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Saturn Ion fuel smell problems

214 of the 4,344 owner complaints about the Saturn Ion describe gas smell in the cabin, most of them for the 2006 model year.

owner complaints
214
worst model year
2006
typical repair cost reported
$700
typical mileage
82,000
Is there a fix? There are 4 recalls for this area of the car. See below

By model year

What owners say

Filed Jul 25, 2023 · Fuel system · WV

The contact's parents own a 2007 Saturn Ion. The contact stated that there was a fuel odor coming from the vehicle when the vehicle was started or turned off. There was no warning light illuminated. The contact's father inspected the vehicle but could not find a fuel leak. Upon investigation, the contact discovered the federal safety agency Campaign Number: 12V459000 (Fuel System, Gasoline) which she linked to the failure. The contact notified the manufacturer of the failure and was informed that the vehicle was not under recall. The dealer was notified of the failure. The vehicle was not repaired. The failure mileage was unknown.

Filed Jan 11, 2023 · Fuel system · 76,000 miles · MO

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 the federal safety agency Campaign Number: 12V459000 (Fuel System, Gasoline). The approximate failure mileage was 76,000.

Filed Jul 10, 2022 · Fuel system · FL

Gas smell when driving and while parked. Mechanic lifted car and saw gas on the top of gas tank, car starting to stall during initial start up.

Filed Apr 13, 2022 · Fuel system · 80,000 miles · CA

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 the federal safety agency 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.

Filed Sep 11, 2021 · Fuel system · MN

Hi I am a kind of new owner of an 04 saturn ion, this is actually the second complaint I've filled out. Last July I had a mechanic friend look at my fuel filter and he had said the fuel line needed to be cut off becuase of how rusted on to the original fuel filter I'd got it with was and I didn't believe him so I replace it myself and when I got it off I had cleaned up the metal fuel line the best I could and put a new filter on. Well now it leaks gas right where the hook up is and very strong fuel smells come from there too, I've gotten numerous comments about how un safe that is to be driving it but I need to have a way to work and then someone had mentioned to check for recalls and I seen on there that this car did have a recall for faulty fuel filter gas lines. If you could get back to me as soon as possible about an inspection if needed or whatever else you'd need on my behalf. Please and thank you for your time

Filed Mar 2, 2021 · Fuel system · 100,000 miles · MN

Tried taking fuel filter off last july took a whole weekend of using penatrating oil and freeze off then I finally got the tabs to come loose, I thought maybe I messed up the new filter or didnt get enough rust off the fuel line and that's what was causing the strong smell of gas nd poor performance but changed it again and still that same problem but now theres a leak. The car was on back tire ramps the girl fuel filter change then the 2nd one was done with a hoist and currently this car is the only thing I can count on to make it to work, thank you for your time and consideration.

Filed Jun 17, 2020 · Fuel system · 123,456 miles · IA

I started smelling gas when getting out of car. Then it got progressively stronger gas smell that lingered on strong an hour after the car had been sitting. So I checked for gas leak on exterior of gas tank and found extreme amount of gas coming from both of the fuel lines of the fuel module on top of tank. This didn't start until the weather has become warm in the 80 s and 90s.

Filed Sep 18, 2019 · Fuel system · 83,000 miles · OK

Service person says that I need to replace the fuel injector line. Thought that was done so by a recall I had done already. Hard to start and smell of gasoline

Filed Aug 30, 2019 · Fuel system · CA

Lately have been noticing by myself and others, strong fuel smell around car. While cleaning out various paperwork, I found a recall letter dated 8/2015 regarding cracked fuel tank inlet control valve. I really need this problem looked into as I am hesitant to drive with the horrid gas smell. Please advise as soon as possible. Thank you

Filed Jun 24, 2019 · Fuel system · IN

The car is having the same difficulties as the other cars covered by the recall. It was made in tennessee. The manufacturer is refusing to correct the problem and states the car is not cover under the recall. Car can't be driven due to smell of gas and due to the information I have researched it may start a fire. I would like them to correct the problem.

