2004 Saturn Ion Fuel system Problems
- Complaints
- 52about this part
- Share
- 6%of 898 total for the year
- Median mileage
- 102,500miles
- Trend
- FallingComplaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
NHTSA recorded 52 complaints about the fuel system of the 2004 Saturn Ion, 6% of the 898 complaints for this model year. Where a mileage was given, the median is 102,500 miles. 1 a fire, according to the filers. 2 recall campaigns on record are filed under a similar system.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“Was driving when I noticed a gas smell really strong it got worse when then I noticed that I was going threw gas like crazy and didn't know why . One day the smell was so strong when I got out the car I looked under that car and saw that one of lines was leaking gas I am worried because I do have kids in my car and that its a bad danger chance of fires to start”
NHTSA complaint #10789289, filed 2015-11, 132,000 miles“Our car, 2004, Saturn ion3, caught on fire in the driveway on it's own about 2 hours after it was driven home on 4 nov 2011. No driver - no key in the vehicle when it caught fire. I submitted an initial request for review to GM claims along with all documentation that we had via emails and our claim was denied.”
NHTSA complaint #10477968, filed 2012-09, 110,000 miles“When the temperature is cold (usually below 40), my car will not start. It simply clicks and security sensors start coming on. If I wait 10 minutes or so and then try again, the car will start and promptly stall out. I have had it stall while I'm driving when it's cold out. There are numerous complaints about this and the manufacturer will not take responsibility.”
NHTSA complaint #10246503, filed 2008-10, 35,000 miles“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.”
NHTSA complaint #11398818, filed 2021-03, 100,000 miles“Smelled gas leaking for a few weeks every time we would fill up. Just assumed it was spillage. Finally noticed drips of gas under car then a whole tank of gas ended up on my driveway. Car would also intermittently not start, presumably due to fuel leakage. Had repair done by private mechanic who determined fuel lines had completely rusted through. Saturn says not responsible due to the original recall only involving a rusted fuel filter, however this was an immediate fire/safety threat.”
NHTSA complaint #10569017, filed 2014-03, 120,000 milesRelated recalls
- 04V281000Jun 8, 2004Certain vehicles equipped with supercharged 2.0l 4-cylinder (lsj) engine were built with a fuel feed pipe that could crack and leak fuel near the fuel rail…Covers: Saturn Ion 2004
- 04V003000Jan 5, 2004Certain passenger vehicles equipped with 2.2l 4-cylinder (l61) engines were built with a fuel filter that could corrode prematurely on the exterior surface.Covers: Saturn Ion 2003–2004
Related service bulletins
- 10208027Jan 14, 2022This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester…
- 10190437Mar 30, 2021This Preliminary Information communication provides information to the technician about engine block of possible cylinder bore damage, scoring or out of round as the possible…
- 10176310May 8, 2020This Preliminary information communicates the use of Winter grade fuel during the warm months of 2020 and the potential rivability issues that it can cause. The ongoing…
- 10171878Jan 2, 2020This informational bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended…
- 10157018Sep 20, 2017This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester…
- 10137635May 10, 2017This informational bulletin advises of a new fuel injection kit used for decarbonizing the intake valves, and explains how toptier fuels should be used to reduce carbon build up.
- 10114831Nov 15, 2016This Preliminary Information communication provides information to the technician about engine block that have a possible cylinder bore damage, scoring or out of round as the…
- 10114954Dec 9, 2015This Preliminary Information communication provides information to the technician about vehicles that have a Service Engine Soon Malfunction Indicator Lamp. Technician may find…
- 10127230Sep 28, 2015This Preliminary Information communication provides information to the technician to help determine if the vehicle is equipped with factory or aftermarket Compressed Natural Gas…
Fuel system: other model years
Other parts of the 2004 Saturn Ion
345 complaintsElectrical system
331 complaintsTransmission and drivetrain
60 complaintsAir bags
52 complaintsEngine cooling
33 complaintsVehicle speed control
27 complaintsExterior lighting
25 complaintsEngine
23 complaintsOther or unknown
21 complaintsVisibility (wipers, defrost, mirrors)
20 complaintsBrakes
19 complaintsSuspension
19 complaints
← All problems reported for the 2004 Saturn Ion
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 30, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology