NHTSA — Fuel/Propulsion System Problems

2006 Saturn Ion (Page 1 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 1 of 5)

problem #90

Dec 232016


  • 170,000 miles


Gas leaking from tank area when driving and sitting. There is a recall for fuel pump for 2006 Ion but don't say this one.

- Tracy, CA, USA

problem #89

Oct 292016


  • 188,000 miles
The contact owns a 2006 Saturn Ion. The contact stated that there had been the presence of a fuel leak associated with the fuel pump. The vehicle was taken to an independent mechanic but the technician was unable to determine where the vehicle was leaking. The vehcile was not repaired. The VIN was not included in NHTSA campaign number: 09V419000 (fuel system, gasoline). The manufacturer was notified of the failure. The approximate failure mileage was 188,000.

- Coopersville, MI, USA

problem #88

Oct 082016


  • 85,900 miles
The contact owns a 2006 Saturn Ion. Upon attempting to enter the vehicle, there was an abnormally strong fuel odor coming from the vehicle. The vehicle was taken to an independent mechanic where it was confirmed that there was a fuel leak, the fuel lines were corroded, and the fuel pump or fuel tank may need to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 85,900.

- Westfield, MA, USA

problem #87

Sep 202016


  • 147,900 miles


Fuel leaking from the top of the fuel tank

- Traverse City, MI, USA

problem #86

Jan 262016

Ion 4-cyl

  • 116,000 miles
Back in Jan. 2016 I started smelling gas when my car was warming up, I'm in mn so it's cold then. After fa couple days of this I looked under my car, omg, I had kinda a slow drip, which turned into a fast drip within a few days. I did research and found out that there was a recall on some Saturn that were sold in different states, I called GM, they told me I needed to go to a GM dealer to see if it was the part that was under recall, if it was, they would pay to replace the part under recall and my gas lines, yeah right!! the dealership charged me $50 and told me it wasn't the recall part. So I had to pay to get new gas lines. After it was fixed I could still smell gas..I should've taken it back right away but I didn't. now, here I sit again, not being able to drive my car because of this again! this whole deal is a bunch of bullshit, does someone have to get seriously injured or die in an explosion before the whole fuel system, tank, lines ect.. get a recall on it? I don't have the money to fix it or another $50 for them to tell me it's not the recall part!

- Monticello, MN, USA

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problem #85

Aug 202016


  • 80,000 miles
Saturn Ion recall on fuel pump module; I am writing due to the recall that replaces the fuel pump module, but does not replace the fuel lines. I do not understand why the recall does not cover to replace both fuel lines and module, considering they are both affected and are a high risk factor. After replacing my module, my car leaked more fuel because my fuel lines were in such bad shape, and at the time I could not afford to replace my fuel lines. I could then only drive my car to my house from the dealership and leave it since it is far to dangerous to drive until I can save up enough money to replace the fuel lines.

- Ashley, OH, USA

problem #84

Jul 182016


  • 84,000 miles


A week ago, my car wouldn┐T start on the first try, but did start on the second. As I drove around town that day running errands (multiple stops/starts), I began to smell gas as I walked around the back of the car. The next time I drove the car was 3 days ago; every time I tried to start the car it took 2 tries, and the gas smell near the back of the car was worse. I also began to smell a strong gas smell as I loaded bags into the trunk. Yesterday, I experienced all of those issues, plus I had to drive with the windows open because the gas smell was now very bad inside the car. When I parked at the supermarket, I was able to see a small amount of gas on the rain-wet pavement, coming from just ahead of the rear driver side tire. The progression of the leak was fast - over 7 days, and only about 70 miles driven (I drive <5,000 mi / yr). I went online to research the problem, and found GM recall #090226 / NHTSA campaign id# 09V419000, which perfectly describes what's happening. I┐M planning to call GM tomorrow about this, but I expect to be disappointed, since my car was not purchased or registered in any of the states listed in the recall. It shouldn't matter where I bought or registered my Saturn; if my car demonstrates the same defect, the repair should be covered by GM. I also found a scary number of complaints on various websites from other Saturn owners who are experiencing the same problems, but are also not included in the recall. How many is ┐enough┐ for GM to expand the recall? GM's failure to address* of the cars affected by this problem is appalling and dangerous.

- Davenport, NY, USA

problem #83

Dec 212015


  • 195,000 miles
The contact owns a 2006 Saturn Ion. While driving 35 mph, a strong odor of fuel was present in the vehicle. The vehicle was taken to an independent mechanic where it was diagnosed that the fuel pump assembly failed and needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure. The failure mileage was approximately 195,000.

