Fuel line rusted out near fuel filter and directly above exhaust pipe. Large puddle of fuel on ground after car was shut off. When restarted, fuel continued to flow out of rusted fuel line and onto the exhaust pipe.

- Hicksville, NY, USA

The contact owns a 2004 Saturn Ion. While driving at various speeds, the steering wheel seized without warning. The contact stated that there was also a smell of fuel coming from the vehicle. The contact stated that the steering shaft and fuel lines failed and needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 20,000.

- Clinton Township, MI, USA

On the 20th of July I noticed a very strong smell of gasoline in my garage. I checked the gas can for my lawn equipment and it was not the source on the odor. I backed out of the garage and noticed a somewhat substantial puddle of gas right in front of where my rear tire was. As the car was still running I looked under the car at the suspect location and noticed steady drips coming from under a plastic clip which held the fuel lines. Further investigation showed that the fuel lines had rusted through right at that clip. After reading up on this problem it seems that this is a extremely common problem which affects both Ion and cobalt vehicles since I believe they are "delta" bodies. Due to the nature and the amount of occurrences this problem should be addressed by GM. It is my only vehicle and I do not have the 400-500 dollars to repair this. A recall should be issued since the leak is scant inches from the exhaust pipe and therefore is a safety issue and a severe fire hazard. GM should cover the cost of the repair. I am the original owner of the car.

- Beloit , WI, USA

After having my emissions tested in wi in which it passed at the time on or about May 27, 2015. About a week latet, I began to smell a gasoline smell coming from the diiver's side of the car, after I drove it and then parked it and turned off the ignition. I didn't see anything dripping from the car to the grounc, I noticed that the smell of gasoline became more and more prevalent until about June 17, 2015 when the smell was so great and I hadnt driven the car for well over a week because I was afraid something was leaking or would happen while driving. My brother smelled it also when I backed up and pulled forward. We checked under hood, but nothing and no spots on the ground. Took it to a garage and the mechanic and owner said that the fuel lines, fuel filter, etc. Needed replacing and R which cost approximately $263.. I also looked up information by a mechanic who states that every signgle cobalt and Ion have this same problem since the cars were built. He gave a description of what it takes to remove and replace fuel lines, fuel filter, etc. Whenever I took out the car, that car could have exploded or started an engine fire. This is a dangerous situation that could have involved the loss of not only the vehicles, but peoples lives. I firmly believe that GM should have to have these vehicles on recall for this very dangerous malfunction of the fuel tank, fuel filter and fuel lines and be required to pay for these repairs on the cars affected. Thank you for your consideration in this situation.

- St. Francis, WI, USA

The contact owns a 2004 Saturn Ion. The contact stated that the fuel filter and fuel lines prematurely rusted without warning. The vehicle was taken to the authorized dealer who diagnosed that the two fuel lines needed to be replaced as well as the fuel filter. The contact was not included in NHTSA campaign number: 04V003000 (fuel system, gasoline). The manufacturer was notified of the failure. The approximate failure mileage was 137,000.

- Newfield, NJ, USA

Gas leaking near the door behind the driver. Strong smell of inside car as well still waiting to hear from dealer. This model may not be part of the recall from GM it does seen to be a common issue this is a real fire danger..

- Fairfield, OH, USA

While under the rear of the car to fix the exhaust system, it became apparent that the fuel lines in the location under the trunk and behind a flexible shield are extremely and severely rusted and corroded. They are corroded to the point where they could potentially leak at any moment. The fuel lines are pressurized during and after operation of the vehicle and also run very close to a hot exhaust pipe. Not only is this a reliability issue, but more so, it is an incredible safety hazard and needs to be addressed. After doing some internet searching I found numerous complaints of other Ion owners with the exact same condition - many who have had leaks and either required towing, or experienced a fuel spill. Dealer wants $800 to fix. This is not a normal wear item.

