2007 Saturn Ion: fire, smoke or burning smell

Filed Nov 20, 2014 · Fuel system · 90,000 miles · TX

Because of a 'hidden recall' by gm, I was driving down the road when I smelled fuel. My fuel pump had become defective, causing a leak, and therefore, rusted fuel lines, which then broke. This 'hidden recall' was not covered at the dealership and I had to get gm involved on a corporate level, and even then, I still had to pay for their mistake! My car was steadily dripping fuel, and aside from emptying the tank there was nothing I could do about this. It is dangerous, and gm knows about it but will not acknowledge the danger in the situation. I have children. What if the car would have caught fire? Then would they have listened?? It is absolutely absurd that they would not warn owners of these vehicles (even the dealership claimed to know many others in my situation exactly) when it is something so dangerous, let alone make them pay for the repair. I am absolutely disgusted.

Filed Feb 26, 2014 · Electrical, Fuel system · 60,210 miles · WA

I heard on tv that gm had recalled the ion because of deaths associated with fires from leaking fuel modules and failing ignition switches. So, I called gm and was told that they will only fix the the ignition if it fails and the fuel module when you can show it is leaking. It seems like if they have a problem with their parts they should try to fix them prior to stalling on the freeway or having the vehicle burst into flames from leaking fuel. Am I off base here?

Filed May 16, 2013 · Fuel system · 162,000 miles · MI

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?

Filed Aug 23, 2012 · Fuel system · 144,000 miles · WI

Vehicle exhibits the exact same issue described below, but because I do not live in these states, my vehicle is not covered under this recall. I fear that my vehicle could start on fire any day now and gm will not care. This is a serious safety hazard to not only me, but other drivers as well. A fuel leak is a serious issue that I feel should not be ignored. General motors is recalling certain model year 2006 chevrolet cobalt and saturn ion vehicles originally sold in or currently registered in the states of arizona and nevada; and model year 2007 chevrolet cobalt, pontiac g5 and saturn ion vehicles originally sold in or currently registered in the states of arizona, california, florida, nevada and texas. 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.

Filed Aug 17, 2011 · Fuel system · 73,000 miles · TX

Gasoline leaking from under the car. Used dealer ship drive time did not tell me about the recall before they sold me the car, even though they were aware of the recall that had been in place for 4-5 months! I have a child that was with me in the car when the gas started leaking, the car could have caught on fire. Drive time should have told me about the problem, but instead they risked my life and my daughters. They only care about money!! Gm is going to try to fix problem, due to recall. Drive time is still trying to charge me my co-pay for having my car looked at, but yet won't cover me with a rental car cause it falls under the manufacture warranty.

Filed Jul 16, 2010 · Fuel system · 70,000 miles · IL

I have a 2007 saturn ion which was purchased brand new in the state of illinois. I started smelling a large amount of gas inside and outside of the vehicle about two weeks ago. Then it started leaking gas near the right back tire well. We took it to get looked at and the mechanic stated the fuel pump module was cracked and leaking gas 3 inches away from my muffler which is dangerous because if ignited in some way the car could catch fire. I looked up any known issues with this model of vehicle and I found a recall that was issued oct 2009 for 2007 saturn ions in a lot of states but not illinois. I am very concerned that this potentially hazard issue is happening to vehicles in illinois also but no one is being notified of the danger. My family was at risk. If there would have been an accident or someone threw a cigarette at my car and the vehicle could of caught fire. I also park my car in an attached garage which also brought risk to my home. Please consider also adding illinois and any other states that may be having the same problem that you have already issued the previous recall campaign 09v419000 for. Please contact me for any additional information. Thank you for your time and consideration.

Filed Jul 1, 2009 · Steering · 45,000 miles · OK

We have a 2007 saturn ion with 45,000 miles. Yesterday the power steering motor went out. Motor is part of the steering column so we have to have it all replaced. Quote by a saturn dealer is $1000. We talked to a local, reputable, mechanic and he informed us that driving the car in such a condition could result in the car catching on fire from the heat generated from turning without the power assist. This is an ongoing issue going back several year models of ion's. We do not feel we should have to pay to have a safety issue fixed on the car. There should be a recall.