2003 Saturn Ion Fuel System Problems

FUEL LINE ROTTED SO MUCH THAT ONE DAY I START MY CAR AND EVERY DROP OF GAS I HAD POURED OUT ONTO THE GROUND UNDER MY DRIVERS SEAT. IT WAS A FIRE HAZARD AND NOW I AM STUCK WITHOUT A CAR. THE GARAGE WANTS OVER $600 TO REPLACE THE FUEL LINE AND I LITERALLY HAVE NO WAY TO FIX IT. THE VEHICLE WAS ON A CITY STREET.

FUEL LINE LEAK. I OWN A 2003 SATURN ION 3, WITH 120,481 MILES ON IT. THE CAR WAS GARAGE KEPT TILL THE PAST 6 MONTHS. WHEN DRIVING ON 4/15/18, THE CAR SUDDENLY DEVELOPED A STRONG FUEL SMELL. THE VEHICLE WAS BROUGHT INTO THE REPAIR SHOP ON 4/16/18. THE VEHICLE WAS DIAGNOSED WITH A LEAKING, RUSTED FUEL LINE. THE LEAK WAS FROM LINE COMING OUT OF FUEL PUMP. MY RESEARCH SHOWS THIS WAS A KNOWN AND COMMON FOR THE SATURN ION, ALSO SEEMS THAT GM IS AWARE OF THE ISSUE. FUEL LINE/S SHOULD NOT RUST THROUGH LIKE THIS. THIS CAR IS WELL MAINTAINED, INSPECTED REGULARLY AT EVERY 3000 MILE OIL CHANGE INTERVALS. THE VEHICLE WAS MAINTED BY SATURN AS LONG AS THEY WERE IN BUSINESS. THIS IS A SAFETY RELATED DEFECT THAT SHOULD BE INVESTIGATED AND A RECALL CAMPAIGN STARTED AND I SHOULD BE REIMBURSED FOR THE REPAIR.

GAS ODOR COMING FROM UNDER VEHICLE. FUEL LINE NEXT TO FRAME DIRECTLY UNDER LEFT REAR PASSENGER SEAT WAS LEAKING, FUEL LINES WERE RUSTED THROUGH CAUSING GAS TO LEAK. FIRE HAZARD

SAME ISSUE AS IN SATURN ION 2004 RECALL: RUSTED AREA ON FUEL LINE NEAR REAR DOOR. VERY SUDDEN FUEL LEAK (HALF GALLON) WHEN I ARRIVED HOME AND PARKED MY CAR

TL* THE CONTACT OWNS A 2003 SATURN ION. THE CONTACT STATED THAT THE ODOR OF FUEL WAS PRESENT OUTSIDE THE VEHICLE. THE CAUSE OF THE FAILURE WAS NOT DIAGNOSED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS INVALID. THE FAILURE MILEAGE WAS 152,000.

TL* THE CONTACT OWNS A 2003 SATURN ION. WHEN THE CONTACT STARTED THE VEHICLE, HE SMELLED FUEL AND NOTICED A SIGNIFICANT AMOUNT OF FUEL ON THE GROUND. THE MANUFACTURER STATED THERE WERE NO RECALLS AVAILABLE. THE VEHICLE WAS NOT DIAGNOSED. THE FAILURE MILEAGE WAS 130,000.

TL* THE CONTACT OWNS A 2003 SATURN ION. THE CONTACT STATED THAT THE VEHICLE HAD AN ABNORMAL ODOR AND WAS LEAKING FUEL FROM UNDERNEATH. THE VEHICLE WAS NOT TAKEN TO THE DEALER OR INDEPENDENT MECHANIC TO BE DIAGNOSED OR REPAIRED. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBER: 04V003000 (FUEL SYSTEM, GASOLINE) HOWEVER, THE VIN WAS NOT INCLUDED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 103,000.