- Rockaway, NJ, USA

The contact owns a 2004 Saturn Ion. The contact stated that there was a strong odor of fumes coming from the vehicle. The vehicle was taken to a dealer, who diagnosed that the fuel pump needed to be replaced due to an internal failure with the fuel pump module. The VIN was not included in NHTSA campaign numbers: 04V003000 (fuel system, gasoline), 12V459000 (fuel system, gasoline) and 09V419000 (fuel system, gasoline). The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 57,000.

- Middletown, NJ, USA

Gas started to pour out of my car creating a hazard. Took it to auto-lab and was told there was a rusted fuel line which is common with Saturn Ion.

- Mount Pleasant , MI, USA

The contact owns a 2004 Saturn Ion. The contact smelled a strong fuel odor near the vehicle. The dealer stated that the seals around the fuel pump and the fuel pump itself needed to be replaced. The vehicle was not repaired. The manufacturer stated that the VIN was not included in NHTSA campaign numbers: 04V003000 (fuel system, gasoline), 04V281000 (fuel system), and 09V419000 (fuel system, gasoline). The VIN was unavailable. The approximate failure mileage was 64,654.

- Joppa, MD, USA

The contact owns a 2004 Saturn Ion. The contact stated that fuel fumes were emitted in and around the vehicle. The contact mentioned that after refueling to capacity, the fuel gauge read that there was only half tank of fuel left. Also, the contact noticed a puddle of fuel on the ground near the rear of the vehicle. The vehicle was not taken to a dealer or independent mechanic for a diagnosis. The manufacturer was not notified of the failure. However, the contact was made aware that the VIN was not included in NHTSA campaign number: 04V003000 (fuel system, gasoline). The approximate failure mileage was 52,000.

- Springfield , MA, USA

The contact owns a 2004 Ion Saturn. The contact stated that she noticed gasoline fuel had spilled on the ground while the vehicle was parked. The contact's personal mechanic inspected the vehicle and found that one of the fuel lines was corroded and leaking. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure and current mileage was 172,000.

- Hinckley , MN, USA

The contact owns a 2004 Saturn Ion. The contact stated that fuel was leaking into the engine. The vehicle was taken to an independent mechanic and the technician diagnosed that the fuel filter was corroded causing the leak. As a result, the fuel filter and fuel lines needed to be replaced. The manufacturer was made aware of the failure but did not offer any assistance since the vehicle had already been repaired under recall NHTSA campaign number: 04V281000 (fuel system, other). The vehicle was repaired. The VIN was not available. The failure mileage was 90,000 and the current mileage was 100,000.

- Stamford, CT, USA

The portion of the fuel lines near the fuel pump, which is hidden by a flexible cover underneath car, was discovered to be severely rusted nearly to the point of leaking, requiring fuel line replacement. In contrast, the portion of the fuel lines exposed underneath car was still in pristine condition. (car has been garaged at night since delivery.) service manager said that recently they have been finding many Saturn Ions with this condition. Although GM has issued a recall for fuel pump leaks, the problem often is instead the fuel line has rusted through and is leaking. This problem would not be expected, and thus appears to be due to a Saturn design or manufacturing defect. Because of the prevalence and significant safety issue, the service manager expects GM will eventually issue a recall for the fuel line problem. Because the portion of the fuel line subject to severe rusting is hidden behind the flexible cover underneath the car and not the exposed section, it is likely to be noticed only after leaking occurs, resulting in a fire hazard. A recall appears desirable to inspect particularly the hidden portion of the fuel lines near the fuel pump and replace them if needed. Although a manufacturer must provide a remedy to safety-related defect a no cost to the owner, in this instance GM refuses to pay for the fuel line replacement unless the NHTSA compels them to issue a recall.

- Wilmington, DE, USA

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 claim was denied.

- Newport News, VA, USA

Started leaking gas from fuel filter and I checked on line for recalls and was one for that vehicle I called Saturn they said there wasn't.

- Buffalo, NY, USA