- Adamsville, TN, USA

problem #82

Apr 272016


  • 0 miles
I recently bought this vehicle and started smelling gasoline fumes while driving the car and after the car has been parked. Looked online and seen there was a recall for the fuel pump module but only in certain states. This car came from Florida but was purchased in Kentucky. Im really getting scared to drive my own car out of fear it may ignite and cause a fire or maybe even blow up. Please I need help with some kind of recall on this vehicle to get this problem fixed! seems to be a problem considering there was a recall on these vehicles. Thank you

- Harlan, KY, USA

problem #81

May 152016


  • miles
Re the 2013 fuel system recall. Parts cracked and fuel leaked. GM recalled and promised to replace system. My vehicle began leading in may of 2016. I brought it to the dealer where it has sat for one month. Dealer unable to get fuel filler assembly part 15918244 from GM and GM making no promises about fixing it or getting the part. They have said the problem may or may not ever be resolved. They claim the supplier may be able to supply by mid-August. Then they updated it to maybe in September. In the meantime, I have to rent a car with no end in sight. Can;T get definitive answer from GM regarding if or when part will be delivered.

- Cummaquid, MA, USA

problem #80

Jun 012016


  • 0 miles


I started smelling gasoline and seen that the fuel pump was part of a recall. I've only had this car a few months and it came from Florida which was one of the states in the recall.

- Harlan, KY, USA

problem #79

Mar 022016


  • miles
My car started having a terrible gas smell in andout of the car, when I drive to work and then leave for the day you can still smell it. When I get up in the am to go to work I can still smell it, I took it to be checked out to a mechanic and he put it through all checks and found something wrong and went on line and saw that there is a recall for this problem..I never received a recall notice. So I called the dealer where I bring my recalls and he said he doesnt have to fix it because my VIN # is not part of the recall, even though I have a 2006 Saturn Ion and they are being recalled. I am a little worried driving it, but I have no choice at the time, please advise, ,ty elaine hernandez 516 439-8272

- Bellmore, NY, USA

problem #78

May 162016


  • 116,000 miles
My car is leaking fuel from the plastic supply that connects the tank and the line. This issue was recalled in certain Ions of the same year, but not for my VIN despite the issue being exactly the same as the recalled part. I noticed a puddle of gasoline under my car and observed a substantial leak from the supply while my car was idling and after shutting the engine off. Unsure if it is also leaking when the engine is off and cold.

- Grand Rapids, MI, USA

problem #77

Apr 162016


  • miles
There is a very strong smell of fuel - sometimes when driving, but most often after turning the vehicle off - inside and outside of the passenger compartment and inside the trunk. I believe it may also be leaking a small amount of gasoline. The smell is very strong and definitely noticeable, and I am concerned that if there is in fact a leak in the fuel system somewhere, that a fire may start from a stray spark, etc. There is a recall for 2006 Saturn Ions sold and registered in Arizona and Nevada due to for possible cracks in the plastic supply or return port on the modular reservoir assembly (NHTSA campaign 09V419000). My car was bought and registered in Illinois, so it does not apply. Why would cars in all 50 states not be covered - if it has to do with heat, I would think that you would be more concerned for vehicles in states that have variable temperatures, since that could cause plastic to crack, too. I am the original owner of the vehicle - which has low mileage for its age - and I have tried to maintain my vehicle so I can continue to drive it for as long as possible. This is not caused by me, but a known manufacturing defect and should be fixed by the manufacturer at no cost.

- Chicago, IL, USA

problem #76

Apr 112006


  • 70,000 miles
The gas tank line leaking gas

- Lubbock, TX, USA

problem #75

Apr 082016


  • 120,100 miles
I am starting to smell fuel and the fuel system has developed a slow leak.

- Columbus, OH, USA

problem #74

Mar 252016


  • miles
Takata recall, ,,I have been smelling fuel from my car about 2 weeks, ,I took it to an automotive for diagnostic and they told me and gave me a print out of a recall that was sent July 2015, ,this I never received, so I called a GM place where I prev had my recall done and said that my VIN number is not recalled for this problem! they said that all 2006 Saturn Ions are not the same, since my VIN # is not part of this recall they wont fix M Y car, ,,I dont understand, I am smelling fumes not only when I drive, but hours later it still smells. They said I could bring it in for 300.oo diag. And then pay to have it fixed!! can you explain this to me please!?

- Bellmore, NY, USA

problem #73

Mar 052016


  • 160,000 miles
A few weeks ago I noticed a smell of fuel coming from my car when I stop, or slow down. The last couple days the smell has bin getting stronger.. I see all these complaints, but nothing being done or it only for a few states. As a single mother of two I don't feel safe having my kids in the car.

- Williamstown, PA, USA

problem #72

Feb 202014


  • 0 miles
My car smell light gas and cuts off intermittent. It lot recall on this card. I think my gas fule leak on def parts on it. My emails laquinta85@hotmail.com

- Memphis, TN, USA

problem #71

Nov 022015


  • 120,000 miles
The contact owns a 2006 Saturn Ion. While driving at various speeds and when the vehicle was parked, the contact noticed a fuel odor emitting from the vehicle. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was 120,000.

- Radcliff, KY, USA

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