2005 Saturn Ion Fuel system Problems

“While traveling on highway, I stopped and filled up gasoline and I noticed a continuing strong gas smell in car. Thought I spilled gas on myself but later upon inspection in my garage, I found gas dripping from plastic fuel line (under car, right behind driver's door). Due to danger, I immediately set up appointment with polar chevrolet, who decided the fuel line needed replacement. Cost was $623.44”

“In cold weather my Saturn ION will fail to start. The ignition will click a couple of time then nothing. I wait 8-10 minutes and try again sometimes it will attempt to start sometimes not. Then I have to wait some more and try again, eventually it will start. I had 2 new batteries replaced and still problem persists. I found a Saturn message board that addressed this very problem. Hope you can get Saturn to recall this issue.”

“My fuel line began leaking and when I checked I determined there was a hole in it near the drivers back tire near the clip, the fuel line is also rusted out. I had to have the entire thing replaced and was a cost of over $850.00. I feel this is a safety issue and should be on a recall list. Fuel lines should not rust out like this and I have been advised this by 2 reputable mechanics. This is also very dangerous, if I had not noticed it I could have run the risk of my car catching on fire. This issue put my family and I in danger. …”

“I bought the car brand new, drove one mile off the lot, the engine stopped and would not start. It was towed the next morning to the dealer and they replaced the engine control module. At 15,400 miles the car again would not start, they replaced the ignition switch. At 16,000 miles the chime for the ignition would not turn off and the ignition housing was replaced. At 19,500 miles I complained that the car would start and immediately turn off again, the dealer said nothing was wrong. The next day the ignition would not turn off and the key was stuck. They replaced the ignition housing again. …”

“Vehicle was stationary when problem occurred. Fuel intake and return lines in front of the rear drivers side wheel flaking badly and rusted through, about an 8 inch section of line was flaking and rusted through. Fuel line was rubbed when putting on new oem exhast and broke through the lines. Gas was leaking bad enough that it was deemed not safe to drive as these lines are about 5 inches away from the exhaust.”