TL* THE CONTACT OWNS A 2003 SATURN ION. THE CONTACT STATED THAT THE VEHICLE FAILED TO START AND FUEL WAS LEAKING FROM THE REAR DRIVER SIDE OF THE VEHICLE. THE FAILURE RECURRED SEVERAL TIMES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE CONTACT WAS MADE AWARE OF NHTSA CAMPAIGN NUMBER: 04V003000 (FUEL SYSTEM, GASOLINE); HOWEVER, THE VIN WAS NOT INCLUDED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 201,000.

RAN OUT OF GAS. INSPECTION INDICATES THAT FUEL IS LEAKING FROM RUSTED FUEL LINE IN FRONT OF LEFT (DRIVER'S SIDE) REAR TIRE. FURTHER INSPECTION SHOWS HEAVY/EXTENSIVE RUST ON THE FUEL LINES ALONG THE ENTIRE LENGTH OF THE UNDERCARRIAGE. PROBLEM APPEARS IDENTICAL TO ANOTHER INCIDENT PREVIOUSLY REPORTED AS #10668929.

FUEL SYSTEM - FUEL LINE RUSTED OUT UNDER CARRIAGE - JUST IN FRONT OF LEFT REAR TIRE. CAUSING GASOLINE TO LEAK OUT THRU HOLE IN FUEL LINE WHILE ENGINE IS RUNNING. ENTIRE FUEL LINE MUST BE REPLACED , CANNOT JUST REPLACE SECTION RUSTED CAUSING HOLE FOR FUEL TO LEAK OUT. THE COST FOR THIS REPAIR IS IN EXCESS OF $600 ( PARTS & LABOR). THIS PROBLEM HAS BEEN REPORTED HAPPENING TO NUMEROUS OTHER VEHICLE OWNERS, WITH NO SOLUTION ISSUED BY GM; NOR REIMBURSEMENT TO OWNERS. *TR

VEHICLE WAS IN FOR RECALL ON IGNITION SWITCH, AT THE DEALERSHIP CHANGED OIL AND CONDUCTED MULTIPOINT INSPECTION OF VEHICLE. EIGHT WEEKS LATER VEHICLE WAS RETURNED FOR SERVICE FOR SMELL OF GAS, DEALERSHIP REPORTED ALL GAS LINES CORRODED AND LEAKING GAS AND NEED TO BE REPLACED, DEALERSHIP STATES NOT RELEATED TO FUEL FILTER CORROSION RECALL (NTHSA 04V003000) EVEN THOUGH RECALL SERVICE NOT PERFORMED. CORRODED, LEAKING GAS LINES MAKE VEHICLE UNSAFE TO OPERATE AND HAVE THE POTENTIAL FOR FIRE. BELIEVE THIS SHOULD BE A RECALL AS OPERATING THE VEHICLE WITH LEAKING GAS LINES PUT ME AND MY FAMILY IN DANGER. NOT MENTION THE $1000 PLUS REPAIRS VEHICLE. *TR

THE FUEL LINES BETWEEN THE GAS TANK AND ENGINE HAVE RUSTED OUT. THEY ARE RUSTED DUE TO THE BRACKETS HOLDING THEM TO THE FRAME AS WELL AS A WATER SOAKED INSULATING BLANKET THAT HAD BEEN PUT AROUND THE FUEL LINES TO PROTECT THEM FROM THE EXHAUST PIPES HEAT. THIS ONLY SPED UP THE RUSTING PROCESS. THEY ARE RUSTED TO THE POINT THAT THE GAS IS SPRAYING ON THE EXHAUST PIPES CAUSING A POSSIBLE FIRE OR EXPLOSION. THE LEAK IS ONLY WITHIN A FOOT FROM THE GAS TANK MAKING IT EVEN MORE DANGEROUS. UPON MY RESEARCH I HAVE FOUND THAT SATURN HAS ADDRESSED THIS SAME PROBLEM WITH THEIR 2004 MODELS BUT NOT THE 2003 MODEL. (GM RECALL NO. 04053) THE DIFFERENCE IN THE MODEL YEARS HAS NOT MADE THIS ANY LESS OF A HAZARD. IN A CALL TO SATURN THEY TOLD ME THAT NOTHING CAN BE DONE WITH MY 2003 BUT IF I OWNED A 2004 THIS WOULD BE COVERED ON A SAFETY RECALL. THIS REASONING SOUNDS RATHER FOOLISH TO ME AND THE HAZARD SHOULD BE FIXED REGARDLESS OF THE YEAR VEHICLE. A FIRE OR EXPLOSION DOESN'T KNOW WHAT THE MODEL YEAR IT IS. WHY DID SATURN NOT MAKE THESE FUEL LINES OUT OF STAINLESS STEEL, A MATERIAL THAT WOULD NOT HAVE RUSTED AND BECOME A SAFETY HAZARD? I WOULD APPRECIATE ANY UPDATES ON THIS MATTER. THANK YOU *TR

