The 2004 Saturn Ion has 53 fuel system complaints filed with NHTSA — 5% of the year's total, and up sharply from the prior model year.
53
Fuel System complaints
5%
Share of year
0
Crash-involved
2
Related recalls
Defect
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.
Consequence
FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
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.
Defect
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.
Consequence
IF CORROSION ON THE EXTERIOR SURFACE OF THE FUEL FILTER PROGRESSES TO THE POINT OF CREATING A HOLE IN THE SHELL, FUEL DROPLETS COULD FORM AND DROP TO THE GROUND. IF AN IGNITION SOURCE IS PRESENT, A FIRE COULD RESULT.
Remedy
DEALERS WILL REPLACE THE FUEL FILTER ASSEMBLY. OWNER NOTIFICATION BEGAN ON DECEMBER 30, 2003. OWNERS SHOULD CONTACT SATURN AT 1-800-972-8876.
“OUR CAR, 2004, SATURN ION3, CAUGHT ON FIRE IN THE DRIVEWAY ON IT'S OWN ABOUT 2 HOURS AFTER IT WAS DRIVEN HOME ON 4 NOV 2011. NO DRIVER - NO KEY IN THE VEHICLE WHEN IT CAUGHT FIRE. I SUBMITTED AN INITIAL REQUEST FOR REVIEW TO GM CLAIMS ALONG WITH ALL DOCUMENTATION THAT WE HAD VIA EMAILS AND OUR…”
NHTSA has 53 complaints about the 2004 Saturn Ion fuel system — 5% of all complaints filed for that model year.
Yes — 2 NHTSA recall campaigns for this model year are tied to the fuel system: 04V003000, 04V281000.
Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.
Compiled by Sharon Ben-Moshe, Founder.