Problems · by component
2004 Saturn Ion fuel/propulsion system problems
36 owner complaints to NHTSA about the 2004 Saturn Ion cite fuel/propulsion system, 4% of all 898 complaints for this model year.
Complaints
36
4% of all complaints
Crashes
0
Reported by owners
Fires
1
Reported by owners
Injuries
0
Reported by owners
What owners say about the fuel/propulsion system
Verbatim from NHTSA complaints, newest first
“Hi I am a kind of new owner of an 04 saturn ion, this is actually the second complaint I've filled out. Last July I had a mechanic friend look at my fuel filter and he had said the fuel line needed to be cut off becuase of how rusted on to the original fuel filter I'd got it with was and I didn't believe him so I replace it myself and when I got it off I had cleaned up the metal fuel line the best I could and put a new filter on. Well now it leaks gas right where the hook up is and very strong fuel smells come from there too, I've gotten numerous comments about how un safe that is to be driving it but I need to have a way to work and then someone had mentioned to check for recalls and I seen on there that this car did have a recall for faulty fuel filter gas lines. If you could get back to me as soon as possible about an inspection if needed or whatever else you'd need on my behalf. Please and thank you for your time”
“TRIED TAKING FUEL FILTER OFF LAST JULY TOOK A WHOLE WEEKEND OF USING PENATRATING OIL AND FREEZE OFF THEN I FINALLY GOT THE TABS TO COME LOOSE, I THOUGHT MAYBE I MESSED UP THE NEW FILTER OR DIDNT GET ENOUGH RUST OFF THE FUEL LINE AND THAT'S WHAT WAS CAUSING THE STRONG SMELL OF GAS ND POOR PERFORMANCE BUT CHANGED IT AGAIN AND STILL THAT SAME PROBLEM BUT NOW THERES A LEAK. THE CAR WAS ON BACK TIRE RAMPS THE GIRL FUEL FILTER CHANGE THEN THE 2ND ONE WAS DONE WITH A HOIST AND CURRENTLY THIS CAR IS THE ONLY THING I CAN COUNT ON TO MAKE IT TO WORK, THANK YOU FOR YOUR TIME AND CONSIDERATION.”
“THE FUEL PUMP IS LEAKING, GM REFUSES TO FIX IT BECAUSE THE VIN ISN'T ASSOCIATED WITH THE RECALL, BUT THE SAME YEAR MAKE AND MODEL OF MY CAR SAYS IT HAS A RECALL FOR THE FUEL SYSTEM AND PUMP.”
“FUEL LEAK ON REAR DRIVER SIDE WHEN THE ENGINE IS RUNNING WHILE CAR IS STATIONARY. IT MAY HAVE HAPPENED BEFORE THE DATE AND MILEAGE STATED BELOW BUT THAT'S WHEN I FIRST NOTICED THE FUEL LEAK.”
“IT LOOKS LIKE MY CAR IS LEAKING FUEL. DON'T KNOW IF IT'S THE FUEL INJECTOR LINE OR FUEL PUMP BUT I KNOW THERE IS A RECALL FOR THIS ON MY CAR BUT IT'S NOT SHOWING UP ON MY VIN NUMBER”
“2004 SATURN ION 2.2/4 ENGINE STARTED SMELLING GAS FUEL LINE ISSUES FOUND ... OTHERS HAVING SAME ISSUE THERE ARE RECALLS BUT ONLY ON CERTAIN VIN #S 107,000 MILES HOW MANY CARS BEFORE NATION WIDE RECALL ??!!”
Showing 6 of 36 reports. Read every report on NHTSA.gov.
Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 9, 2026NHTSA vehicle page
Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.