2004 Saturn ION Manufacturer communications & TSBs.Page 4
Original record summaries, dates and identifiers for this model-year. Records 301–400 of 525, ordered newest first. Dated records on this page: Jun 1, 2009–Apr 11, 2014.
Read the applicability before drawing a conclusion.
This archive includes service bulletins, warranty notices, software instructions and other communications. Records may repeat or supersede earlier instructions. A model-year association is not proof that a document covers every engine, trim, VIN or reported symptom, or that a repair is free.
NHTSA download snapshot: Sep 28, 2026. These are communication associations for this vehicle, not unique defects. How records are joined and counted.
Apr 11, 2014Service Bulletin/Repair Instructions
SB-0000189716-A
NHTSA communication ID: 10061156
NHTSA source summary · Original PDF not reviewed by Recallfolio
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication provides information to the technician about vehicles that when a Canadian customer may comment that when they travel to the United States, they are unable to connect to OnStar or use hands free calling. Dealer can advise the customer that the existing cell phone provider not having roaming agreements in areas outside of Canada. At this time, a customer has the option of contacting OnStar to have a 500 number loaded for OnStar operation while in the United States.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication provides information to the technician about a customer?s request to install OnStar Bluetooth. Dealer should be advised at this time, there are no provisions to add this option to vehicles that were not built with it.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication provides information to the technician about vehicles that have the OnStar system does not respond properly to some numbers and/or voice commands. Dealer should direct the customer to review the operational characteristics in the OnStar Users Guide.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication provides information to the technician about vehicles that have a Service Engine Soon Malfunction Indicator Lamp. Technician may find Diagnostic Trouble Code P0442. Technician will need to review Techlink article from May 2013 titled "Using the Evaporative Emissions System Tester" Technician will need to follow these steps to help diagnose the issue. First after the P0442 has been verified do not disturb any of the fuel system components. The technician now can use the scan tool to close the Evaporative Emissions System. If possible change the tank pressure sensor units from inch_H2O to milimeter_Hg for better resolution. Now the vehicle can be stared to monitor the tank pressure sensor output value for approximately two minutes. If the tank pressure sensor value does change, pressurize the fuel tank side of the purge solenoid with the GE 41413-A / J 41413-A and the necessary adaptors. Now add smoke and allow pressure to stabilize for 2 minutes. If smoke is allowed to pass through the purge solenoid, replace the purge solenoid. If the tank pressure sensor value does not change, then install CH-48096 adaptor between the purge line from the canister and the purge solenoid. With the Evaporative Emissions System closed, pressurize the system through the CH-48096 adaptor and allow the system to completely stabilize, by observing the Press / Vac Gauge for a minimum of 5 minutes. Now add smoke to the system with GE 41413-A / J 41413-A after system stabilization. Now inspect the purge solenoid, engine side, fuel cap, canister vent solenoid filter and any line quick connects. When the leak is unable to be located, test under a vacuum condition. his type of leak may be detected by using the scan tool Purge/Seal function to create a vacuum in the Evaporative Emissions System and then observe the FTP sensor parameter for vacuum decay.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication provides information to the technician that General Motors and General Motors of Canada Company do not support cross border sales. The General Motors of Canada Customer Care Centre is the sole authorized provider of a certification confirmation letter which helps our customers identify if their vehicles meets the required USA regulatory standards necessary for importation into the USA.
NHTSA source summary · Original PDF not reviewed by Recallfolio
Refinishing Aluminum Wheels This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening o re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility Outside Company later in this bulletin.
NHTSA source summary · Original PDF not reviewed by Recallfolio
Refinishing Aluminum Wheels This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening o re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility Outside Company later in this bulletin.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication provides information to the technician about vehicles that may have an issue when using Bluetooth voice recognition with an iPhone. Technician should work with the customer to insure the phone contacts to not have any Emojis loaded to any contact.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication advises the technician that a noise or a vibration in the vehicle that seems to be abnormal may not have been there when the vehicle was purchased. Technician should look for Non - General Motors aftermarket accessories installed on the vehicle that can cause these issues.
