NHTSA — Fuel/Propulsion System Problems

2004 Saturn Ion (Page 1 of 2)

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CarComplaints.com Notes: Ahh, the 2004 Saturn Ion: defective transmission, deadly ignition switch, temperamental power steering and a cheap plastic exterior that won’t protect you in a crash. What more could you want?

The 2004 Ion was part of GM’s massive ignition switch recall where it was revealed they waited 10 years – and let 13 people die – before doing anything about it. It also features GM’s now infamous VTi continuously variable transmission. Let me tell you, the only thing the VTi did continuously was fail on its owners. GM scrapped it after only two model years.

10.0

really awful
Crashes / Fires:
0 / 1
Injuries / Deaths:
0 / 0
Average Mileage:
90,155 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.

2004 Saturn Ion fuel system problems

fuel system problem

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2004 Saturn Ion Owner Comments (Page 1 of 2)

problem #36

Sep 082021

Ion

  • miles

A D V E R T I S E M E N T S

My car started getting a strong odor of gas. A fuel pipe leak is causing the odor

- Las Vegas, NV, USA

problem #35

Jul 182020

Ion

  • miles
Hi I am a kind of new owner of an 04 saturn ion, this is actually the second complaint I've filled out. Last July I had a mechanic friend look at my fuel filter and he had said the fuel line needed to be cut off becuase of how rusted on to the original fuel filter I'd got it with was and I didn't believe him so I replace it myself and when I got it off I had cleaned up the metal fuel line the best I could and put a new filter on. Well now it leaks gas right where the hook up is and very strong fuel smells come from there too, I've gotten numerous comments about how un safe that is to be driving it but I need to have a way to work and then someone had mentioned to check for recalls and I seen on there that this car did have a recall for faulty fuel filter gas lines. If you could get back to me as soon as possible about an inspection if needed or whatever else you'd need on my behalf. Please and thank you for your time

- Fergus Falls, MN, USA

problem #34

Jul 072020

Ion

  • 100,000 miles
Tried taking fuel filter off last July took a whole weekend of using penatrating oil and freeze off then I finally got the tabs to come loose, I thought maybe I messed up the new filter or didnt get enough rust off the fuel line and that's what was causing the strong smell of gas nd poor performance but changed it again and still that same problem but now theres a leak. The car was on back tire ramps the girl fuel filter change then the 2nd one was done with a hoist and currently this car is the only thing I can count on to make it to work, thank you for your time and consideration.

- Fergus Falls, MN, USA

problem #33

Dec 292020

Ion

  • 85,000 miles

A D V E R T I S E M E N T S

The fuel pump is leaking, GM refuses to fix it because the VIN isn't associated with the recall, but the same year make and model of my car says it has a recall for the fuel system and pump.

- Mesa, AZ, USA

problem #32

Nov 242020

Ion

  • 167,573 miles
Fuel leak on rear driver side when the engine is running while car is stationary. It may have happened before the date and mileage stated below but that's when I first noticed the fuel leak.

- Orlando, FL, USA

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problem #31

Jan 062020

Ion

  • miles
It looks like my car is leaking fuel. Don't know if it's the fuel injector line or fuel pump but I know there is a recall for this on my car but it's not showing up on my VIN number

- Methuen, MA, USA

problem #30

Jun 182018

Ion

  • miles

A D V E R T I S E M E N T S

2004 Saturn Ion 2.2/4 engine started smelling gas fuel line issues found... others having same issue there are recalls but only on certain VIN #S 107,000 miles how many cars before nation wide recall ??!!

- Everett, MA, USA

problem #29

Mar 272017

Ion

  • 0 miles
The car is under 80,000 miles and has a leaking fuel line.

- Youngstown, OH, USA

problem #28

Mar 012017

Ion

  • 200,000 miles
The contact owns a 2004 Saturn Ion. While driving 30 mph, the contact was stopped by the police due to the smell of fuel and sparks coming from the fuel tank. The vehicle was towed to a mechanic who diagnosed that the fuel line was rusted and needed to be repaired. A police report was filed. The failure mileage was 200,000. The manufacturer was aware of the failure.

