Fuel Hoses Lines/piping And Fittings Problems of Saturn ION

2007 Saturn Ion. Consumer writes in regards to faulty ignition switch recall issues. The consumer stated after the recall was performed, he noticed the remote no longer worked, which worked prior. The next problem, was the key being difficult to remove from the ignition and sometimes it was difficult to insert the key into the ignition. Occasionally, the vehicle would not shut off. The consumer would have to turn the key to off and then on, which would require several attempts, to get the vehicle to turn off. The vehicle was taken to the dealer, whey the shaved the keys and said that should fix the problem. As for the remote, the dealer couldn't reprogram it, and they suggested, just buying a new one. The consumer soon discovered, the problem remained the same. Also, the fuel pump had to replaced. The pump was built with plastic fuel lines molded into the top of the pump. At about 70,000, the plastic lines cracked at the top of the pump, probably due to vibration. The problem could have been avoided, by using steel lines connected to the pump, or coming off the pump with a short section of the hose. The fracture leak was small at first, but smell gas was present, but a leak could not be found, until the pressure line cracked at the point it made a puddle under the vehicle. The pump was replaced at a cost of $ 600. However, the new pump was built exactly like the failed pump.

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The contact owns a 2004 Saturn Ion. The contact smelled gasoline fuel coming from the vehicle and noticed a fuel leak. The dealer stated that the fuel lines needed to be replaced. The vehicle was repaired and the manufacturer was notified. The failure mileage was 94,000.

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2003 Saturn Ion. Consumer writes in regards to reimbursement for faulty ignition recall repairs. The consumer stated upon returning to her vehicle, she discovered she was unable to use the remote, so she used the key, instead. She attempted to place the key inside the ignition and discovered the slot was not in the off position. The vehicle would not start due to the ignition not being in the off position and enabling her to pull the key out, as the battery was dead. It wasn't until January 7, 2014, she began experiencing problems again with the ignition, and the battery died again. After the vehicle was jump started, the consumer smelled gas. It was determined the rear fuel line had corroded, which formed holes and gas was pouring out the holes on both sides.

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The fuel line started dripping. The entire line is rusted and the car cannot be turned on, it will cause a fire.

The contact owns a 2004 Saturn Ion 2. The contact stated that an odor of gasoline fuel was emitted inside of the vehicle. The contact noticed that the rear seat was soaked with fuel. The vehicle was taken to an authorized dealer where they advised the contact that the fuel lines and fuel filter were rusted, causing the fuel to leak into the rear seats of the vehicle. The vehicle was repaired with a new fuel system. The failure mileage was 146,000 and the current mileage was 146,100.

The contact owns a 2006 Saturn Ion. While parked, the contact noticed a fuel odor emitting in the vehicle. The vehicle was taken to an independent mechanic who stated there was a leak from the fuel pump monitor through the fuel line and leading to the fuel tank. The mechanic stated there was a recall under NHTSA campaign id number: 09v419000 (fuel system, gasoline:delivery:fuel pump) that could have been related to the failure. The manufacturer was made aware of the failure and advised that the VIN was not included in the recall. The vehicle was not repaired. The approximate failure mileage was 45,000.

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Began experiencing a strong odor of raw gas and fumes in August of 2011. I scheduled an appointment with my local repair facility to have the problem evaluated. Upon raising the vehicle and doing a visual inspection of the fuel system, run marks from gasoline could be seen coming down from the top of the tank. An evap test was performed as well and smoke could be seen rising out of the tank area. The tank is plastic and no visual cracks could be seen. My technician felt this was unusual at such low mileage. After further digging the technician discovered a recall on the fuel pump module for my year, make and model. I was advised to return to the dealer to see if it was covered which I did. I found out that my vehicle did not fall under the factory recall. I returned to my regular mechanic to have the problem resolved. Once the tank was lowered another evap test was performed. The test revealed that the fuel supply lines coming off the fuel pump sending unit were leaking. This was were the two hoses were press fitted to the sending unit from the factory. The only means of correcting was to replace the entire fuel pump module. I had the repair completed using an oe fuel pump module. I feel after reading the parameters set forth under this recall that my vehicle should have been repaired under this recall. I urge NHTSA to once again evaluate this defect. In my opinion these defective parts were used on more vehicles than initially stated. This is a severe safety issue and has the potential for serious injury.

The contact owns a 2007 Saturn Ion level 2. The contact stated that the fuel tank was leaking. The vehicle was taken to a mechanic who inspected the failure and found a fractured line at the top of the fuel pump. The vehicle was repaired at the owners expense. The manufacturer was notified and stated that there were no recalls and offered no assistance. The failure mileage was 12,601. Updated 09/27/11.

