general problems of the 2003 Saturn ION

19 problems related to other fuel system have been reported for the 2003 Saturn ION. The most recently reported issues are listed below.

1 Other Fuel System problem

Failure Date: 05/29/2018

Fuel line rotted so much that one day I start my car and every drop of gas I had poured out onto the ground under my drivers seat. It was a fire hazard and now I am stuck without a car. The garage wants over $600 to replace the fuel line and I literally have no way to fix it. The vehicle was on a city street.

2 Other Fuel System problem

Failure Date: 04/13/2018

Fuel line to throttle body leaked fuel due to stress cracks. Part that failed is " no longer available" according to gm parts sales. . Mechanic welded cracked pipe and said eh has fixed quite a few of these. I have receipt from repair shop.

3 Other Fuel System problem

Failure Date: 09/08/2017

Gas odor coming from under vehicle. Fuel line next to frame directly under left rear passenger seat was leaking, fuel lines were rusted through causing gas to leak. Fire hazard.

4 Other Fuel System problem

Failure Date: 07/16/2017

Same issue as in Saturn Ion 2004 recall: rusted area on fuel line near rear door. Very sudden fuel leak (half gallon) when I arrived home and parked my car.

5 Other Fuel System problem

Failure Date: 06/01/2016

The contact owns a 2003 Saturn Ion. The contact stated that the odor of fuel was present outside the vehicle. The cause of the failure was not diagnosed. The vehicle was not repaired. The manufacturer was not notified of the failure. The VIN was invalid. The failure mileage was 152,000.

6 Other Fuel System problem

Failure Date: 04/04/2016

The contact owns a 2003 Saturn Ion. When the contact started the vehicle, he smelled fuel and noticed a significant amount of fuel on the ground. The manufacturer stated there were no recalls available. The vehicle was not diagnosed. The failure mileage was 130,000.

7 Other Fuel System problem

Failure Date: 03/20/2016

The contact owns a 2003 Saturn Ion. The contact stated that the vehicle had an abnormal odor and was leaking fuel from underneath. The vehicle was not taken to the dealer or independent mechanic to be diagnosed or repaired. The contact referenced NHTSA campaign number: 04v003000 (fuel system, gasoline) however, the VIN was not included. The manufacturer was not notified of the failure. The failure mileage was 103,000.

8 Other Fuel System problem

Failure Date: 05/29/2015

Tl-the contact owns a 2003 Saturn Ion. The contact stated that the vehicle failed to start and fuel was leaking from the rear drivers side of the vehicle. The failure recurred several times. The vehicle was diagnosed or repaired. The contact was made aware of NHTSA campaign id number: 04v003000 (fuel system, gasoline) however, the VIN was not included. The manufacturer was notified of the failure. The approximate failure mileage was 201,000. Mf.

9 Other Fuel System problem

Failure Date: 05/08/2015

Ran out of gas. Inspection indicates that fuel is leaking from rusted fuel line in front of left (driver's side) rear tire. Further inspection shows heavy/extensive rust on the fuel lines along the entire length of the undercarriage. Problem appears identical to another incident previously reported as #10668929.

10 Other Fuel System problem

Failure Date: 01/02/2015

Fuel system - fuel line rusted out under carriage - just in front of left rear tire. Causing gasoline to leak out thru hole in fuel line while engine is running. Entire fuel line must be replaced , cannot just replace section rusted causing hole for fuel to leak out. The cost for this repair is in excess of $600 ( parts & labor). This problem has been reported happening to numerous other vehicle owners, with no solution issued by gm; nor reimbursement to owners.

11 Other Fuel System problem

Failure Date: 10/27/2014

Vehicle was in for recall on ignition switch, at the dealership changed oil and conducted multipoint inspection of vehicle. Eight weeks later vehicle was returned for service for smell of gas, dealership reported all gas lines corroded and leaking gas and need to be replaced, dealership states not releated to fuel filter corrosion recall (nthsa 04v003000) even though recall service not performed. Corroded, leaking gas lines make vehicle unsafe to operate and have the potential for fire. Believe this should be a recall as operating the vehicle with leaking gas lines put me and my family in danger. Not mention the $1000 plus repairs vehicle.

