Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety.

NHTSA — Fuel/Propulsion System Problems

2004 Saturn Ion (Page 1 of 2)

CarComplaints.com Seal Of This Might Hurt

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.

1.6

hardly worth mentioning
Crashes / Fires:
0 / 1
Injuries / Deaths:
0 / 0
Average Mileage:
104,750 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

Find something helpful? Spread the word.
Get notified about new defects, investigations, recalls & lawsuits for the 2004 Saturn Ion:

Unsubscribe any time. We don't sell/share your email.

2004 Saturn Ion Owner Comments (Page 1 of 2)

problem #24

Oct 252016

Ion

  • 62,683 miles

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

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

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

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

Search CarComplaints.com for these popular complaint phrases...

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

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

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

problem #16

Sep 102015

Ion

  • 129,475 miles
Fuel line rusted out near fuel filter and directly above exhaust pipe. Large puddle of fuel on ground after car was shut off. When restarted, fuel continued to flow out of rusted fuel line and onto the exhaust pipe.

- Hicksville, NY, USA

problem #15

Feb 052011

Ion

  • 20,000 miles
The contact owns a 2004 Saturn Ion. While driving at various speeds, the steering wheel seized without warning. The contact stated that there was also a smell of fuel coming from the vehicle. The contact stated that the steering shaft and fuel lines failed and needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 20,000.

- Clinton Township, MI, USA

problem #14

Jul 212015

Ion

  • 112,430 miles

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

On the 20th of July I noticed a very strong smell of gasoline in my garage. I checked the gas can for my lawn equipment and it was not the source on the odor. I backed out of the garage and noticed a somewhat substantial puddle of gas right in front of where my rear tire was. As the car was still running I looked under the car at the suspect location and noticed steady drips coming from under a plastic clip which held the fuel lines. Further investigation showed that the fuel lines had rusted through right at that clip. After reading up on this problem it seems that this is a extremely common problem which affects both Ion and cobalt vehicles since I believe they are "delta" bodies. Due to the nature and the amount of occurrences this problem should be addressed by GM. It is my only vehicle and I do not have the 400-500 dollars to repair this. A recall should be issued since the leak is scant inches from the exhaust pipe and therefore is a safety issue and a severe fire hazard. GM should cover the cost of the repair. I am the original owner of the car.

- Beloit , WI, USA

problem #13

Jun 042015

Ion

  • 81,388 miles
After having my emissions tested in wi in which it passed at the time on or about May 27, 2015. About a week latet, I began to smell a gasoline smell coming from the diiver's side of the car, after I drove it and then parked it and turned off the ignition. I didn't see anything dripping from the car to the grounc, I noticed that the smell of gasoline became more and more prevalent until about June 17, 2015 when the smell was so great and I hadnt driven the car for well over a week because I was afraid something was leaking or would happen while driving. My brother smelled it also when I backed up and pulled forward. We checked under hood, but nothing and no spots on the ground. Took it to a garage and the mechanic and owner said that the fuel lines, fuel filter, etc. Needed replacing and R which cost approximately $263.. I also looked up information by a mechanic who states that every signgle cobalt and Ion have this same problem since the cars were built. He gave a description of what it takes to remove and replace fuel lines, fuel filter, etc. Whenever I took out the car, that car could have exploded or started an engine fire. This is a dangerous situation that could have involved the loss of not only the vehicles, but peoples lives. I firmly believe that GM should have to have these vehicles on recall for this very dangerous malfunction of the fuel tank, fuel filter and fuel lines and be required to pay for these repairs on the cars affected. Thank you for your consideration in this situation.

- St. Francis, WI, USA

problem #12

Apr 292015

Ion

  • 137,000 miles
The contact owns a 2004 Saturn Ion. The contact stated that the fuel filter and fuel lines prematurely rusted without warning. The vehicle was taken to the authorized dealer who diagnosed that the two fuel lines needed to be replaced as well as the fuel filter. The contact was not included in NHTSA campaign number: 04V003000 (fuel system, gasoline). The manufacturer was notified of the failure. The approximate failure mileage was 137,000.

- Newfield, NJ, USA

problem #11

Feb 152015

Ion 4-cyl

  • 67,000 miles
Gas leaking near the door behind the driver. Strong smell of inside car as well still waiting to hear from dealer. This model may not be part of the recall from GM it does seen to be a common issue this is a real fire danger..

- Fairfield, OH, USA

problem #10

Aug 152014

Ion 4-cyl

  • 180,000 miles
While under the rear of the car to fix the exhaust system, it became apparent that the fuel lines in the location under the trunk and behind a flexible shield are extremely and severely rusted and corroded. They are corroded to the point where they could potentially leak at any moment. The fuel lines are pressurized during and after operation of the vehicle and also run very close to a hot exhaust pipe. Not only is this a reliability issue, but more so, it is an incredible safety hazard and needs to be addressed. After doing some internet searching I found numerous complaints of other Ion owners with the exact same condition - many who have had leaks and either required towing, or experienced a fuel spill. Dealer wants $800 to fix. This is not a normal wear item.

- Rockaway, NJ, USA

problem #9

Dec 032012

Ion

  • 57,000 miles
The contact owns a 2004 Saturn Ion. The contact stated that there was a strong odor of fumes coming from the vehicle. The vehicle was taken to a dealer, who diagnosed that the fuel pump needed to be replaced due to an internal failure with the fuel pump module. The VIN was not included in NHTSA campaign numbers: 04V003000 (fuel system, gasoline), 12V459000 (fuel system, gasoline) and 09V419000 (fuel system, gasoline). The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 57,000.

- Middletown, NJ, USA

problem #8

Oct 232014

Ion 4-cyl

  • 200,000 miles
Gas started to pour out of my car creating a hazard. Took it to auto-lab and was told there was a rusted fuel line which is common with Saturn Ion.

- Mount Pleasant , MI, USA

problem #7

Aug 112014

Ion

  • 64,654 miles
The contact owns a 2004 Saturn Ion. The contact smelled a strong fuel odor near the vehicle. The dealer stated that the seals around the fuel pump and the fuel pump itself needed to be replaced. The vehicle was not repaired. The manufacturer stated that the VIN was not included in NHTSA campaign numbers: 04V003000 (fuel system, gasoline), 04V281000 (fuel system), and 09V419000 (fuel system, gasoline). The VIN was unavailable. The approximate failure mileage was 64,654.

- Joppa, MD, USA

problem #6

Aug 252014

Ion

  • 52,000 miles
The contact owns a 2004 Saturn Ion. The contact stated that fuel fumes were emitted in and around the vehicle. The contact mentioned that after refueling to capacity, the fuel gauge read that there was only half tank of fuel left. Also, the contact noticed a puddle of fuel on the ground near the rear of the vehicle. The vehicle was not taken to a dealer or independent mechanic for a diagnosis. The manufacturer was not notified of the failure. However, the contact was made aware that the VIN was not included in NHTSA campaign number: 04V003000 (fuel system, gasoline). The approximate failure mileage was 52,000.

- Springfield , MA, USA

problem #5

Mar 282014

Ion

  • 172,000 miles
The contact owns a 2004 Ion Saturn. The contact stated that she noticed gasoline fuel had spilled on the ground while the vehicle was parked. The contact's personal mechanic inspected the vehicle and found that one of the fuel lines was corroded and leaking. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure and current mileage was 172,000.

- Hinckley , MN, USA

Read the next 4 complaints »

Search CarComplaints.com for these popular complaint phrases...

Not what you are looking for?