The contact owns a 2006 Saturn Ion. While examining the vehicle, the contact noticed an odor of gasoline; he also noticed that the vehicle had trouble starting at times. The vehicle was taken to a local repair shop where the fuel line and fuel pump were replaced. The current and failure mileages were approximately 27,000.

Fuel leak as a result of a cracked line at fuel pump module. This is the identical defect which a recall was issued by gm for Saturn Ion's registered in states other than NY.

The contact owns a 2007 Saturn Ion2. The contact stated that her circuit board burned out and the fuel line cracked spilling gasoline all over the vehicle. The vehicle was being repaired by the dealer for a different recall when the failure occurred. After the vehicle was repaired the abs light, battery, power steering, oil light, and the odometer lights all illuminated at the same time while driving 55 mph. The vehicle was parked immediately and was towed back to the dealer for an inspection of the failures. The dealer informed her that the cluster board burned out and the fuel line was cracked. The fuel line will be repaired under the warranty and the repairs to the cluster board at no cost were being reviewed by the manufacturer. She was awaiting a call from the dealer and manufacturer. The failure mileage was 80,000.

Smell of gas coming from the car. Upon further investigation supply/return line from top of fuel pump has developed a crack. Replaced fuel pump to resolve issue. There is a recall already for this however it's only effecting 2 states. Nhtsa 09v419000.

We noticed a strong of gasoline and a leak at the rear of the car. Mechanic said that the plastic line connecting on the fuel pump module was cracked and gas was leaking. We purchased the part from a Saturn dealership and had our mechanic install. The part cost $346. 00 and our mechanic charged us $100. 00 to install it. Our mechanic suggested we do some research regarding a possible recall on this part and when I did that I found a recall for our vehicle but only for certain states. Our state, missouri, is not included in this recall, but I don't understand why it matters what state you live in.

Vehicle had a strong fuel odor. Vehicle was checked after engine line came on. Main fuel line connected to fuel pump came apart and vehicle was leaking fuel. If I had a collision car would have exploded due to amount of fuel leaking. New fuel pump was replaced cost to 400. 00 plus labor costs. Just bought used vehicle in August 2009 from dealer.

I have been having starting problems with my car (2006 Saturn Ion) and smelling gasoline. It turns out the hose connected to the fuel pump was cracked and leaking gas. The mechanic said that this is a safety issue and should be recalled. He feels that the one hose is not connected and harnessed properly and the vibration to the hose eventually caused the crack. I googled "Saturn 2006 Ion fuel leak" and several other people have had the same issue. What is also the major problem here is that the hose is configured with the fuel pump itself. So, the entire mechanism had to be replaced. It cost me 700. 00 for a cracked hose because the fuel pump had to be replaced and my car only is 46,000 miles. This is a major safety issue. I drove for 2 weeks with a car that was leaking fuel. Saturn must know about this and is waiting for the same situation to happen, but for the car to blow up instead.

The contact owns a 2006 Saturn Ion. When the vehicle was stationary, the contact smelled a strong odor of fuel inside and outside of the vehicle. The vehicle was taken to an authorized dealer for inspection and the technician stated the failure was contributed to a crack in the fuel tank line. The fuel pump was replaced by an independent mechanic. The contact had concerns of a potential safety hazard. The failure mileage was 55,200 and the current mileage was 55,595. Updated 12/07/09. The dealer also fixed the front window that had dropped into the door, a cracked speaker and dome light. Updated 12/08/09.

Smell of gas at back of car on passenger side. Took vehicle to have oil changed and they found gasoline leaking. Saturn dealership pointed out one of the fuel lines had cracked. I bought the car 2 months before the problem was discovered. Had to replace the entire fuel pump assembly. This was a recall on the 2004 Ion. Did they really fix the problem from the 2004 or does the 2006 have the same problem. Phone interview (August 4, 2009): the complainant indicated that the fuel tank had not been removed previously as far as she knows. The repair invoice indicates that the fuel pump was leaking and was replaced.

Took my 06 Saturn into the dealer due to stalling. Was told by the mech. That the fuel pump was leaking that the plastic elbow had a crack in it due to the road vibration my concern is that tis is a line that is under appos 20psi located above the exhaust pipe and directly under the back seat. If gas is being sprayed out over the exhaust a spark is all that is missing to have a rolling flame thrower. In my simple mind this part should not be prone to cracking because of normal driving. I still remember the pinto I hope some one will take action before something happens think you for your time in this matter.