NHTSA — Fuel/Propulsion System Problems

2006 Saturn Ion (Page 5 of 5)

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CarComplaints.com Notes: When it comes to the 2006 Ion, the biggest questions are: what big problem is going to pop up next? And how long until GM chooses to address it?

The 2006 Ion has a defective ignition switch that gave owners fits. Their keys would get stuck in the ignition, the engine wouldn’t shut off or in some cases it would shut off at the most dangerous time. The ignition was eventually recalled as part of one of the largest recalls of all-time , but it took GM 10 years to do it. Then there’s this car’s temperamental power steering which is prone to stop working randomly while driving. It too was eventually recalled, even if GM took their sweet time about it.

Lastly, it turns out a car built with plastic doors, fenders and bumpers – while fun for a game of “shopping cart bocce” – is horrible for safety.


really awful
Crashes / Fires:
0 / 1
Injuries / Deaths:
1 / 0
Average Mileage:
90,014 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.

2006 Saturn Ion fuel system problems

fuel system problem

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2006 Saturn Ion Owner Comments (Page 5 of 5)

« Read the previous 20 complaints

problem #10

Aug 062012

Ion 4-cyl

  • 76,283 miles


A friend advised me they could smell gas by my car. I searched and learned there was a recall. I've seen online there have been difficulties getting this fixed with certain VIN numbers and/or states therefore I wanted to be sure to report the issued in an effort to expand the recall. I do not know how long the issue has been present but it was observed on August 06, 2012. During normal business hours I will seek assistance.

- Warr Acres, OK, USA

problem #9

Aug 032012

Ion 4-cyl

  • 75,000 miles
I started smelling gas when was stopped. I figured there may be a leak. I took it to a shop and they said I have one. I researched online and found that there was a recall on parts of the fuel system but that it doesn't apply in my state. So now im going to have to pay the $600 or so to get it fixed.

- Nanticoke, PA, USA

problem #8

Jul 212012


  • 131,000 miles
The contact owns a 2006 Saturn Ion. The contact stated that the vehicle refused to start. The contact was able to start the vehicle after several attempts. The vehicle was taken to dealer for diagnosis where the dealer informed her that they needed to replace the fuel pump. The vehicle was not repaired. The manufacturer was contacted and stated that the vehicle was not under recall. The failure and the current mileage was 131,000.

- San Antonio , TX, USA

problem #7

Nov 152011


  • 80,000 miles


Every time fuel is slightly below a quarter tank the engine stalls as if the car is running out of gas and the cars drastically reduces speed with minimum power. Also, after the incident occurred I went online to research the problem and found out that the vehicle had been recalled for fuel pump problems as well as lighting irregularities. Furthermore, as I continued using my vehicle the ignition switch cylinder broke causing the key to be stuck and was unable to turn off the ignition of the car. Luckily, I have a stick shift transmission and was able to turn off the car by putting it into 4th gear and letting go of the clutch to turn off the ignition. Unfortunately, the car battery remains on and in order to completely turn off the car I have to disconnect the battery cable so the batter life is not drained.

- Watsonville, CA, USA

problem #6

Jul 062012


  • 158,000 miles
The contact owns a 2006 Saturn Ion. The contact stated that while driving approximately 30 mph, there was a strong odor of fuel inside of the vehicle. In addition, fuel was leaking from the fuel tank. The vehicle was taken to an authorized dealer for diagnosis. The technician stated that the fuel tank module would need to be replaced. There was a recall associated with NHTSA campaign id number 09V419000 (fuel system, gasoline: Delivery: Fuel pump) and the VIN was included. The manufacturer was notified and stated that the vehicle exceeded 120,000 miles and they would not honor the recall. There was no mileage mentioned in the recall defect. The vehicle had not been repaired. The approximate failure mileage was 158,000.

- Edinburg, TX, USA

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problem #5

Jul 052012


  • miles
Fuel pump module assy.

- Coral Springs, FL, USA

problem #4

Jul 052012


  • 142,000 miles


Fuel leaks from under car.

- Coral Springs, FL, USA

problem #3

Jun 242012

Ion 4-cyl

  • 130,000 miles
After parking the car on a short drive to the store, I smelled gasoline around the car. When I checked underneath the car, fuel was visibly pouring from the fuel tank area and was pooling under the car. Upon inspection of the fuel system, the return port of the fuel pump was discovered to be cracked and broken-off, enabling fuel returning to the pump to pour out of the system.

- North Augusta, SC, USA

problem #2

Jun 172012

Ion 4-cyl

  • 61,000 miles
The plastic supply on the modular reservoir assembly cracked. Fuel leaked from the port. Fuel may be observed dripping onto the ground and vehicle started after several seconds of cranking.

- Pittsburgh, PA, USA

problem #1

May 042012


  • 90,000 miles
Strong smell of gasoline in car. Gas leaking under the car. It has a crack in the fitting on the fuel pump. The same problem GM has had a partial recall on. Informed by Saturn that our car isn't covered by the recall. How can this be when its the exact same part and problem. We are not happy with GM or Saturn and will never by other GM again if this is how they do business. This is a huge safety issue.

- Bella Vista , AR, USA

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