NHTSA — Fuel/Propulsion System Problems

2007 Saturn Ion (Page 3 of 5)

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CarComplaints.com Notes: With the 2007 model year we finally get to bid adieu to a car famous for poor safety marks, a dangerously defective ignition and power steering that would work … sometimes.


hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
79,196 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.

2007 Saturn Ion fuel system problems

fuel system problem

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2007 Saturn Ion Owner Comments (Page 3 of 5)

« Read the previous 20 complaints

problem #57

Jun 012014

Ion 4-cyl

  • 153,000 miles


Fuel lines have rotted and breached causing fuel to leak. This leak location is on the rear drivers side of the vehicle, approximately 3 inches from the exhaust system, a critical safety issue. This fuel line failure has been documented by the bradshaw automotive service dept. (864-879-3536), a GM factory dealership. Bradshaw automotive has confirmed that there is nothing which I or any other owner or operator of this vehicle either did or failed to do which would cause or contribute to this catastrophic fuel line failure. It is also confirmed that this fuel line damage was not caused by an accident or any other type trauma to the vehicle or the fuel system. This vehicle has no history of accident damage verified as per carfax I am the owner of this vehicle and our son has been the most recent operator of this vehicle for appox the last 6 months. I purchased this vehicle in 2013. I have requested full assistance from GM to remedy this apparent design flaw and / or manufacturing defect. The cost quoted to me for repair by bradshaw (GM authorized) is appox $600. I contacted GM (866-790-5600). The case number assigned by GM is # [xxx]. I have spoken to tier 2 district specialists jenny (ext 11619) and sarah (ext 21577). GM has decided as of June 13, 2014 to refuse assistance stating the basic warranty is expired and refuses to put their position in writing. The unsafe vehicle is presently sitting in the bradshaw automotive facility lot in greer SC near our home. Please help ! information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6)

- Greer, SC, USA

problem #56

Jan 012014


  • 130,000 miles
My 2007 Saturn Ion is leaking gas. I called the GM (800) number and was told my fuel system had a recall. When I left my vehicle with the GM dealership they called after a few hours stating they replaced the fuel system and I was good to go. A few days later my car smelled like gas again, so I took it back. The manager called me stating, "my fuel tank was cracked". I picked up my vehicle and left. If my fuel tank was cracked they would have related that information the first time. I honestly believe this is a GM issue, because I googled this problem and a lot of consumers with my model car have the same issue.

- Goose Creek, SC, USA

problem #55

Oct 102013


  • 58,000 miles
Top of fuel pump cracked and leaked gas fumes in car. Gas leaked out of car as it was driven. Faulty fuel pump problem that was recalled in a few other states. Family member has smelling problem due to past surgery and could not realize gasoline leaking from the car. Mechanic stated that fuel pump should never have cracked in this area and could have resulted in a much worse scenario.

- Hellertown, PA, USA

problem #54

Apr 082009


  • 15,000 miles


The contact owns a 2007 Saturn Ion. The contact stated that while the vehicle was stationary, a strong odor of fuel emitted inside and outside of the vehicle. The failure also occurred when the vehicle was in motion. The contact was not able to detect a fuel leak. The fuel pump module was replaced under a service warranty in 2009 however, the failure recently recurred. There was a voluntary recall issued by the manufacturer related to the fuel module. The manufacturer was notified and refused to repair the vehicle because they informed the contact that the vehicle had been previously repaired under the manufacturer's recall. The approximate failure mileage was 15,000.

- Haines City , FL, USA

problem #53

Sep 212013


  • 47,000 miles
The contact owns a 2007 Saturn Ion. The contact stated that there was an abnormal gasoline odor coming from the vehicle without warning. The vehicle was not taken to a dealer for diagnostic testing. The contact was awaiting the results of the diagnosis. The manufacturer was not made aware of the failure. The vehicle was not repaired. The approximate failure and current mileage was 47,000.

- Ruther Glen , VA, USA

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problem #52

Sep 042013


  • miles
I've been smelling gas in my car. I thought that I had spilt gas on myself but now I see there's a leak and I'm getting horrible mileage. It appears there's a recall in certain "warm weather" states for this exact problem. I live in nc. How is that not a warm weather state? so I have to pay out of a pocket for a problem that GM knows exist but somehow they managed to eek out of taking responsibility except in a few select areas. I don't know what I'm supposed to do. This is a serious problem and I can't afford a repair like this right now

- Durham, NC, USA

problem #51

Apr 202013


  • 80,000 miles


The contact owns a 2007 Saturn Ion. The contact stated that while the vehicle was parked, a strong odor of gasoline fuel emitted with a puddle of fuel visible on the ground. There was a recall associated with NHTSA campaign id number 12V459000 (fuel system, gasoline) and the vehicle was previously repaired under the recall in 2010. The failure recurred and the vehicle had not been recently repaired for the failure. The manufacturer was notified of the problem. The approximate failure mileage was 80,000.

