Spoon Sports 4/29/2011Your Passlock switch is failing in cold weather. This is a known issue with the ION. You will require a new Passlock switch. I suggest contacting Saturn customer service to see if this can be covered under warrant as it is a known issue.
Here is the TSB:
Subject: No Crank or No Start, DTC B2960 and/or B3033 Set (Replace Ignition Switch) #04-08-45-005D - (03/15/2006)
Models: 2003-2006 Saturn ION
Built Up To and Including VIN Breakpoint 6Z147837
This bulletin is being revised to modify the Correction Information. Please discard Corporate Bulletin Number 04-08-45-005C (Section 08 - Body and Accessories).
Some customers may comment that their vehicle will not start. This comment is referred to as "no crank, no start with complete power."
Additional customer comments may be as follows:
• A clicking noise may be noticed when the key is first turned to the START position, but no noise is heard after the initial start attempt.
• The "Security" light may flash immediately after trying to start the car along with the message "Service Vehicle" in the Driver Information Center.
• The vehicle may not start for at least 10 minutes after the first attempt to start the vehicle. Diagnostic trouble codes (DTCs) B2960 and or B3033 may be set in history in the BCM.
When the key is rotated from RUN to START there is a voltage signal sent to the BCM that goes through the PASSLOCK resistor in the ignition switch. This voltage signal may have an early ignition switch bounce (when going from RUN to START) that the BCM interprets as a failure in the PASSLOCK system and disables the starting circuit.
Nissan Technical Advisor 4/30/2011Air intake temperature sensor and engine coolant sensor are possibly defective, replace it. Check EGR valve if stuck open.