One problem related to tank filler pipe and cap has been reported for the 2006 Saturn ION. The most recently reported issues are listed below.
The contact owns a 2006 Saturn Ion. The vehicle has a very strong gasoline smell inside the passenger compartment and outside as well. There is also a fuel leakage in the vehicle. The contact is a mechanic and stated that the leak originated from the fuel tank. He is concerned that the leak could cause a potential fire hazard. Ever since the leak occurred, the vehicle now has to be cranked for a while before the engine starts. The vehicle has not been taken to any dealer; however, the manufacturer was notified. The current and failure mileages were 51,000. Phone interview (August 4, 09): mr. Hornback repaired the fule pump himself. He said that one of the nipples on the fuel module had cracked. Mr. Hornback inserted a brass pipe into the broken nipple and epoxy it in place. He agreed to email me pictures of the fuel pump module. He believes that the cracked nipple was for the fuel 'return' side.