Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Saturn Ion owners, lightly cleaned up (personal details are redacted by NHTSA).
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. …
After having my emissions tested in wi in which it passed at the time on or about May 27, 2015. About a week latet, I began to smell a gasoline smell coming from the diiver's side of the car, after I drove it and then parked it and turned off the ignition. I didn't see anything dripping from the car to the grounc, I noticed that the smell of gasoline became more and more prevalent until about June 17, 2015 when the smell was so great and I hadnt driven the car for well over a week because I was afraid something was leaking or would happen while driving. My brother smelled it also when I backed up and pulled forward. We checked under hood, but nothing and no spots on the ground. Took it to a garage and the mechanic and owner said that the fuel lines, fuel filter, etc. Needed replacing and r which cost approximately $263 .. …
On the 20th of July I noticed a very strong smell of gasoline in my garage. I checked the gas can for my lawn equipment and it was not the source on the odor. I backed out of the garage and noticed a somewhat substantial puddle of gas right in front of where my rear tire was. As the car was still running I looked under the car at the suspect location and noticed steady drips coming from under a plastic clip which held the fuel lines. Further investigation showed that the fuel lines had rusted through right at that clip. After reading up on this problem it seems that this is a extremely common problem which affects both Ion and cobalt vehicles since I believe they are "delta" bodies. Due to the nature and the amount of occurrences this problem should be addressed by GM. It is my only vehicle and I do not have the 400-500 dollars to repair this. …
While under the rear of the car to fix the exhaust system, it became apparent that the fuel lines in the location under the trunk and behind a flexible shield are extremely and severely rusted and corroded. They are corroded to the point where they could potentially leak at any moment. The fuel lines are pressurized during and after operation of the vehicle and also run very close to a hot exhaust pipe. Not only is this a reliability issue, but more so, it is an incredible safety hazard and needs to be addressed. After doing some internet searching I found numerous complaints of other Ion owners with the exact same condition - many who have had leaks and either required towing, or experienced a fuel spill. Dealer wants $800 to fix. This is not a normal wear item.
After the car was looked at by a Chevy dealer to have recalls preformed and the fuel leak looked at, they said, on paper, "c/s fuel leaking under vehicle." "fuel feed line leaking fuel,active leak,do not recommend to drive. Replace for $689.99 plus tax customer declined." I declined because that's a lot of money, which I will take their caution and not drive the vehicle till it can fixed. I am bringing the car to another mechanic to have their claims verified by a none GM company. I live in ny, they used to use salts on the road which May have attributed to the issue, the car is 12 years old at only 62K miles. Disappointing. Car was bought used. 1 month ago at 61K miles privately, I assume the seller sold the car due to the gas leak and didn't inform me.
Tl* the contact owns a 2004 Saturn Ion. The contact stated that while driving at an undisclosed speed, the vehicle loss power steering without warning. The contact turned off and restarted the vehicle and the vehicle operated as intended. Additionally, the windows rolled up and down independently. The contact also stated there was an abnormal fuel outside the vehicle. The vehicle was not taken to be diagnosed. A dealer was not contacted however, the manufacturer was made aware of the failure. The contact was referred to the local dealer to have the vehicle diagnosed. The vehicle was not repaired. The failure mileage was 172,639.
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.
I bought a 2004 Saturn Ion 2.2l l4 (VIN: [redacted]) for my son 4 months ago. It is now leaking a puddle gasoline after being shut down. I looked on line and there dozens of others with this problem (please see attached) yet my VIN is not on a recall list. Called Saturn [phone], they said it wasn't on a recall list also. Dealer wants $600+ for repairs. Any suggestions? Thanks
Tl* the contact owns a 2004 Saturn Ion. The contact stated that the fuel filter and fuel lines prematurely rusted without warning. The vehicle was taken to the authorized dealer who diagnosed that the two fuel lines needed to be replaced as well as the fuel filter. The contact was not included in NHTSA campaign number: 04V003000 (fuel system, gasoline). The manufacturer was notified of the failure. The approximate failure mileage was 137,000.
Tl* the contact owns a 2004 Saturn Ion. While driving at various speeds, the steering wheel seized without warning. The contact stated that there was also a smell of fuel coming from the vehicle. The contact stated that the steering shaft and fuel lines failed and needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 20,000.
Related recalls
Fuel system, other › Delivery › Fuel pump
Certain 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. If fuel leaks from the fuel feed pipe, there would be a noticeable fuel odor around the vehicle.
Remedy: Dealers will replace the fuel feed pipe assembly. Owner notification began on June 9, 2004. Owners should contact Saturn at 1-800-972-8876.
Fuel system, gasoline
Certain passenger vehicles equipped with 2.2l 4-cylinder (l61) engines were built with a fuel filter that could corrode prematurely on the exterior surface.
Remedy: Dealers will replace the fuel filter assembly. Owner notification began on December 30, 2003. Owners should contact Saturn at 1-800-972-8876.
Fuel System complaints in other Ion years
Frequently asked questions
How common are fuel system problems on the 2004 Saturn Ion?
NHTSA has 52 complaints about the fuel & propulsion system of the 2004 Saturn Ion, 6% of the model year's 898 complaints. The component named most often is storage › tank assembly › filler pipe and cap (1 mentions).
Is there a recall for 2004 Saturn Ion fuel system problems?
Yes — NHTSA recall 04V-281 (fuel pump, Jun 8, 2004); NHTSA recall 04V-003 (fuel system, gasoline, Jan 5, 2004). Recall repairs are free at authorized dealers.
At what mileage do 2004 Saturn Ion fuel system problems start?
Half of the complaints with a recorded mileage happened before about 104,000 miles, and 9% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.