- Springhill, FL, USA

problem #50

Jun 012013


  • 93,000 miles
Several times per week (and sometimes 2-3 times per day) there is a strong gasoline odor inside my car while I am driving. It is so strong it gives me a headache, and I have sometimes become sick to my stomach. My passenger is able to smell it as well.

- Hustler, WI, USA

problem #49

Jun 252013

Ion 4-cyl

  • 144,055 miles
Early in 2013, we noted some moisture in the trunk of this vehicle. In late may, we hung a "damp rid" desiccant device in the trunk and noted that the "damp rid" device rapidly saturated with moisture and also formed clumps and/or crystals in the trunk of the auto. (the "damp rid" in the trunk was saturated within two weeks, whereas it takes a couple of months when hanging inside a closet in the house 1-888-326-7743). This week, I inserted a brand new 9 volt battery into a kidde model number kn-coeg-3 carbon monoxide/explosive gas monitor and placed the monitor in the trunk. Within 24 hours, the monitor was chirping. The peak level of gas after 24 hours in the trunk of the car was 10. (this household monitor can not discriminate the precise type of gas in this particular case). Today, I opened the trunk and cleaned everything out. The source of the moisture was clearly noted on the passenger side inside of the trunk because the interior of the trunk was actually muddy close to a one way flapper vent/valve on the passenger side. The one way valve measures around 4 inches high and 6 inches long. I am reporting this because of the proximity to the gas tank filler cap on the passenger side, 12 volt ac delco battery on the passenger side in the trunk, and auto emissions from this Saturn and other cars. Inhalation of any or all of these fumes or vapors can lead to health problems including erratic behavior, drowsiness, etc. Of course the risk of explosion and corrosion of sensitive electrical and fuel components is accelerated in damp conditions.

- Leland, NC, USA

problem #48

May 102013

Ion 4-cyl

  • 162,000 miles
I was driving on the expressway when I lost all throttle response. After investigating I found it had to be the fuel pump that quit. When investigating why the fuel pump quit after a new one did not fix my problem, I noticed the wires got too hot and burned black and actually burned through the positive wire at the connector going into the fuel tank. Hot wires and burning wires inside a gas tank is not a safe combination. To top it off, I had to drill through the connector and wire in a pigtail connector purchased from the dealer since they would not sell me the whole fuel tank cover to replace it properly. Only after haggling with dealers that would not give me part number or sell me the fuel tank cover that they finally gave me the part number of 25815572 but it is under restriction to sell so that is why they sold me the "backyard mechanic fix". my worry is still that I have my family travel in the car and I do not want this thing catching fire or exploding. Is there a defect in the part is why it almost caught fire on me" and is there still a defect and that is why the part is on restriction? what is the correct, safe fix for my family? I just want a safe working vehicle and a explanation in why it is so difficult to get the part I wanted at first. It is running now but it is with the drilling through the connector, sealing it, and soldering the new wires in. I was hoping for thicker wire to maybe handle the current to the pump or an assurance that the vehicle is safe. Sorry, one last complaint. My Saturn is a California emission vehicle but is currently in mi. Why is this not covered under some of the recalls? is this like the ca cancer warnings that are only in that state? my car will only explode in those states and not Michigan"

- Grand Blanc, MI, USA

problem #47

Apr 262013


  • miles


The contact owns a 2007 Saturn Ion 3. the contact stated that he smelled gasoline fuel while inside the vehicle. The vehicle was taken to a private mechanic where it was found that the fuel pump had failed. The manufacturer was contacted and informed the contact that the vehicle was not included in NHTSA campaign number: 12V459000 (fuel system, gasoline). The vehicle was scheduled to be repaired. The failure mileage was not available.

