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.


definitely annoying
Typical Repair Cost:
No data
Average Mileage:
138,648 miles
Total Complaints:
2 complaints

Most Common Solutions:

  1. replace fuel line (2 reports)
2004 Saturn Ion fuel system problems

fuel system problem

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2004 Saturn Ion Owner Comments

problem #2

Dec 072016

Ion Turbo 2

  • Manual transmission
  • 150,000 miles


RE: Saturn - Ion 2004 Model - Fuel Tank Filler Neck Assembly Leaking. Sensor Code P0442

I am looking for some help in fixing my Saturn Ion Car's Fuel Tank Filler Neck Assembly Leaking. Sensor Code P0442.. Kindly let me know if you know some Mechanic who can get this work done.

Kind regards,

Mark Fanning

Ph. 602-465-6385

- , Phoenix, AZ, US

problem #1

Apr 082016

Ion 2.2L L4 Dhoc

  • Automatic transmission
  • 127,296 miles

click to see larger images

fuel leak

Getting ready to move across the country and was having some work done on my car and having the suspension system and fuel filter replaced. The part of the line that feeds into the filter was covered with a heat shield that apparently held moisture. Two feet of the fuel line was totally corroded and broke off. It couldn't have been more than a millimeter thick in cross section. My mechanic was able to MacGuyver a replacement while I look for the actual replacement part, but I am supposed to leave town in 3 days and my car reeks of gas fumes whenever I turn it on. This just seems like a crummy design, and a load of crap given two earlier recalls related to the fuel system.

- , Poplar Bluff, MO, US

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