NHTSA — Engine And Engine Cooling: Exhaust System Problems

CarComplaints.com Seal Of Avoid Like The Plague

CarComplaints.com Notes: When it comes to the 2006 Ion, the biggest questions are: what big problem is going to pop up next? And how long until GM chooses to address it?

The 2006 Ion has a defective ignition switch that gave owners fits. Their keys would get stuck in the ignition, the engine wouldn’t shut off or in some cases it would shut off at the most dangerous time. The ignition was eventually recalled as part of one of the largest recalls of all-time , but it took GM 10 years to do it. Then there’s this car’s temperamental power steering which is prone to stop working randomly while driving. It too was eventually recalled, even if GM took their sweet time about it.

Lastly, it turns out a car built with plastic doors, fenders and bumpers – while fun for a game of “shopping cart bocce” – is horrible for safety.


hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
74,000 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2006 Saturn Ion exhaust system problems

exhaust system problem

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2006 Saturn Ion Owner Comments

problem #1

Feb 282010

Ion 4-cyl

  • 74,000 miles


I own a 2006 Saturn Ion. My car is at 80,000 but since this started a few months ago I would say 74,000 miles was the occurrence. The car was running rougher and rougher. I knew the sound to be an exhaust leak. I had my mechanic look and he just checked the hoses, and saw nothing. I kept driving with it. I started getting bad headaches, and slightly nauseous when I drove long distances. I travel 400 miles roundtrip when I visit family out of town at least once a month. I also noticed the odor of exhaust in the cabin when I started my car. I cracked my windows when I drove and when I had a chance my mechanic found I had a cracked exhaust manifold. He said he has seen the same crack in the same place on the same GM engine 2.2L 4cyl about 6 times this year already. Chevy has it on cobalt I think. He said it is probably a factory defect since it is wearing thin in the same place. Considering my car was poisoning me for months I think this qualifies as a safety concern and should be investigated. I knew the sound and warning signs because of past experience. It is a danger to the majority of drivers, because they don't.

- Houston, TX, USA

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