- Des Moine, IA, USA

problem #46

Nov 212012

Ion 4-cyl Diesel

  • 2,000 miles
The car, when just weeks old, smelled of gas coming from the front grille, a strong odor 5 minutes after shutting it off. Dealer checked said all was normal. Along with this issue was a loss of vacuum in the brake assist canister when it sat in the driveway " when you got in the car the brake the brake pedal was rock-hard. There should be 5 " 10 pumps of vacuum in the canister on any car. This is noticeable in a stick shift (it is) or any car you have to step on the brake for the interlocked starter. Dealer checked also said was normal. Then about two years after the smell of gas stopped altogether and the power assist seemed normal as the peddle had power when the car was left to sit. About 6 months ago the gas smell started coming back when it was parked " this time for just a minute or so ? intermittent. Then about 3 months ago it started getting worse " not just when the car was shut off but now gas odor with closed windows at the first few lights you came to after starting the car, with windows shut in cold weather. Now the odor is strong, sometimes nauseating at traffic lights. The brake pedal issue also returned in February on very cold mornings. I do not know if a vacuum leak and a fuel smell are related here. I cannot see any leaking gas or spots on the pavement and I have looked a few dozen times over the two time periods this problem(s) have occurred. A very strong smell of gas and no visible leak. I am familiar that car is recalled in southern states only for a fuel pump that has cracks in the plastic return lines ? and also have read (although cannot be sure if this is true leak fuel in a pool on top of the tank and not drip and the evaporating odor will make its way forward to the engine compartment or the back wheel wells - I can smell gas in the rear wheel wells also although sometimes not as strong as the grille.

- Cincinnati, OH, USA

problem #45

Mar 012010

Ion 4-cyl

  • 60,000 miles
The contact owns a 2007 Saturn Ion. The contact stated that when driving at various speeds or when standing outside the vehicle, he noticed a strong odor of gasoline. In addition, he also noticed that the power steering would fail when completing a turn. The vehicle was not inspected by a dealer or an independent mechanic. The manufacturer was not contacted. The failure mileage was approximately 60,000. The current mileage was approximately 85,000.

- Huntington, WV, USA

problem #44

Feb 022013

Ion 4-cyl

  • 76,000 miles
After replacing the fuel pump last year I am now facing a cracked gas tank. I asked the mechanic if it could be due to me hitting anything, I had not been in any accidents, and I was advised there wasn't anything to indicate and outside damage. Just that the tank itself has worn away.

- Tampa, FL, USA

problem #43

Dec 272012


  • miles
The contact owns a 2007 Saturn Ion. The contact stated that fuel fumes were emitted in and around the vehicle. The vehicle was not taken to the dealer. The manufacturer was made aware of the failure but did not offer any assistance since the vehicle was not included in any recalls. The vehicle was not repaired. The failure mileage was unknown and the current mileage was 65,000.

- Wichita, KS, USA

problem #42

Jan 252013

Ion 4-cyl

  • 83,000 miles
The fuel pump assembly unit on my 2007 Saturn Ion has cracked and developed a leak causing a significant fire and environmental hazard. There was no incident that lead to the crack, just a faulty part. There was a recall issued for this same problem, but it does not extend to the state in which I reside.

- Thornton, CO, USA

problem #41

Dec 142012

Ion 4-cyl

  • 49,927 miles
I had smelled a very strong gas odor in my car and contacted GM/Saturn customer service on November 28, 2012 in regards to the smell and to find out if my car was included in a recent recall for the fuel pump. I was told that the fuel pump recall was only included in certain states and my state was not included. I took my car to my mechanic on 12/14/12 and they confirmed that my car smelled of gas due to a faulty fuel pump and it needed to be replaced. They also said that the fuel pump faults were due to being in states that high heat. I live in Maryland and the fuel smell came about during the summer which is very hot in the state. I contacted GM because I feel that I should be reimbursed for a faulty fuel pump since it is a fire and safety hazard.

- Westminster, MD, USA

problem #40

Sep 042012


  • 119,000 miles
The contact owns a 2007 Saturn Ion. The contact stated that there was a strong gasoline fuel smell odor from the exterior of the vehicle. The vehicle was taken to a mechanic, who advised that the fuel pump module was fractured and needed to be replaced. The mechanic replaced the fuel pump and the dealer was notified of the failure. The dealer advised the contact that there had been a recall for the failure but his VIN was not included in the recall campaign (NHTSA campaign id number: 12V459000: Fuel system, gasoline: Delivery: Fuel pump). The manufacturer was notified who confirmed that the recall did not include the contact's VIN. The failure mileage was 119,000.

- Davison, MI, USA

problem #39

Dec 282012


  • 130,000 miles
The contact owns a 2007 Saturn Ion. The contact stated that gasoline fuel fumes were emitted into the vehicle. The contact mentioned that after inspecting the vehicle he noticed that there was a fuel leak under the fuel tank. The vehicle was taken to the dealer. The technician diagnosed that there was a leak on the fuel pump that needed to be replaced. The manufacturer was made aware of the failure but did not offer any assistance since the vehicle was not included in NHTSA campaign id number: 09V419000 (fuel system, gasoline:delivery:fuel pump). The vehicle was not repaired. The failure and current mileage was 130,000.

- Havertown , PA, USA

problem #38

Nov 142012

Ion 4-cyl

  • 68,000 miles
There is a crack in the plastic fuel line coming out of the fuel pump. I see online there is a recall for this problem but GM says my car is not included. Even though it is for the exact problem the recall addresses.

- Norman, OK, USA

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