NHTSA CAMPAIGN NUMBER: 04V003000 FUEL SYSTEM, GASOLINE VEHICLE WAS REPAIRED DUE TO SEVERAL RECALLS. SHORTLY AFTER THE VEHICLES FUEL FILTER SYSTEM WAS REPLACED: MAY, 2014, THERE IS A HOLE IN THE FUEL LINE AND IS LEAKING FUEL. *TR

TL* THE CONTACT OWNS A 2003 SATURN ION. THE CONTACT STATED AFTER DRIVING THE VEHICLE FOR A FEW MILES THERE WAS A FUEL ODOR THROUGHOUT THE VEHICLE. THE CONTACT STATED THAT AFTER THE VEHICLE WAS PARKED, THE FUEL ODOR INCREASED. THE FAILURE RECURRED ON A REGULAR BASIS. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE AND CURRENT MILEAGE WAS 165,000.

KEY CAME OUT, BUT CAR WAS STILL RUNNING. PUT KEY BACK IN MANAGED TO GET TURN OFF ENGINE, HOWEVER KEY WOULD NOT RELEASE FOR OVER 15MIN! THIS KEEPS HAPPENING TO ME. SCHEDULED APPOINTMENT WITH CHAPMAN CHEVROLET TEMPE, AZ TO REPAIR ACCORDING TO RECALL INSTRUCTIONS THAT I SUBMITTED TO THEIR CUSTOMER SERVICE DEPT. THEY SAY THEY WILL NOTIFY ME WHEN THE PARTS COME IN, BUT IT HAS BEEN APPROXIMATELY ONE MONTH OR MORE ALREADY. I BELIEVE MY FAMILY AND MY SELF ARE IN DANGER OF A FATAL ACCIDENT OR SOMETHING; SOMETIMES THE CAR WILL NOT SURRENDER THE IGNITION KEY FOR IN HOUR. ALREADY HAD NEW KEY MADE AT CHAPMAN CHEVROLET WHICH MAKES STARTING SOMEWHAT EASIER, BEFORE, IT WOULD TAKE, OFTEN TIMES, 10MIN OR MORE JUST TO GET THE KEY TO TURN. PLEASE HELP CHAPMAN CHEVROLET GET THE PARTS THEY NEED OR STOP IGNORING MY REQUEST FOR THE HONORING OF THE RECALL WORK I REQUESTED OF THEM. IM AFRAID THIS WILL NOT HOLD UP MUCH LONGER AS IS. *TR