NHTSA source summary · Original PDF not reviewed by Recallfolio
Underbody Component Corrosion The following information may be helpful when addressing underbody component corrosion with customers. Some customers may comment that one or more of their vehicle's underbody components are showing some form of corrosion. This corrosion may be red in appearance (rust) if the component is steel, forged iron or cast iron. This corrosion may also be grey or white in color if the component is constructed of an aluminum alloy.
Source components: EQUIPMENT ADAPTIVE/MOBILITY · STRUCTURE:FRAME AND MEMBERS:UNDERBODY SHIELDS.
NHTSA source summary · Original PDF not reviewed by Recallfolio
Underbody Component Corrosion The following information may be helpful when addressing underbody component corrosion with customers. Some customers may comment that one or more of their vehicle's underbody components are showing some form of corrosion. This corrosion may be red in appearance (rust) if the component is steel, forged iron or cast iron. This corrosion may also be grey or white in color if the component is constructed of an aluminum alloy.
Source components: EQUIPMENT ADAPTIVE/MOBILITY · STRUCTURE:FRAME AND MEMBERS:UNDERBODY SHIELDS.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication provides information to the technician about engine block of possible cylinder bore damage, scoring or out of round as the possible cause of engine oil consumption, misfire, cylinder leakage or blow by. Technician will need to inspect the engine for Cylinder damage or scoring, An out of round cylinder bore, Dirt intrusion, and Catalytic Converter failure.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication provides information to the technician about installing General Motors Accessory pats. Technician can check Service Information for some accessories. Technician can also contact Partech for assistance.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication provides information to the technician about vehicles that the OnStar system will not connect. Technician should record module info per the latest version of PIC4310 and contact General Motors Technical Assistance Center.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This informational bulletin provides a revision for 11-00-89-005D to add additional Mandatory Minimum Tables and additional information concerning Policy decision making.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This informational bulletin provides a revision for 02-08-98-002C to add the 2010-2013 model years and revise the Approved Refinish Materials booklet information.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This informational bulletin provides a revision for 09-00-89-008 to add model years, update the Labor Operation Information and Transaction Submissions Procedure and general content updates.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication provides information to the technician that after replacing the Instrument Panel Cluster the exchange center is unable to program the actual mileage on the odometer or the actual mileage is unknown. Dealer will need to follow dealer to the General Motors service policies and procedures manual section 3.2.4 odometer servicing.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This informational bulletin provides information on the appearance of chromed aluminum wheels due to chemical staining, pitting corrosion and/or spotted.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication advises the technician that a noise or a vibration in the vehicle that seems to be abnormal may not have been there when the vehicle was purchased. Technician should look for Non - General Motors aftermarket accessories installed on the vehicle that can cause these issues.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication advises the technician that, when testing any circuit for open or resistance, it is imperative that all related terminal pin fit and tension be checked when the test steps require disconnection of the connector or component, prior to any component replacement. Always use the recommended terminal test tool during these tests.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication provides information to the technician about vehicles that have a loud tick or rattle noise under the hood at all operating conditions. Technician will need to check the lower and oil pressure to the upper end oil pressure. Technician will need to inspect the oil feed orifice in the cylinder head. Technician will clean out and debris found in the orifice.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication provides information to the technician about vehicles may have a no power or no connect concern. Technician will find that the OnStar led is red and Diagnostic Trouble Code U1500 is set. Technician will need to replace the Vehicle Communication Interface Module if the Station Identification number falls in the ranges 14,000,000 - 16,000,000 or 22,000,000 - 23,200,000.