NHTSA — Fuel System, Gasoline Problems

2007 Saturn Ion (Page 1 of 3)

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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.

10.0

really awful
Crashes / Fires:
0 / 0
Injuries / Deaths:
1 / 0
Average Mileage:
59,493 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 1 of 3)

problem #58

Oct 202022

Ion

  • 76,000 miles

A D V E R T I S E M E N T S

The contact owns a 2007 Saturn Ion. The contact stated while starting the vehicle, there was an abnormal fuel odor entering the cabin of the vehicle. The contact then noticed fuel leaking from the vehicle. The vehicle was not taken to be diagnosed or repaired. The dealer was not contacted. The manufacturer was contacted and stated that the vehicle was not included in NHTSA Campaign Number: 12V459000 (Fuel System, Gasoline). The approximate failure mileage was 76,000.

- Troy, MO, USA

problem #57

Jan 012021

Ion

  • 80,000 miles
The contact owns a 2007 Saturn Ion. The contact stated that while he was attempting to start the vehicle failed to start. The contact stated no warning light was illuminated. The contact stated he began to smell a fuel odor inside and outside the vehicle and also saw a fuel leak between the rear tires. The contact took the vehicle to an independent mechanic and was informed that the fuel pump module needed to be replaced. The contact called and made the local dealer aware of the failure. The vehicle was not diagnosed or repaired. Upon investigation, the contact associated the failure with NHTSA Campaign Number: 12V459000 (Fuel system, Gasoline) however, the VIN was not included. The manufacturer had been informed of the failure. The failure mileage was approximately 80,000.

- Temecula, CA, USA

problem #56

Sep 202017

Ion

  • miles
2007 Saturn Ion. Consumer writes in regards to gas leak at fuel tank. The consumer stated the vehicle experienced a strong odor of gas on the inside and outside. The consumer was advised not to drive the vehicle as it could explode or catch fire. Due to the vehicle having reconstructed title, the warranty was voided. Updated 11/07/2017

- Parkersburg, WV, USA

problem #55

Jan 042017

Ion 4-cyl

  • 68,946 miles

A D V E R T I S E M E N T S

I have a strong gas smell coming from the rear passenger wheel well after driving the vehicle. There is no visible leak out puddle under the vehicle. I researched and found there were recalls for certain vehicles of the same model and year. I believe my vehicle is having the same issue but no recall has been issued.

- Greenville, SC, USA

problem #54

Aug 012016

Ion 4-cyl

  • miles
2007 Saturn Ion. Consumer writes in regards to vehicle VIN not listed in fuel odor-fuel pump module service bulletin. Consumer requests reimbursement for fuel pump repairs. Consumer sent additional correspondence. The consumer stated the vehicle was taken in for repair, immediately upon detecting a smell of gas.

- Sidney, NE, USA

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problem #53

Jul 012014

Ion 4-cyl

  • miles
2007 Saturn Ion. Consumer writes in regards to vehicle fuel leak repairs and consumer seeks reimbursement. The consumer stated the vehicle developed a fuel leak in July 2014. There was a strong odor inside and outside the vehicle. The consumer received a recall notice regarding the same issue in August 2015. The consumer claim for reimbursement was denied. According to GM, the repair performed, was not the repair covered by the customer service action program. The consumer referenced recall # 12V459000.

- Hershey, PA, USA

problem #52

Jan 022014

Ion

  • 90,000 miles

A D V E R T I S E M E N T S

The contact owns a 2007 Saturn Ion. The contact stated that gasoline fuel fumes emitted inside and outside of the vehicle after turning the engine off. The vehicle was not diagnosed or repaired. The manufacturer was not notified. The failure mileage was 90,000.

- Buckeye, AZ, USA

problem #51

Aug 142014

Ion

  • 62,490 miles
Bill Dodge auto group, westbrook me 04092, invoice 841019, customer states can smell fuel check for leak, 00 diag and replace leaking fuel pump and sender. 8986 cgm $us 198.00,1 19257125 nb- (s) module kit $390.32. Parts $390.32 labor 198 other 0 total $588.32 62491 fuel sending unit found fuel leaking by tank area, removed tank and found sending unit return line broken of sending unit, will need new sending unit, removed and replaced sending unit & checked for leaks, O.K. NHTSA campaign id number 12V459000 Sept 19, 2012 fuel system, gasoline delivery pump, fuel leakage in the presence of an ignition source may result in a fire.

- Nanuet, ND, USA

problem #50

Oct 232014

Ion 4-cyl

  • 120,000 miles
The Saturn Ion 2007 that I own is bleeding gas. Fuel lines are rusted near the plastic retain clip. Fuel pump plastic is cracked, fuel tank has rusted in a small but significant spot. Recall #09V419000 is not being adhered to by GM. This is the most unsafe problem I have ever heard of. I live in virgina, very humid state. 100% humidity is common. I should have been notified of the problem since it is recalled. If this has not caused multiple fires and fatalities it would be a miracle. My complaint is the state specifically of the recall leaves lots of people without notification of a very serious problem with those cars.

- Hopewell, VA, USA

problem #49

Sep 012014

Ion

  • 98,000 miles
There is a strong odor of gasoline both outside and inside the vehicle. This seems to be a result from some sort of flaw in the plastic supply or return port of the modular reservoir assembly located near the fuel tank. GM has issued a recall in several states under GM recall no. 090226 and NHTSA campaign id number 09V419000. As this could potentially cause a fire and is massive safety concern, this should be broadened to all states for this model.

