Two problems related to other fuel system hoses lines/piping, and fittings have been reported for the 2004 Saturn ION. The most recently reported issues are listed below.
After having my emissions tested in WI in which it passed at the time on or about may 27, 2015. About a week latet, I began to smell a gasoline smell coming from the diiver's side of the car, after I drove it and then parked it and turned off the ignition. I didn't see anything dripping from the car to the grounc, I noticed that the smell of gasoline became more and more prevalent until about June 17, 2015 when the smell was so great and I hadnt driven the car for well over a week because I was afraid something was leaking or would happen while driving. My brother smelled it also when I backed up and pulled forward. We checked under hood, but nothing and no spots on the ground. Took it to a garage and the mechanic and owner said that the fuel lines, fuel filter, etc. Needed replacing and r which cost approximately $263 . . I also looked up information by a mechanic who states that every signgle cobalt and Ion have this same problem since the cars were built. He gave a description of what it takes to remove and replace fuel lines, fuel filter, etc. Whenever I took out the car, that car could have exploded or started an engine fire. This is a dangerous situation that could have involved the loss of not only the vehicles, but peoples lives. I firmly believe that gm should have to have these vehicles on recall for this very dangerous malfunction of the fuel tank, fuel filter and fuel lines and be required to pay for these repairs on the cars affected. Thank you for your consideration in this situation.
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.
| Other Fuel System problems | |
| Other Fuel System Pump problems | |
| Other Fuel System Tank Assembly problems | |
| Other Fuel System Hoses Lines/piping, And Fittings problems |