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication provides information to the technician that fluid contamination may be directed to one of the following testing centers according to the type of fluid needing testing. Dealer should send the correct fluid to the proper testing center.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This informational bulletin provides a list off all the issues revolving around new vehicles for a one stop place to find growing concerns around them.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This informational bulletin provides a list off all the issues revolving around new vehicles for a one stop place to find growing concerns around them.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This informational bulletin provides a step by step procedure on how to properly use the GM chemicals to eliminate unwanted odors in vehicles and which products to use for each application.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication provides information to the technician about vehicle that may have an OnStar system that has progression tones when pressing the blue or red button. Technician will need to call General Motors Technical Assistance Center with the scan tool data from the OnStar system.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This warranty administration bulletin provides information regarding customer concerns not duplicated and which labor operations to claim when the concern cannot be duplicated. Also provides information on how to submit claims within the global warranty managment.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This warranty administration bulletin provides information regarding customer concerns not duplicated and which labor operations to claim when the concern cannot be duplicated. Also provides information on how to submit claims within the global warranty managment.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This informational bulletin provides information and rules for GM keycode look up applicationa dn the key code security rules and regulations for Canada only.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This informational bulletin provides information and rules for GM keycode look up applicationa dn the key code security rules and regulations for Canada only.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This informational bulletin provides information and rules for GM keycode look up applicationa dn the key code security rules and regulations for Canada only.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This informational bulletin provides a single point reference and strategy document to aid in reducing customer comebacks, and the possibility of buyback situations by outlining specific guidelines, strategy and forms that will assist with this goal, by identifying, clarifying and documenting customer concerns accurately at each service visit.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This informational bulletin provides a list of newly released PI and Bulletins in regards to recent released vehicles so that vehicles can be fixed right the first time in for service.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication provides information to the technician about brake rotors on new vehicles and replacement parts from General Motors Service Parts Operations. Technician should be advised the costing should not be removed from the brake rotor it will wear off with normal brake usage. Dealer should communicate to the customer this condition is a normal operating characteristic of their vehicle.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication provides information to the technician about vehicles that during battery parasitic drain test, there may be some confusion as to what the normal power consumption reading should be from the OnStar system. Technician should understand the power cycles of the various OnStar systems. All Generation 6, 7, 8, and 9 systems are powered up continuously for 48 hours from ignition off. After 120 hours from ignition off, these systems then completely power off. The Onstar modules draw: * IGN ON - 240 to 400 Milliamp. * IGN OFF - 3 to 20 Milliamp for 48 hours or 120 hours on Gen 9 and vehicle communication platforms. * IGN OFF - 0.2 to 0.8 Milliamp after 48 hours or 120 hours on Gen 9 and vehicle communication platforms.
NHTSA source summary · Original PDF not reviewed by Recallfolio
This Preliminary Information communication provides information to the technician about installing General Motors Accessory parts. Technician can check Service Information for some accessories. Technician can also contact Partech for assistance.
NHTSA source summary · Original PDF not reviewed by Recallfolio
SATURN SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. SPECIAL COVERAGE ADJUSTMENT-POWER STEERING ASSIST. SOME VEHICLES EQUIPPED WITH ELECTRIC POWER STEERING MAY EXPERIENCE A SUDDEN LOSS OF POWER STEERING ASSIST, WHICH COULD OCCUR AT ANY TIME WHILE DRIVING THE VEHICLE. IF THE POWER STEERING ASSIST IS LOST, A CHIME WILL BE HEARD AND THE MESSAGE CENTER WILL DISPLAY A PWR STR WARNING MESSAGE. *PE UPDATED 06/18/2012 *JS
Source components: STEERING:ELECTRIC POWER ASSIST SYSTEM.
