There are 17 owner-reported fuel system complaints for the 2005 Saturn Ionin NHTSA's database. These are unverified consumer reports and may not reflect confirmed defects.
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.
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.
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 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'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 304-725-3448) 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.
AS SOON AS YOU TURN THE KEY ON THE FUEL PUMP STARTS PUMPING FUEL OUT OVER THE LEFT REAR WHEEL WITH OUT STARTING THE CAR.I HAVE READ THAT THE 2006 AND UP SATURNS HAVE A RECALL ON THE FUEL PUMPS BUT NOT THE 2005 WHY. WILL THEY RECALL THE 2005 MODELS IN THE FUTURE.
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
NOTICED LIQUID DRIPPING FROM DRIVER SIDE OF CAR BY REAR WHEEL WHILE CAR WAS PARKED IN MY PARKING STALL. TOOK THE CAR INTO DEALERSHIP. DEALER CONFIRMED FUEL LINES HAD RUSTED OUT. FUEL LINES AND FUEL FILTER WERE REPLACED.
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.
TL* THE CONTACT OWNS A 2005 SATURN ION. THE CONTACT NOTICED FUEL LEAKING OUT OF THE FUEL TANK. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 130,000. UPDATED 11/19/15*LJ
TL* THE CONTACT OWNS A 2005 SATURN ION. THE CONTACT STATED THAT WHILE DRIVING AT LOW SPEED, FUEL FUMES EMITTED INTO THE VEHICLE. AFTER INSPECTING THE VEHICLE, THE CONTACT NOTICED THAT THERE WAS A LEAK IN THE FUEL LINE PIPE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN DIAGNOSED THAT THE FUEL LINE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN.
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.
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. THIS IS AS DEPLORABLE AS THE POWER STEERING AND IGNITION ISSUES. GM NEEDS TO CORRECT THIS ISSUE AT NO COST TO THE CAR OWNERS WHO TRUSTED THEM TO BUILD A SAFE CAR. I AM ALSO CONSULTING LEGAL ADVISE, AND REACHING OUT THE ATTORNEY GENERAL AND THE BETTER BUSINESS BUREAU. *TR
THE FUEL LINE HAS RUSTED & LEAKING GASOLINE ONTO THE EXHAUST PIPE NEAR THE DRIVER'S SIDE REAR TIRE. *TR
TL* THE CONTACT OWNS A 2005 SATURN ION. THE CONTACT STATED THAT AFTER REFUELING AND PULLING OUT THE NOZZLE, THE FILLER NECK CAME COMPLETELY OUT WITH IT. THE CONTACT MENTIONED THAT THE ENGINE WARNING LAMP WAS ALSO ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE FAILURE COULD NOT BE DIAGNOSED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 80,000 AND THE CURRENT MILEAGE WAS 108,184.
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. *TR
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. AT 22,300 MILES I COMPLAINED THAT THE KEY WAS STICKING IN THE IGNITION, THE DEALER SAID NOTHING WAS WRONG. ABOUT 6 MONTHS LATER (LAST WEEKEND BEFORE LEAVING TO GO OUT OF TOWN) AT 27,200 MILES THE IGNITION WOULD NOT TURN OFF AND THE KEY WAS STUCK AGAIN. THE IGNITION HOUSING WAS REPLACED FOR THE THIRD TIME! I CONTACTED THE MANUFACTURER AND WAS ONLY OFFERED A ONE YEAR EXTENSION ON THE WARRANTY. WHAT GOOD WILL AN EXTENDED WARRANTY DO FOR A CAR THAT YOU CAN'T TRUST TO DRIVE BECAUSE YOU NEVER KNOW WHETHER IT WILL START OR TURN OFF WHEN YOU NEED IT TO!!! I WILL NEVER BUY ANOTHER SATURN AGAIN!!!!! *TR
Complaints are unverified consumer reports submitted to NHTSA. A high complaint count may reflect vehicle popularity, not defect severity. Data sourced from NHTSA public records.
Data synced from NHTSA on Apr 25, 2026