled out and would not crank to restart. Engine will need to be replaced. Cost: approximately $4,000.
My 2005 Ion 2 was serviced continuously by the Saturn dealership since its new purchase. This car has never had a engine incident, overheating, or missed oil change/service and at approximately 35,000 miles the engine service light would activate intermittently. The problem was brought to the Saturn technician and deduced to either a gas tank sealing issue or oxygen sensor malfunction. The oxygen sensor was finally replaced on it 48,000 service checkup, yet the light was still active. A complete computer code diagnostic revealed internal misfire issues with the #1 cylinder. The mechanics evaluation was that the engine cylinder or block is warped and causing compression blow by & misfiring. The recommended solution is to change the engine block at a cost of $6, 800. Or work on tearing down the engine at an un-estimated amount. …
We bought our 2005 Saturn Ion used sept. 4, 2012,(87,812) before even could take off lot they had to install an ignition cylinder and cut new key, and the throttle was stuck could press all the way to floor, and would only get up to about 20mph. This was also fixed. (or so we thought). Since our purchase, we still have trouble with the key getting stuck, it not turning off with car still running, or the car won't start, it happens so much that our daughter who drives it just figures that's they way it's suppose to be, because when take back to dealer either it won't do it for them or doesn't do it for a month or so. Now the warranty has ran out so if it happens again they told us we had to take care of, well it happened again today, she parked would not shut off, called dealership, they can't do anything because GM hasn't given them recall yet! Was in accident on jan. …
Engine complaints in other Ion years
Frequently asked questions
How common are engine problems on the 2005 Saturn Ion?
NHTSA has 37 complaints about the engine & cooling of the 2005 Saturn Ion, 6% of the model year's 573 complaints. The component named most often is engine (5 mentions).
Is there a recall for 2005 Saturn Ion engine problems?
No. NHTSA lists no engine & cooling recall for the 2005 Saturn Ion, though it has 3 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2005 Saturn Ion engine problems start?
Half of the complaints with a recorded mileage happened before about 96,000 miles, and 15% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 1 fire and 1 injury to engine & cooling problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.