NHTSA source summary · Original PDF not reviewed by Recallfolio
GM: THERE ARE SEAT BELT PROBLEMS: DIFFICULTY LATCHING AND UNLATCHING BUCKLE. BUCKLE RELEASE BUTTON IS STICKING. SEAT BELT WARNING LIGHT ILLUMINATED. LIKELY CAUSED BY STICKY BEVERAGES THAT ARE SPILLED INTO THE BUCKLE ASSEMBLY. *RM UPDATED 4/3/12. *PE
NHTSA source summary · Original PDF not reviewed by Recallfolio
SATURN: LOW BRAKE FLUID WARNING AND/OR RED BRAKE LIGHT ON DUE TO POSSIBLE BRAKE FLUID RESERVOIR OR FLUID SWITCH BEING REPLACED. BRAKE AND BRAKE PEDAL OPERATION NOT AFFECTED. *PE UPDATED 2/8/12. *PE
Source components: SERVICE BRAKES, AIR:SUPPLY:RESERVOIR/TANK · SERVICE BRAKES, HYDRAULIC:FLUID.
NHTSA source summary · Original PDF not reviewed by Recallfolio
CLUCK, THUMP OR RATTLE NOISE FROM FRONT SUSPENSION WHILE DRIVING OVER ROUGH ROAD CONDITIONS OR WHEN BRAKING (REPLACE FRONT LOWER CONTROL ARM REAR BUSHING). *MJ UPDATED 10/5/07. *NJ UPDATED 5/20/11. *PE
NHTSA source summary · Original PDF not reviewed by Recallfolio
NORMAL OPERATING CHARACTERISTICS OF ELECTRIC POWER STEERING (EPS) SYSTEM DURING EXTENDED LOCK-TO-LOCK (MAXIMUM STEERING WHEEL ROTATION) USAGE. *TT UPDATED 3/30/11. *PE
NHTSA source summary · Original PDF not reviewed by Recallfolio
SATURN CHEVROLET SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. SOME 2004-07 SATURN ION RED LINE AND 2005-07 CHEVROLET COBALT SS VEHICLES, EQUIPPED WITH 2.0L 4 CYLINDER (RPO LSJ) ENGINE, MAY HAVE ILLUMINATION OF THE MALFUNCTION INDICATOR LAMP (MAL) AND/OR LACK OF ENGINE POWER. THIS MAY BE CAUSED BY FAILURE OF THE CATALYTIC CONVERTER. *PE
Source components: ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR.
NHTSA source summary · Original PDF not reviewed by Recallfolio
SATURN SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. NEW SPECIAL REIMBURSEMENT POLICY FOR VEHICLES EQUIPPED WITH VARIABLE TRANSMISSION WITH INTELLIGENCE (VTI) TRANSMISSION-50 PERCENT OF TRANSMISSION REPAIR COST WILL BE PAID BY GM OR CUSTOMER MAY ELECT THE OPTION OF $5,000 CUSTOMER CREDIT INSTEAD OF REPAIR. CSC LETTER WAS RECEIVED. *PE
Source components: POWER TRAIN:AUTOMATIC TRANSMISSION.
NHTSA source summary · Original PDF not reviewed by Recallfolio
CHEVROLET/PONTIAC/SATURN: BLOCKED SHIFT, GEAR HOP OUT 1ST, 3RD, 5TH GEAR OR DIFFICULTY SHIFTING. THE SHIFT LEVER ON THE MANUAL TRANSMISSIONS ROLL PIN CAN BACK OUT AND CONTACT THE SHIFT COVER DURING A SHIFT EVENT. THIS CAN CAUSE AN INCOMPLETE, BLOCKED SHIFT OR DIFFICULTY SHIFTING THE TRANSMISSION. *PE
Source components: POWER TRAIN:MANUAL TRANSMISSION.
NHTSA source summary · Original PDF not reviewed by Recallfolio
POWER STEERING INOPERATIVE/STEERING WHEEL HARD TO TURN, PWR STR DISPLAYED ON DRIVER INFORMATION CENTER (DIC). AFTER JUMP STARTING THE VEHICLE. *KB (REPLACE FUSE AND INSTRUCT OWNER HOW TO JUMP START VEHICLE). UPDATED 2/17/10. *PE