NHTSA — Fuel/Propulsion System Problems

2004 Saturn Ion (Page 2 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.


hardly worth mentioning
Crashes / Fires:
0 / 1
Injuries / Deaths:
0 / 0
Average Mileage:
100,560 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 2 of 2)

« Read the previous 20 complaints

problem #5

Mar 282014


  • 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

problem #4

Jul 282013


  • 90,000 miles
The contact owns a 2004 Saturn Ion. The contact stated that fuel was leaking into the engine. The vehicle was taken to an independent mechanic and the technician diagnosed that the fuel filter was corroded causing the leak. As a result, the fuel filter and fuel lines needed to be replaced. The manufacturer was made aware of the failure but did not offer any assistance since the vehicle had already been repaired under recall NHTSA campaign number: 04V281000 (fuel system, other). The vehicle was repaired. The VIN was not available. The failure mileage was 90,000 and the current mileage was 100,000.

- Stamford, CT, USA

problem #3

Apr 262013

Ion 4-cyl

  • 133,271 miles
The portion of the fuel lines near the fuel pump, which is hidden by a flexible cover underneath car, was discovered to be severely rusted nearly to the point of leaking, requiring fuel line replacement. In contrast, the portion of the fuel lines exposed underneath car was still in pristine condition. (car has been garaged at night since delivery.) service manager said that recently they have been finding many Saturn Ions with this condition. Although GM has issued a recall for fuel pump leaks, the problem often is instead the fuel line has rusted through and is leaking. This problem would not be expected, and thus appears to be due to a Saturn design or manufacturing defect. Because of the prevalence and significant safety issue, the service manager expects GM will eventually issue a recall for the fuel line problem. Because the portion of the fuel line subject to severe rusting is hidden behind the flexible cover underneath the car and not the exposed section, it is likely to be noticed only after leaking occurs, resulting in a fire hazard. A recall appears desirable to inspect particularly the hidden portion of the fuel lines near the fuel pump and replace them if needed. Although a manufacturer must provide a remedy to safety-related defect a no cost to the owner, in this instance GM refuses to pay for the fuel line replacement unless the NHTSA compels them to issue a recall.

- Wilmington, DE, USA

problem #2

Nov 042011

Ion 4-cyl

  • 110,000 miles
Our car, 2004, Saturn ion3, caught on fire in the driveway on it's own about 2 hours after it was driven home on 4 Nov 2011. No driver - no key in the vehicle when it caught fire. I submitted an initial request for review to GM claims along with all documentation that we had via emails and our claim was denied.

- Newport News, VA, USA

problem #1

Jul 112012

Ion 4-cyl

  • 94,376 miles
Started leaking gas from fuel filter and I checked on line for recalls and was one for that vehicle I called Saturn they said there wasn't.

- Buffalo, NY, USA

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