One problem related to tank assembly has been reported for the 2004 Saturn ION. The most recently reported issues are listed below.
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 -20â° 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.