NHTSA — Fuel System, Gasoline 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:
1 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
71,129 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 #11

Jun 192009


  • 55,000 miles


Fuel pump has a crack where hoses connected to pump. Saturn has issued a recall for certain years but does not cover mine even though the info I found on your website supports that they should.

- Kingsland, TX, USA

problem #10

Nov 062009


  • 39,000 miles
Fuel leak on 2006 Saturn Ion.

- The Woodlands, TX, USA

problem #9

Nov 062009


  • 90,000 miles
The plastic supply or return port on the modular reservoir assembly may crack. If either of these ports develops a crack, fuel will leak from the area. If the crack becomes large enough, fuel may be observed dripping onto the ground and vehicle performance may be affected.

- Santa Barbara, CA, USA

problem #8

Nov 022009


  • 69,100 miles


The past month my car has gotten harder to start. Nov. 2 I started smelling gas. I had assumed I was smelling exhaust prior to this and planned on checking for a vacuum leak, so I was driving with my windows down. The gas smell got stronger and worse after a 186 mile drive home. I googled the problem and read of the same symptoms resulting from a cracked hose attached to the fuel pump. After work I looked under the hood at home and didn't see anything. Went to dinner and back in a separate car. After being gone 1.5 hours we could smell gas as soon as we got out of the car. Looking underneath there was a softball size puddle of fuel underneath the gas tank/fuel pump and fuel all over the backend of my car. I took it to the dealership that night. The next morning the mechanic calls and says I need a new fuel pump because the hose is cracked and it's all one assembly. With that amount of fuel leaking it seems very hazardous to me. I see a recall posted Oct. 28th but it does not include Texas for 2006. It does include Texas for 2007 though. I think I had fuel leaking for a few weeks before it was obvious. These need to be fixed before someone is hurt. Please extend the recall to Texas.

- Houston, TX, USA

problem #7

Sep 102009


  • 45,000 miles
I have been having starting problems with my car (2006 Saturn Ion) and smelling gasoline. It turns out the hose connected to the fuel pump was cracked and leaking gas. The mechanic said that this is a safety issue and should be recalled. He feels that the one hose is not connected and harnessed properly and the vibration to the hose eventually caused the crack. I googled "Saturn 2006 Ion fuel leak" and several other people have had the same issue. What is also the major problem here is that the hose is configured with the fuel pump itself. So, the entire mechanism had to be replaced. It cost me $700 for a cracked hose because the fuel pump had to be replaced and my car only is 46,000 miles. This is a major safety issue. I drove for 2 weeks with a car that was leaking fuel. Saturn must know about this and is waiting for the same situation to happen, but for the car to blow up instead.

- Orlando, FL, USA

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problem #6

Sep 092009


  • 50,000 miles
Emissions light would come on, smell of gasoline, car would suddenly reduce to half power while driving. Would have to pull over and get out, remove the gas cap, let the fumes out, and car would restore to normal power. This went on for a year and one half. Saturn Agency could not find the problem. Finally Saturn did some sort of bypass and problem ceased but car drove sluggishly. Few months passed without any problem.two weeks ago strong odor of gasoline. The fuel pump was leaking and was replaced. Car has significantly more power with new fuel pump however this week the emissions light came on again and has stayed on but no loss of power experienced as of yet. Slight odor of gasoline again.

- Concord, CA, USA

problem #5

Aug 032009


  • 65,000 miles


Fuel leak due to failed fuel pump seals. Fuel pump didn't fail, but the seal failed. Had to replace the complete fuel pump and assemble. Fuel was leaking from the fuel tank along with gas fumes around car. None dealer mech. Stated that the seal shouldn't fail. Also none dealer mech stated the car was a bomb on 4 wheels.

- Allen, TX, USA

problem #4

Jul 202009


  • 47,885 miles
Smell of gas at back of car on passenger side. Took vehicle to have oil changed and they found gasoline leaking. Saturn dealership pointed out one of the fuel lines had cracked. I bought the car 2 months before the problem was discovered. Had to replace the entire fuel pump assembly. This was a recall on the 2004 Ion. Did they really fix the problem from the 2004 or does the 2006 have the same problem. Phone interview (August 4, 2009): The complainant indicated that the fuel tank had not been removed previously as far as she knows. The repair invoice indicates that the fuel pump was leaking and was replaced.

- Peoria, AZ, USA

problem #3

Oct 152008


  • 30,000 miles
Smell of gasoline detected. Ignored by dealer. Only recognized when I pointed it out to them. Needed new fuel pump. Only 30,000 miles on car. Daughter has exact same make and model and had the same problem at same mileage. Saturn replaced both fuel pumps. Seems dangerous when gasoline is leaking.

- Scottsdale, AZ, USA

problem #2

Aug 212008


  • 51,000 miles
The contact owns a 2006 Saturn Ion. The vehicle has a very strong gasoline smell inside the passenger compartment and outside as well. There is also a fuel leakage in the vehicle. The contact is a mechanic and stated that the leak originated from the fuel tank. He is concerned that the leak could cause a potential fire hazard. Ever since the leak occurred, the vehicle now has to be cranked for a while before the engine starts. The vehicle has not been taken to any dealer; however, the manufacturer was notified. The current and failure mileages were 51,000. Phone interview (August 4, 09): Mr. Hornback repaired the fule pump himself. He said that one of the nipples on the fuel module had cracked. Mr. Hornback inserted a brass pipe into the broken nipple and epoxy it in place. He agreed to email me pictures of the fuel pump module. He believes that the cracked nipple was for the fuel 'return' side.

- Tucson, AZ, USA

problem #1

Aug 072008


  • 61,000 miles
Took my 06 Saturn into the dealer due to stalling. Was told by the mech. That the fuel pump was leaking that the plastic elbow had a crack in it due to the road vibration my concern is that tis is a line that is under appos 20psi located above the exhaust pipe and directly under the back seat. If gas is being sprayed out over the exhaust a spark is all that is missing to have a rolling flame thrower. In my simple mind this part should not be prone to cracking because of normal driving. I still remember the pinto I hope some one will take action before something happens think you for your time in this matter.

- Katy, TX, USA

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