2005 Saturn Relay Fuel system Problems
- Complaints
- 6about this part
- Share
- 7%of 91 total for the year
- Median mileage
- 96,300miles
- Trend
- Not enough dataFewer than 15 complaints, too few for a reliable trend.
NHTSA recorded 6 complaints about the fuel system of the 2005 Saturn Relay, 7% of the 91 complaints for this model year. Where a mileage was given, the median is 96,300 miles.
Fewer than 15 complaints name this part, so treat the figures as a rough indication only.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“Every time we fill up with fuel, the gas gauge shows empty,and the display tells us we have low fuel. After awhile the gauge will go to full, then become erratic and show us different fuel levels. It takes quite a while for the gauge to give an actual reading. I recommend that this vehicle be put on the recall list for the fuel sensor problem that other GM vehicles have had.”
NHTSA complaint #10595574, filed 2014-06, 92,600 miles“The first time I was parked and the van would not start. I was told it might be the fuel pump. I had the van tow to a service center. They said it was the fuel Relay. I paid to have the fuel Relay replaced. A few days later same thing happened again. The van would not start. This time we thought it was the battery or spark plugs. I paid to have a new battery, new spark plugs, spark plug cables. A few days later I was leaving from work and the van would not start again. I had it tow and they said it might be the fuel pump. …”
NHTSA complaint #10758509, filed 2015-08, 110,000 miles“The contact stated when the vehicle was facing down hill moving or parked, with 1/4 of a tank of gas or less, the fuel gauge indicator needle would move toward empty and fuel would not flow to the engine causing a problem starting the vehicle. Also, this caused the vehicle to stall while the vehicle moved down hill. The sales/service dealer and manufacturer were notified, and the contact was informed by both the service dealer and the manufacturer, that the design of the vehicle required at least a half full tank of fuel to prevent engine failure. Updated 1/19/2007 -”
NHTSA complaint #10175584, filed 2006-12, 31,239 miles“With a 1/4 of a tank of gas my Saturn Relay 2005 shut off on a decline causing the loss of power brakes and steering. The manufacture said the vehicle is operating as designed!”
NHTSA complaint #10149277, filed 2006-02Related 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.
Fuel system: other model years
Other parts of the 2005 Saturn Relay
41 complaintsElectrical system
24 complaintsBody and structure
10 complaintsLatches, locks and linkages
9 complaintsOther or unknown
8 complaintsExterior lighting
7 complaintsElectronic stability control
4 complaintsSuspension
4 complaintsTransmission and drivetrain
4 complaintsSteering
3 complaintsTires
3 complaintsEngine cooling
2 complaints
← All problems reported for the 2005 Saturn Relay
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