SMELLED GAS FUMES. NOTICED LEAKING GAS ON GROUND. UPON FURTHER INSPECTION, NOTICED THE FUEL LINES ARE COMPLETELY RUSTED OUT, CAUSING GAS TO LEAK OUT ONTO THE GROUND. THERE IS NO OTHER AREA ON THE CAR WITH RUST. RESEARCHING THIS ISSUE, I CAME ACROSS MANY OTHERS EXPERIENCING THE SAME PROBLEM WITH FUEL LINES RUSTING OUT. THE FUEL LINES THAT WERE PUT IN WERE WRAPPED WITH A HEAT RESISTANT COVERING WHICH CAUSED WATER TO STAY AND MOISTURE TO BUILD UP, EVENTUALLY RESULTING IN CORROSION. FURTHERMORE, THE GASOLINE LEAKAGE OCCURRED WITHIN CLOSE PROXIMITY OF THE EXHAUST SYSTEM, WHICH COULD CAUSE FIRE OR EXPLOSION. THE FUEL LINES ARE INADEQUATE, AND DANGEROUS. POTENTIAL FIRE HAZARD. THIS ISSUE NEEDS TO BE ADDRESSED IMMEDIATELY AS IT IS VERY DANGEROUS LEFT UNATTENDED. COULD CAUSE SERIOUS BODILY HARM OR DEATH. *TR

TL* THE CONTACT OWNS A 2003 SATURN ION. THE CONTACT STATED THAT A FUEL LEAK WAS PRESENT FROM THE DRIVER'S SIDE REAR WHEEL AREA. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO DIAGNOSED THAT THE FUEL SUPPLY LINE WAS DEFECTIVE AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 178,000.

WHILE DRIVING NOTICED INCREASE OF SPEED. CHECKED ACCELERATOR PEDAL, NOT STUCK. TAPPED ACCELERATOR WITH NO CHANGE. DEPRESSED THE BRAKE AND SLOWED DOWN AND STOPPED. SHUT VEHICLE OFF AND VERIFIED THE THROTTLE BODY WAS IN IDLE POSITION. RESTARTED CAR AND VEHICLE RPM WENT UP TO 4000 AND STARVED FOR AIR AND SURGED UP AND DOWN AT THAT LEVEL. SHUT VEHICLE OFF AGAIN AND CONTACTED GM. SAME VEHICLE ALSO HAS PASSLOCK PROBLEMS.

2003 SATURN ION. CONSUMER WRITES IN REGARDS TO REIMBURSEMENT FOR FAULTY IGNITION RECALL REPAIRS. *SMD THE CONSUMER STATED UPON RETURNING TO HER VEHICLE, SHE DISCOVERED SHE WAS UNABLE TO USE THE REMOTE, SO SHE USED THE KEY, INSTEAD. SHE ATTEMPTED TO PLACE THE KEY INSIDE THE IGNITION AND DISCOVERED THE SLOT WAS NOT IN THE OFF POSITION. THE VEHICLE WOULD NOT START DUE TO THE IGNITION NOT BEING IN THE OFF POSITION AND ENABLING HER TO PULL THE KEY OUT, AS THE BATTERY WAS DEAD. IT WASN'T UNTIL JANUARY 7, 2014, SHE BEGAN EXPERIENCING PROBLEMS AGAIN WITH THE IGNITION, AND THE BATTERY DIED AGAIN. AFTER THE VEHICLE WAS JUMP STARTED, THE CONSUMER SMELLED GAS. IT WAS DETERMINED THE REAR FUEL LINE HAD CORRODED, WHICH FORMED HOLES AND GAS WAS POURING OUT THE HOLES ON BOTH SIDES.

SIGNIFICANT RUST AND STRESS FRACTURES ON FUEL LINE RESULTING IN NOTICEABLE FUEL LEAKAGE WITH THE POTENTIAL OF INCENDIARY INCIDENT IN THE CASE OF COLLISION. AFTER VEHICLE MESSAGE BOARD QUERIES THIS PROBLEM SEEMS TO OCCUR WITH UNUSUAL FREQUENCY IN SATURN IONS SPANNING 2003-2007. PAID OUT OF POCKET TO HAVE THE FUEL LINE REPLACED; WAS TOLD THAT NO RECALL EXISTS FOR THIS PROBLEM SO I WANTED TO REPORT IT. *TR