The Saturn Relay marked the first and only time automaker Saturn made an entry into the minivan market. Related to the other minivans of the General Motors (GM) family--the Buick Terraza, Chevrolet Uplander and Pontiac Montana SV6--it was essentially a rebadged Chevrolet/Pontiac vehicle. Perhaps because of that, consumer reaction was lukewarm, and the Relay lasted only two years: 2005 to 2007. It was replaced by the crossover SUV, the Outlook.
A common problem with Saturn Relays is with their electrical systems. A defective chip in the powertrain control module (PCM) could adversely affect the fuel pump and the exhaust gas recirculation (EGR) system, thus requiring replacement of the PCM.
Also, there could be minor problems with OnStar, a subscription-based electronic service only installed in GM vehicles. In some Relays, the entire system may refuse to power up, which can be solved by removing the fuse for about 5 minutes. In other cases, the global positioning system might lose precision, which could be due to the car's window tinting--or caused by objects placed on the rear parcel shelf if the antenna is placed there.
2005 and 2006 Relays are prone to engine stalling or failing to start. In some cases, the wiring connectors under the driver's seat would need to be replaced due to wetness and/or corrosion. In other cases, the vehicle might need a replacement of the fuel level sender.
In some 2005 Relays with 3.5-liter engines, a whistling noise may be produced during acceleration, thus requiring replacement of the PCV tube.
The "Check Engine" light may illuminate in some 2005 and 2006 Relays due to failure of the Delphi EGR valve installed. In such cases, the Delphi valves are replaced with Seimens ones.
Some 2005 and 2006 Relays may have difficulty with the proper function of their car horns due to extra pressure required on some spots of the steering wheel pads. Softer springs are available to retrofit on the wheel.
Some 2005 Relays may fail to conform the requirements of FMVSS (Federal Motor Vehicle Safety Standard) No. 135 for car brake systems. The standard requires that the vehicle not move for 5 minutes when it stops on a steep hill while being in neutral. At no cost, dealers can check for parking brake lever slippage at each rear brake caliper, performing caliper replacement if necessary.