Related recalls

Fuel system, gasoline: delivery: fuel pumpReported September 19, 2012 · 49,768 vehicles affected
What is wrong
General Motors (GM) is recalling certain model year 2007 Chevrolet Equinox and Pontiac Torrent vehicles originally sold or currently registered in Arizona, California, Nevada, and Texas; model year 2007 Chevrolet Cobalt, Pontiac G5, and Saturn ION vehicles originally sold, or currently registered in, Arizona, California, Florida, Nevada, or Texas; model year 2008 Chevrolet Cobalt and Pontiac G5 vehicles originally sold, or currently registered in, Arizona; and model year 2009 Chevrolet Cobalt and Pontiac G5 vehicles originally sold, or currently registered in, Arkansas, Arizona, California, Nevada, Oklahoma, or Texas. Some of these vehicles have a condition in which the plastic supply or return port on the fuel pump module may crack, which could cause a fuel leak.
Risk
Fuel leakage in the presence of an ignition source may result in a fire.
Remedy
GM will notify owners, and dealers will replace the fuel pump module, free of charge. Notification to owners began on on November 21, 2012. Owners were instructed to not bring their vehicles in for repair until January 2013. Owners may contact General Motors at 1‑800‑521‑7300.

Recall number 12V459000 · Recall details

Fuel system, gasoline: delivery: fuel pumpReported October 29, 2009 · 69,139 vehicles affected
What is wrong
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.
Risk
Fuel leakage, in the presence of an ignition source, could result in a fire.
Remedy
Dealers will replace the fuel pump module free of charge. A special coverage will be implemented in the same time frame for model year 2006 vehicles registered in alabama, arkansas, california, florida, georgia, hawaii, louisiana, mississippi, north carolina, new mexico, oklahoma, south carolina, tennessee and texas and model year 2007 vehicles registered in: alabama, arkansas, georgia, hawaii, louisiana, mississippi, north carolina, new mexico, oklahoma, south carolina and tennessee. The safety recall is expected to begin on or before february 4, 2010. Owners may contact chevrolet at 1‑800‑630‑2438, saturn at 1‑800‑972‑8876 and pontiac at 1‑800‑620‑7668 or at the owner center at www.gmownercenter.com.

Recall number 09V419000 · Recall details

Fuel system, other: delivery: fuel pumpReported June 8, 2004 · 670 vehicles affected
What is wrong
Certain vehicles equipped with supercharged 2.0l 4-cylinder (lsj) engine were built with a fuel feed pipe that could crack and leak fuel near the fuel rail. If fuel leaks from the fuel feed pipe, there would be a noticeable fuel odor around the vehicle.
Risk
Fuel leakage, in the presence of an ignition source, could result in a fire.
Remedy
Dealers will replace the fuel feed pipe assembly. Owner notification began on june 9, 2004. Owners should contact saturn at 1‑800‑972‑8876.

Recall number 04V281000 · Recall details

Fuel system, gasolineReported January 5, 2004 · 127,285 vehicles affected
What is wrong
Certain passenger vehicles equipped with 2.2l 4-cylinder (l61) engines were built with a fuel filter that could corrode prematurely on the exterior surface.
Risk
If corrosion on the exterior surface of the fuel filter progresses to the point of creating a hole in the shell, fuel droplets could form and drop to the ground. If an ignition source is present, a fire could result.
Remedy
Dealers will replace the fuel filter assembly. Owner notification began on december 30, 2003. Owners should contact saturn at 1‑800‑972‑8876.

Recall number 04V003000 · Recall details

Questions about the Saturn Ion fuel smell

Which Saturn Ion years have gas smell in the cabin problems?

The model years with the most reports are 2006 (94 complaints), 2007 (92 complaints) and 2004 (15 complaints).

How much does it cost to fix gas smell in the cabin on the Saturn Ion?

Owners who mentioned a price put the repair at about $700 (median of 23 complaints that include a dollar amount). Costs vary with mileage, warranty and where the work is done.

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