- Bremerton, WA, USA

problem #48

Jul 092014

Ion 4-cyl

  • miles

A D V E R T I S E M E N T S

2007 Saturn Ion. Consumer writes in regards to faulty ignition switch recall issues. The consumer stated after the recall was performed, he noticed the remote no longer worked, which worked prior. The next problem, was the key being difficult to remove from the ignition and sometimes it was difficult to insert the key into the ignition. Occasionally, the vehicle would not shut off. The consumer would have to turn the key to off and then on, which would require several attempts, to get the vehicle to turn off. The vehicle was taken to the dealer, whey the shaved the keys and said that should fix the problem. As for the remote, the dealer couldn't reprogram it, and they suggested, just buying a new one. The consumer soon discovered, the problem remained the same. Also, the fuel pump had to replaced. The pump was built with plastic fuel lines molded into the top of the pump. At about 70,000, the plastic lines cracked at the top of the pump, probably due to vibration. The problem could have been avoided, by using steel lines connected to the pump, or coming off the pump with a short section of the hose. The fracture leak was small at first, but smell gas was present, but a leak could not be found, until the pressure line cracked at the point it made a puddle under the vehicle. The pump was replaced at a cost of $ 600. However, the new pump was built exactly like the failed pump.

- Twin Falls, ID, USA

problem #47

Jun 282014

Ion 4-cyl

  • 92,000 miles
Started smelling gasoline around the car. Upon inspection found that the gas tank was leaking at the seam where the filler tube goes into the tank. The leak was not just at one point but practically all the way around. The gas was literally streaming out. I took it to the dealership and all they said was that it was not covered under any recall and unless the fuel pump itself is leaking they would charge me $120 diagnosis fee. I patched it and got it down to a seep. About 2 months later the fuel pump started leaking. I took it to a different dealer and they said they would replace the pump but I had to pay for the fuel tank ($831). Labor would be free since the tank is off anyway. My complaint is that the fuel tank should never start leaking. It was leaking far more than the pump and in my opinion was far more dangerous. Even at very low levels it would leak a considerable amount, especially if parked on a upward incline.

- Tyler, TX, USA

problem #46

Jul 282014

Ion

  • 74,000 miles
The contact owns a 2007 Saturn Ion. The contact stated that fuel fumes were emitted around the vehicle. After inspecting the vehicle, the contact was unable to locate a leak. The problem recurred several times. The vehicle was not diagnosed or repaired. The VIN was unavailable. The manufacturer was not notified of the issue. The approximate failure mileage was 74,000.

- Emmitsburg, MD, USA

problem #45

Aug 082014

Ion 4-cyl

  • 151,200 miles
I don't know what caused it, but I recently started noticing a strong fuel odor around my car within the last month. I crawled underneath the car to check for leaks and determined that the fuel tank has cracked at the seam where the plastic spout was mated/molded to the main part of the plastic fuel tank on the rear side of the tank. Fuel currently leaks from the crack when the tank is approximately more than 3/4 full; especially when accelerating and fuel is forced to the back of the tank. The only replacement part (currently part number 20870462, which replaced the old part number of 25947829) is available from a GM dealership and the retail price is $695.

- Cedar Rapids, IA, USA

problem #44

Jul 142014

Ion 4-cyl

  • 95,000 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.) 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.

- Newport News, VA, USA

problem #43

Feb 202014

Ion

  • 42,000 miles
The contact owns a 2007 Saturn Ion. The contact stated while driving over a bump approximately 30 mph, a strong odor of gasoline emitted inside of the vehicle. The failure occurred sporadically. There was a recall related to the failure under NHTSA campaign id number 12V459000 (fuel system, gasoline). The vehicle was ineligible under the recall due to not originally being registered or currently sold in one of the states mentioned in the recall. The vehicle had not been repaired. The manufacturer was notified of the defect. The approximate failure mileage was 42,000.

- East Islip, NY, USA

problem #42

Mar 032014

Ion 4-cyl

  • 60,000 miles
Cracked fuel pump housing.

- Taylorsville , UT, USA

problem #41

Apr 232014

Ion 4-cyl

  • 114,000 miles
Car suddenly stops on hill. Meter in car says car is 3/4 full with gas. So the car was not out of gas. Car must have something wrong with the fuel ignition or something for it to stop. Went and put gas in car to just to make sure, and as soon as I did the car started. It makes no sense for the gas gauge to read it has gas and the car stops. Also when car is parked fuel is on the ground leaking. Not sure what is going on but according to a safety recall in 2012 I think that is the problem with my Ion also.

- Wooster, OH, USA

problem #40

Oct 142013

Ion 4-cyl

  • 70,000 miles
I have had trouble with this ignition for years, having to jiggle it to start the car, a key tip broke off from trying to turn it. I also was never contacted about fuel line recall that I had to have repaired and paid for. My engine has also lost power and the engine light has been on for years and they don't know why? I don't feel safe even driving this piece of junk to the dealer.

- Provincetown , MA, USA

problem #39

Aug 312012

Ion 4-cyl

  • 20,449 miles
Noticed fuel leakage while parked in front of home. Immediately took auto to repair shop for check after checking GM website noticed recalls for fuel leakage in several states, va not included. Mechanic said fuel tank was leaking and cracked resulting of removal of tank and fuel pump sending unit replaced at a cost of $609.51.

- Richmond, VA, USA

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