- Upper Marlboro, MD, USA

problem #27

Feb 082017

Ion

  • miles
Sold me this car with warrantee never guaranteed the warrantee later on also discovered there was a whole patch in the gas tank and I have two small children and I was afraid of their safety and return the vehicle to the lot for selling me a in safe vehicle. There and I want to take fault for the vehicle problems and I want to cover the warranty that was promised to me on the contract.

- Turlock, CA, USA

problem #26

Feb 052017

Ion

  • 179,000 miles

A D V E R T I S E M E N T S

Strong gas smell & started noticing poor gas mileage and it got worse. Then notice it is leaking gas by the rear driver side tire. Also the running lights automatically come on during the day but not at night.

- Port Huron, MI, USA

problem #25

Nov 302016

Ion 4-cyl

  • miles
I have had 3 mechanics look at my 2004 Saturn Ion. I have been advised that my fuel lines need replaced due to leaking. However, my vehicle's VIN number is not associated with the recall on this product and it should be.

- Indianapolis, IN, USA

problem #24

Oct 252016

Ion

  • 62,683 miles
After the car was looked at by a Chevy dealer to have recalls preformed and the fuel leak looked at, they said, on paper, "C/S fuel leaking under vehicle." "fuel feed line leaking fuel, active leak, do not recommend to drive. Replace for $689.99 plus tax customer declined." I declined because that's a lot of money, which I will take their caution and not drive the vehicle till it can fixed. I am bringing the car to another mechanic to have their claims verified by a none GM company. I live in NY, they used to use salts on the road which may have attributed to the issue, the car is 12 years old at only 62K miles. Disappointing. Car was bought used. 1 month ago at 61K miles privately, I assume the seller sold the car due to the gas leak and didn't inform me.

- West Babylon, NY, USA

problem #23

Oct 152016

Ion

  • 62,000 miles
The contact owns a 2004 Saturn Ion. While the vehicle was parked, the contact noticed a strong fuel odor. In addition, fuel leaked from the rear of the vehicle. The vehicle was not diagnosed or repaired. The VIN was not included in NHTSA campaign number: 04V003000 (fuel system, gasoline). The manufacturer was notified of the failure. The failure mileage was 62,000.

- West Babylon, NY, USA

problem #22

Jun 242016

Ion

  • 105,000 miles
The contact owns a 2004 Saturn Ion. When the vehicle was taken to an independent mechanic for routine maintenance, the technician stated that there was a leak in the fuel line. The vehicle was not repaired. The VIN was not included in NHTSA campaign number: 04V281000 (fuel system, other). The manufacturer was notified of the failure. The approximate failure mileage was 105,000.

- East Haven, CT, USA

problem #21

May 182016

Ion

  • 101,000 miles
The contact owns a 2004 Saturn Ion. While driving 50 mph, the vehicle began leaking a tremendous amount of fuel under the driver side. The contact pulled the vehicle over and noticed that the leak stopped. The vehicle was towed to a dealer where it was diagnosed that the fuel pump and the fuel line were severely corroded. The manufacturer was made aware of the issue. The failure mileage was 101,000.

- Lexington, KY, USA

problem #20

Dec 022015

Ion

  • 114,000 miles
Any time the fuel pump is running, fuel is leaking from the top of the tank a running down on the drivers side just in front of the rear tire. Leaves about 12" puddle on the ground after running 10 to 30 seconds.

- Wood Dale, IL, USA

problem #19

Nov 162015

Ion

  • 46,714 miles
The contact owns a 2004 Saturn Ion. The contact stated that there was a fuel odor when the vehicle was started. The failure recurred and the contact reached underneath the driver's seat and felt fuel leaking from the fuel tank. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was 46,714.

- Lake Hopatcong, NJ, USA

problem #18

Nov 022015

Ion

  • 190,000 miles
The contact owns a 2004 Saturn Ion. The contact stated that when the ignition is turned to the on position, the vehicle had a fuel odor. The failure recurred several times. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure. The VIN was invalid. The approximate failure mileage was 190,000.

- Schaumburg, IL, USA

problem #17

Nov 062015

Ion

  • 132,000 miles
Was driving when I noticed a gas smell really strong it got worse when then I noticed that I was going threw gas like crazy and didn't know why. One day the smell was so strong when I got out the car I looked under that car and saw that one of lines was leaking gas I am worried because I do have kids in my car and that its a bad danger chance of fires to start

- Davidsonville, MD, USA

Read the next 16 complaints »

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