Tank Assembly Problems of Saturn ION

Saturn ION owners have reported 12 problems related to tank assembly (under the gasoline fuel system category). The most recently reported issues are listed below.

1 Tank Assembly problem of the 2007 Saturn ION

Failure Date: 09/20/2017

2007 Saturn Ion. Consumer writes in regards to gas leak at fuel tank. The consumer stated the vehicle experienced a strong odor of gas on the inside and outside. The consumer was advised not to drive the vehicle as it could explode or catch fire. Due to the vehicle having reconstructed title, the warranty was voided. Updated 11/07/2017.

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2 Tank Assembly problem of the 2006 Saturn ION

Failure Date: 09/01/2014

The contact owns a 2006 Saturn Ion. The contact stated that after refueling the vehicle, the odor of gasoline was present inside. After inspecting the vehicle the contact discovered that fuel was leaking from the fuel tank. The contact also indicated that the air bag warning light illuminated and the horn would not operate. The vehicle was not diagnosed or repaired. The failure mileage was 115,000.

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3 Tank Assembly problem of the 2006 Saturn ION

Failure Date: 10/27/2013

Was refueling veh. And when almost full ,fuel started to run on ground. Stopped refueling , and looked under car . Fuel was dripping from front , center of tank.

4 Tank Assembly problem of the 2006 Saturn ION

Failure Date: 04/24/2012

The contact owns a 2006 Saturn Ion. The contact stated that there was an overpowering odor of gasoline emitting from the vehicle. A fuel tank leak was later discovered by the contact and the dealer was contacted, who offered no assistance. The vehicle was not repaired. The VIN was not available. The failure and the current mileage was 135,000.

5 Tank Assembly problem of the 2006 Saturn ION

Failure Date: 10/01/2011

The contact owns a 2006 Saturn Ion. The contact noticed fuel leaking from the fuel tank. The fuel tank was fractured and approximately one gallon of fuel was spilled. The vehicle was not taken to the dealer for diagnostics or repairs. The approximate failure mileage was 89,000.

6 Tank Assembly problem of the 2006 Saturn ION

Failure Date: 08/30/2011

Strong fuel odor while driving, lingers when parked. Leak noticed coming from top of gas tank.

7 Tank Assembly problem of the 2006 Saturn ION

Failure Date: 02/16/2011

The contact owns a 2006 Saturn Ion. The contact stated that while driving at approximately 35 mph, there was a fuel odor coming from the vehicle. The failure occurred on numerous occasions. The vehicle was taken to a dealer where it was diagnosed that the fuel tank needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure. The approximate failure mileage was unknown.

8 Tank Assembly problem of the 2007 Saturn ION

Failure Date: 08/30/2010

The contact owns a 2007 Saturn Ion. The contact smelled a very strong fuel odor when the vehicle was turned off. The vehicle was taken to the garage and the diagnostic test confirmed that there was a fuel leak above the fuel tank. The vehicle wasn't repaired. The VIN information wasn't available. The failure mileage was 79,000 and the current mileage was 80,000.

9 Tank Assembly problem of the 2007 Saturn ION

Failure Date: 06/02/2010

2007 Saturn Ion. Consumer request the replacement of a fuel tank the consumer stated she paid an out of pocket expense of $ 988. 05 for the parts and labor to replace the fuel tank. She believed the leak from the fuel tank was a direct result of the service performed when she took the vehicle to the dealer for a safety recall. She stated she had not experienced any problems with the vehicle prior to the recall that she received in March 2010. On June 2, 2010 the consumer took the vehicle to the dealer for the recall repair. Immediately after the repair, she had difficulty starting the vehicle and there was a loud rumbling noise when the vehicle was driven. The consumer returned to the dealer and the fuel pump module was replaced for a second time and an exhaust shield was shifted. The consumer then took a trip. During that time, she smelled gasoline at times, but was unsure if it was coming from her vehicle. After parking the vehicle in a small garage, there was a strong gasoline smell within an hour. When the consumer had her oil changed, the technician noted the vehicle was leaking fuel at the hose to the tank area and recommended that she take the vehicle to the dealer immediately. The dealer informed the consumer there was a leak coming from the filler neck leading to the fuel tank, and the entire fuel tank needed to be replaced. The consumer believed the leak occurred on one of the occasions the fuel tank was dropped for the previous fuel pump replacements.

10 Tank Assembly problem of the 2007 Saturn ION

Failure Date: 10/15/2009

The contact owns a 2007 Saturn Ion. He smelled an odor of gasoline leaking from his vehicle. The vehicle was taken to a repair facility and a mechanic concluded that there was fuel leakage from the fuel tank. He took the vehicle to the dealership and a technician concluded that because the warranty expired they would not provide any assistance. The current and failure mileages were approximately 50,000.

11 Tank Assembly problem of the 2004 Saturn ION

Failure Date: 01/22/2009

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.

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12 Tank Assembly problem of the 2007 Saturn ION

Failure Date: 05/01/2008

Revised brand new car, dent in trunk, 3 months later check engine light and not starting, needs new fuel tank and they need to replace the motor in the ac unit. 05-30-08, car wont start again - service department says that is due to automatic car starter new car purchased on 11-29-08, 6 months old, only 4700 miles on it. Falling apart one piece at a time.


Other Common Gasoline Fuel System related problems of Saturn ION


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