NHTSA Complaint #10255469 — 2003 SATURN ION

DURING EVERY COLD SEASON SINCE THE PURCHASE OF 2003 SATURN ION, THERE IS A PROBLEM WITH STARTING THE VEHICLE IN COLD WEATHER (USUALLY WHEN BELOW 25 DEG F). THIS SEEMS TO BE AN INTERMITTENT PROBLEM. HOW THE PROBLEM MANIFESTS IS AS FOLLOWS: IN COLD WEATHER, WHEN TRYING TO START THE VEHICLE, ENGINE FREQUENTLY (AT LEAST 25% OF THE TIME) WILL NOT "CATCH" AND RUN- JUST TURNS OVER. IF IMMEDIATELY TRYING TO START IT AGAIN AFTER A FIRST FAILED START, ENGINE TURNS OVER SLOWLY AND DIES (SIMILAR TO DEAD BATTERY SYMPTOM, HOWEVER BATTERY HAS BEEN CHECKED AND FOUND TO BE OK). AFTER LETTING THE CAR SIT FOR 5 MINUTES AFTER A FAILED ATTEMPT, TRYING AGAIN MAY RESULT IN A MOMENT OF WHAT APPEARS TO BE FUEL GETTING TO THE ENGINE, AND MORE ENGINE TURNING, HOWEVER ENGINE STALLS. AFTER REPEATED WAITING AND START RE-ATTEMPTS (OFTEN 5- 10 TIMES, AND AN ELAPSED PERIOD OF TIME OF 30- 60 MINUTES OF RE-ATTEMPTS, THE ENGINE WILL FREQUENTLY START AND REMAIN STARTED. HOWEVER THE INCONVENIENCE OF A 30-60 MINUTE DELAY IS DISCONCERTING, AND ON SOME COLD MORNINGS, REPEATED FAILED ATTEMPTS CAUSES BATTERY TO DRAIN AND NEED FOR "JUMP STARTING" THE CAR, AT OWNER EXPENSE AND INCONVENIENCE. AN INTERNET SEARCH ON 2003 SATURN ION COLD STARTING PROBLEM INDICATES A PERVASIVE AND SYSTEMATIC PROBLEM IN IGNITION SWITCH DESIGN, HOWEVER SATURN HAS NOT YET ACKNOWLEDGED THIS DESIGN FLAW IN A FORMAL RECALL. TODAY, REPAIRS HAVE TO BE MADE AT OWNER EXPENSE ($200-300 REPLACEMENT IGNITION SWITCH SEEMS TO BE THE FEEDBACK). SEE WEBSITE HTTP://WWW.CARSURVEY.ORG/VIEWCOMMENTS_REVIEW_97727.HTML MY REQUEST OF THE NHTSA IS THAT YOU URGE SATURN TO ISSUE A FORMAL RECALL FOR THIS PROBLEM IMMEDIATELY. PLEASE RESPOND WITH YOUR INPUTS AND INTENDED APPROACH ON THIS SITUATION. ALSO, IF YOU ARE AWARE OF OTHER AGENCIES THAT I SHOULD CONTACT ABOUT THIS PROBLEM, I WOULD GREATLY APPRECIATE. *TR