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I have an '04 Ion with the 2.2L Ecotec, and so far it's just needed suspension bushings (under extended warranty) and a backup light switch ($28). It's at 107,000 miles (6 years) and I just replaced the battery, and am preparing to replace the plugs and refresh the fluids for the very first time. Mileage is very good (36 mpg with my nightly hill climb is nothing to sneeze at for a pretty decent-sized car, and it gets 40-42 mpg straight freeway.)
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