12 Other Fuel System problem

Failure Date: 06/30/2014

Nhtsa campaign number: 04v003000 fuel system, gasoline vehicle was repaired due to several recalls. Shortly after the vehicles fuel filter system was replaced: may, 2014, there is a hole in the fuel line and is leaking fuel.

13 Other Fuel System problem

Failure Date: 06/16/2014

The contact owns a 2003 Saturn Ion. The contact stated after driving the vehicle for a few miles there was a fuel odor throughout the vehicle. The contact stated that after the vehicle was parked, the fuel odor increased. The failure recurred on a regular basis. The manufacturer was notified of the failure. The vehicle was not diagnosed or repaired. The failure mileage and current mileage was 165,000.

14 Other Fuel System problem

Failure Date: 06/09/2014

Key came out, but car was still running. Put key back in managed to get turn off engine, however key would not release for over 15min! this keeps happening to me. Scheduled appointment with chapman Chevrolet tempe, az to repair according to recall instructions that I submitted to their customer service dept. They say they will notify me when the parts come in, but it has been approximately one month or more already. I believe my family and my self are in danger of a fatal accident or something; sometimes the car will not surrender the ignition key for in hour. Already had new key made at chapman Chevrolet which makes starting somewhat easier, before, it would take, often times, 10min or more just to get the key to turn. Please help chapman Chevrolet get the parts they need or stop ignoring my request for the honoring of the recall work I requested of them. Im afraid this will not hold up much longer as is.

15 Other Fuel System problem

Failure Date: 05/30/2014

Smelled gas fumes. Noticed leaking gas on ground. Upon further inspection, noticed the fuel lines are completely rusted out, causing gas to leak out onto the ground. There is no other area on the car with rust. Researching this issue, I came across many others experiencing the same problem with fuel lines rusting out. The fuel lines that were put in were wrapped with a heat resistant covering which caused water to stay and moisture to build up, eventually resulting in corrosion. Furthermore, the gasoline leakage occured within close proximity of the exhaust system, which could cause fire or explosion. The fuel lines are inadequate, and dangerous. Potential fire hazard. This issue needs to be addressed immediatly as it is very dangerous left unattended. Could cause serious bodily harm or death.

16 Other Fuel System problem

Failure Date: 04/02/2014

The contact owns a 2003 Saturn Ion. The contact stated that a fuel leak was present from the driver's side rear wheel area. The vehicle was taken to an independent mechanic, who diagnosed that the fuel supply line was defective and needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The VIN was not available. The failure mileage was 178,000.

17 Other Fuel System problem

Failure Date: 02/28/2013

Significant rust and stress fractures on fuel line resulting in noticeable fuel leakage with the potential of incendiary incident in the case of collision. After vehicle message board queries this problem seems to occur with unusual frequency in Saturn Ions spanning 2003-2007. Paid out of pocket to have the fuel line replaced; was told that no recall exists for this problem so I wanted to report it.

18 Other Fuel System problem

Failure Date: 10/05/2012

Detected smell of gasoline. Checked recalls. There are some recalls for this car but not this VIN. Took to dealership and had rusty gas line replaced. Paid for parts and work done.

19 Other Fuel System problem

Failure Date: 11/09/2007

Car won't start when it is cold. Have to wait 15 minutes. Saturn repaired the problem back in 10/05. It did it again in 2006 and now it is happening again in 2007. The car thinks that it is being stolen and cuts the fuel line to the car.


Other Other Fuel System related problems of the 2003 Saturn ION


Fuel Economy of ION Vehicles
ION Service Bulletins
ION Safety Recalls
ION Defect Investigations