2005 Saturn Ion Fuel system Problems

My key is stuck in the I can take it out the o2 seners not reading

NHTSA ID

11648021

Incident

Mar 12, 2025

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.

NHTSA ID

11500916

Incident

Jan 7, 2023

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.

NHTSA ID

11207615

Incident

Apr 21, 2019

Mileage

127,000 mi

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.

NHTSA ID

11082692

Incident

Mar 13, 2018

Mileage

115,000 mi

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.

NHTSA ID

11020053

Incident

Aug 26, 2017

Mileage

115,000 mi

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.

NHTSA ID

11001617

Incident

Jun 26, 2017

Mileage

250,000 mi

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.

NHTSA ID

10994377

Incident

Jun 7, 2017

Mileage

100,000 mi

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.

NHTSA ID

10901933

Incident

Aug 26, 2016

Mileage

102,000 mi

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

NHTSA ID

10896889

Incident

Aug 12, 2016

Mileage

102,400 mi

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.

NHTSA ID

10822573

Incident

Dec 23, 2015

Mileage

105,514 mi

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.

NHTSA ID

10811769

Incident

Dec 20, 2015

Mileage

190,000 mi

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.

NHTSA ID

10785866

Incident

Oct 25, 2015

Mileage

116,000 mi

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.

NHTSA ID

10779726

Incident

Sep 28, 2015

Mileage

92,000 mi

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

NHTSA ID

10762569

Incident

Mar 10, 2015

Mileage

130,000 mi

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.

NHTSA ID

10733992

Incident

Sep 19, 2014

Mileage

142,000 mi

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.

NHTSA ID

10730423

Incident

May 15, 2014

Mileage

200,000 mi

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.

NHTSA ID

10662005

Incident

Nov 24, 2014

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

NHTSA ID

10633628

Incident

Sep 10, 2014

Mileage

116,500 mi

THE FUEL LINE HAS RUSTED & LEAKING GASOLINE ONTO THE EXHAUST PIPE NEAR THE DRIVER'S SIDE REAR TIRE. *TR

NHTSA ID

10622387

Incident

Aug 12, 2014

Mileage

200,450 mi

COPY OF EMAIL LETTER TO MS. BARRA (GENERAL MOTORS) REGARDING FRUSTRATION OF BEING A SATURN OWNER. *SMD 2005 SATURN ION. THE CONSUMER STATED SHE NEVER CAME CLOSE, TO GETTING THE GAS MILEAGE AS ADVERTISED. SHE ALSO EXPERIENCED PROBLEMS WITH THE SUSPENSION, AND FOR A LITTLE OVER A YEAR, SHE HAD PROBLEMS WITH THE VEHICLE NOT STARTING. ON ONE OCCASION, WHEN SHE INSERTED THE KEY INTO THE TRUNK, THE ENTIRE TRUNK LOCK FELL INTO THE CAR. THE CONSUMER RECEIVED A RECALL NOTICE, REGARDING THE IGNITION. HOWEVER, THE PARTS WERE NOT AVAILABLE. *JB

NHTSA ID

10614443

Incident

Jul 1, 2014

**THE OTHER AFFECTED PART WAS SPEED CONTROL.... ASIDE OF THE CURRENT RECALL ISSUE HAVING BEEN A PROBLEM SINCE I PURCHASED THE VEHICLE IN 2005 (WHICH HAS "BEEN REPAIRED"-I GUESS SO IF YOU CALL REPAIRED THE CAR TRYING TO START ITSELF, NOT STARTING AT ALL, CURRENT PCM OVERLOAD THANKS TO SOO MANY NEGATIVE CODES BEING THROWN FOR THIS WORTHLESS PIECE OF JUNK.) I HAVE FILED NUMEROUS COMPLAINTS WITH THE DEALERSHIP ABOUT THE THROTTLE BODY AND AM CONSTANTLY AND CONSISTENTLY PROVIDED THE SAME ANSWER AND IT IS BECOMING A BIG PROBLEM. YOU SEE THIS CAR HAS LEFT ME STRANDED NUMEROUS TIMES (TO THE POINT WHERE I CANNOT KEEP COUNT ANY LONGER) BECAUSE THE THROTTLE BODY IS TRASH. NOT ONE BUT TWO CHECK ENGINES LIGHTS APPEAR ON THE DASH, THE CAR SHAKES (LITERALLY TO THE POINT WHERE IT FEELS LIKE EVERY PLASTIC PANEL IS GOING TO FALL OFF), I CANNOT TRAVEL ANY HIGHER THAN APPROX. 10MPH AND HAVE TO PULL OVER, TURN THE CAR OFF (KEYS OF COURSE BECOME STUCK IN THE IGNITION DUE TO THE FAULTY SWITCH) AND WAIT UNTIL MY CAR IS THEN READY TO START AND THE THROTTLE BODY WANTS TO OPERATE AS IT SHOULD. I AM NOW FILING THIS COMPLAINT AS THE MOST RECENT CODES PULLING ARE ONCE AGAIN THE THROTTLE BODY AND THE NOW THE PCM. THIS PART NEEDS TO BE ADDED TO RECENT RECALLS. IT IS NOT SAFE TO BE TRAVELING AT 45MPH OR HIGHER, THEN THE VEHICLE SHUTS DOWN AND LOWERS SPEED TO 10MPH OR LESS-ESP. IF YOU HAVE NO WHERE TO PULL OVER SAFELY (YES, THIS HAS HAPPENED TO ME ON MORE THAN ONCE.) I HAVE MY CAR BACK FROM THE RECALL THE CAR TO STILL WONT START, TRIES TO TURN ITSELF OVER & KEEPS MY KEYS STUCK IN THE IGNITION. MY STEERING COLUMN HAS BEEN BUSTED OPEN ON THE BOTTOM IN ORDER TO RELEASE THE KEYS WHICH IS RIDICULOUS YET MY CAR IS STILL NOT FUNCTIONAL DUE TO OTHER FAULTY, CRAP, JUNK, TRASH (WHATEVER YOU WOULD PREFER TO LIST THEM AS IN THIS DOCUMENTATION) PARTS THAT I WILL MOST LIKELY BE EXPECTED TO PAY FOR YET AGAIN. *TR

NHTSA ID

10605583

Incident

Mar 1, 2006

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.

NHTSA ID

10584198

Incident

Apr 5, 2011

Mileage

80,000 mi

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

NHTSA ID

10575942

Incident

Mar 31, 2014

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

NHTSA ID

10232787

Incident

Dec 18, 2007

Mileage

90,000 mi

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

NHTSA ID

10202238

Incident

Sep 1, 2007

Mileage

5 mi