Smelled gas leaking for a few weeks every time we would fill up. Just assumed it was spillage. Finally noticed drips of gas under car then a whole tank of gas ended up on my driveway. Car would also intermittently not start, presumably due to fuel leakage. Had repair done by private mechanic who determined fuel lines had completely rusted through. Saturn says not responsible due to the original recall only involving a rusted fuel filter, however this was an immediate fire/safety threat.
2004 Saturn Ion fuel system complaints
Page 3 of 3: complaints 41 to 52 of 52, newest first, as owners wrote them.
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.) service manager said that recently they have been finding many saturn ions with this condition. 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 federal safety agency compels them to issue a recall.
The fuel line started dripping. The entire line is rusted and the car cannot be turned on, it will cause a fire.
Our car, 2004, saturn ion3, caught on fire in the driveway on it's own about 2 hours after it was driven home on 4 nov 2011. No driver - no key in the vehicle when it caught fire. I submitted an initial request for review to gm claims along with all documentation that we had via emails and our claim was denied.
Started leaking gas from fuel filter and I checked on line for recalls and was one for that vehicle I called saturn they said there wasn't.
Tl* the contact owns a 2004 saturn ion 2. The contact stated that an odor of gasoline fuel was emitted inside of the vehicle. The contact noticed that the rear seat was soaked with fuel. The vehicle was taken to an authorized dealer where they advised the contact that the fuel lines and fuel filter were rusted, causing the fuel to leak into the rear seats of the vehicle. The vehicle was repaired with a new fuel system. The failure mileage was 146,000 and the current mileage was 146,100.
Hi, I have a 2004 saturn ion, with only 22,000 miles on it. It seems to have a problem starting in cold weather. I had to take my moms 1988 buick to work yesterday because my car wouldn't start in the cold! It happened about two weeks ago, and I waited about 10 minutes and it started right up. About a month ago it happened when I was going out to lunch, same thing after ten minutes it started right up. I can't keep being late for work and missing appointments and when I take my wife's car she has to walk 15 blocks with the kids to school and if it's too cold for this car to start I don't really want my kids to walk. I called saturn today and was told they're not aware of any problems, yet when you search the internet there's thousands of people complaining about this. Any help would be greatly appreciated. Thanks in advance for your help in this matter.
Just about every day I have problems starting my car in the cooler temperatures. The ignition tries to start up, but then does nothing. I can understand when this is a problem in -20 weather, but this happens when the temperatures aren't even below freezing. I have tried adding ignition cleaner, and I add heat to my tank every time I fill up (and never let my tank get below half-full) - nothing seems to work. Online forums I have looked at for this problem say that my make and year (as well as years surrounding mine) have problems with the ignition system and this "should" be a recall but isn't. I've been late to work, or my car hasn't started at all on numerous occasions.
After a few stops, no matter what the temp is outside/nice or cold... My car will not start. It simply clicks and will not turn over... Feels/sounds like it is not getting any fuel. If I wait 10 minutes or so and then try again, the car will start. I have had it stall while I'm driving when it's cold out. I have had it to the shop numerous times and they can not find anything wrong with it!!! My engine light is on due to gross leak emission control, and they can not correct the issue!!!! There have been numerous complaints about this and the manufacturer will not take responsibility, however they do not mind charging me each and every time I take it in, and each and every time they have neglected to fix the problem!!! Frustrated
When the temperature is cold (usually below 40), my car will not start. It simply clicks and security sensors start coming on. If I wait 10 minutes or so and then try again, the car will start and promptly stall out. I have had it stall while I'm driving when it's cold out. There are numerous complaints about this and the manufacturer will not take responsibility.
Tl*the contact owns a 2004 saturn ion. The contact took her vehicle to the service station for routine maintenance. The fuel gauge was not monitoring the fuel, and was indicating that the fuel tank was empty. The fuel sensor was repaired. When the mechanic replaced the fuel sensor, he discovered that the gas pump was corroded and needed to be replaced because it was a fire hazard. The repair of the fuel pump, including diagnostic parts and labor was $900. Saturn customer service department stated that the VIN was not included in the federal safety agency campaign id number 04v281000 (fuel system, other:delivery:fuel pump). The contact has pictures. The current and failure mileages were 23,800. Updated 06/17/08. *lj updated 06/16/08
Saturn ion 2004 i4, engine light came on, was looked at on 19th sept 2004 by dealership. On sep 20th I went to put gas in the car and I could not. Gas spilled out of the car. I can not drive the car, as it will now allow me to put gas in the car. I was stuck at home after returning from gas station.
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