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 2005 Saturn Ion owners, lightly cleaned up (personal details are redacted by NHTSA).
When pressing the gas pedal 2/3 of the way down the pedal got stuck causing the engine to rev high while driving forward. I had to put the car in neutral, shut the engine off and manually get the gas pedal unstuck by reaching down to the floor and pulling the pedal upwards with my hands. Also I had no floor mats in my car for the pedal to get stuck on. This has happened on multiple occasions.
This car leaks fuel when filled and you can smell fuel coming from the car at all times. The check engine light is on and the code indicates that fuel is evaporating from the tank. This make and model has been recalled in several southern states where the fuel evaporates more quickly due to the temperature. The problem is worse as the temperature increases. Mr. Goodwrench and GM refuse to correct this problem without charging for their own diagnosis. It does not take certified mechanic to watch the fuel drip onto the ground or to read a code that has already been read. I have opened a claim with GM but the most assistance that is given is to schedule a service call & tow at my expense. I will not drive a car leaking gas and endanger my life and others to pay to find out it is still leaking gas from mr. Goodwrench.
Tl* the contact owns a 2005 Saturn Ion. The contact stated that the vehicle hesitated upon turning the key in the ignition and an abnormal noise was present. The contact had to turn the vehicle off and reset the computer by restarting the vehicle each time the failure recurred. The vehicle was taken to the dealer for a manufacturer recall and they repaired the vehicle for the ignition switch failure. The contact also noticed strong fumes emitting from outside and inside the vehicle and it idled roughly. The dealer did not diagnose the fuel system failure. The vehicle was also included in NHTSA campaign number: 14V153000 (steering) months ago and was unable to determine when the recall repair would be performed. The manufacturer was notified of the failures. The approximate failure mileage was 200,000.
Tl* the contact's daughter owns a 2005 Saturn Ion. Each time the vehicle was parked, the contact noticed oil spots on the ground. Upon further inspection, the contacted husband noticed that the fuel line was cracked and leaked fuel in the front of the rear driver?s side wheel. There were no warning indicators illuminated. The contact was concerned that the fuel leakage could cause a fire. The contact called the dealer (guy's Buick gems, 1316 n mildred st, ransom, wv 25438 [phone]) and was informed that there no recalls were on the vehicle. The dealer was unable to schedule an appointment and stated that they would call the contact back. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 100,000.
Tl* the contact owns a 2005 Saturn Ion. While driving approximately 30 MPH, the gear shift failed to switch into the reverse position without warning.the vehicle was taken to an independent mechanic where it was diagnosed that the transmission needed to be replaced. The vehicle was repaired. On another occasion, the contact mentioned that there was a fuel odor emitting from the vehicle. The vehicle was taken to an independent mechanic where it was diagnosed that the fuel line was rusted and the fuel pump needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure. The failure mileage was 92,000.
College aged daughter owns and drives a 2005 Saturn Ion with approximately 115,000 miles. We noticed a wet spots on the ground on the drivers side near the rear passenger door when car is stationary (parked) but never detected an odor. Took vehicle to Nissan dealership in maryland since we were unaware that GM owns Saturn. However, we were told by Nissan that fuel lines need to be replaced because the vehicle is leaking gasoline and repairs should be done immediately because it is both unsafe and dangerous.
Tl* the contact owns a 2005 Saturn Ion. The contact stated there was a strong fuel odor coming from the vehicle. There were no warning indicators illuminated before or after the failure. The vehicle was not taken to a dealer to be diagnosed. The manufacturer was notified of the failure. The contact believed the failure was relevant to NHTSA campaign number: 09V419000 (fuel system, gasoline). The vehicle was not repaired. The approximate failure mileage was 115,000. The VIN was not provided.
The car was fueled up, when it was being started it had great difficulty. Once it was running, it was driven and a right turn was made, then all gauges died. The check engine light, the airbag light and the "pwr str" massage remained on. The car was pulled over to the side of the road and turned the ignition switch to the off position the three indicators remained on and the car refused for about two minutes before turning off.
Tl* the contact owns a 2005 Saturn Ion. The contact stated that when he started the vehicle, he noticed an abnormal fuel odor without warning. In addition, once the contact reached his destination he observed fuel leaking out from under the rear passenger side of the vehicle. The vehicle was not diagnosed or repaired. The manufacturer nor the dealer were notified of the failure. The failure mileage was approximately 250,000.
Tl* the contact owns a 2005 Saturn Ion. The contact stated that while in park, the contact noticed fuel leaking from underneath the vehicle. The vehicle was taken to an independent mechanic who diagnosed that the fuel lines were leaking and had corroded. The mechanic stated that the fuel lines needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 190,000.
Fuel System complaints in other Ion years
Frequently asked questions
How common are fuel system problems on the 2005 Saturn Ion?
NHTSA has 27 complaints about the fuel & propulsion system of the 2005 Saturn Ion, 5% of the model year's 573 complaints. The component named most often is storage › fuel gauge system (2 mentions).
Is there a recall for 2005 Saturn Ion fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2005 Saturn Ion, though it has 3 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2005 Saturn Ion fuel system problems start?
Half of the complaints with a recorded mileage happened before about 115,000 miles, and 10% before 25,000 miles.
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.