This service bulletin provides information for maintenance cleaning of the fuel injectors and gasoline detergent additive.
full bulletin at NHTSA ↗2007 Saturn Ion fuel system problems
moderate 75 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Failure mileage
Complaints
75
Recalls
0
Avg fix
$1,200
1crash
1injury
When does it fail?
Of the 75 fuel system complaints filed for the 2007 Saturn Ion, here's the actual mileage breakdown — failures cluster heaviest at 50,000-75,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Owners have filed 75 fuel system complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
No new NHTSA fuel system complaint has been filed on this vehicle in over 11 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering fuel system on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
This service bulletin provides the technician with additional information on fuels, fuel additives and fuel management.
full bulletin at NHTSA ↗This service bulletin provides information for maintenance cleaning of the fuel injectors and gasoline detergent additive.
full bulletin at NHTSA ↗This Preliminary information communicates provides information to the technician on the use of R-99 or R-95 Renewable diesel fuel.
full bulletin at NHTSA ↗This service bulletin provides technicians with updated information to help identify the differences between what is considered a fluid leak, and what is considered fluid seepage.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners consistently report fuel-system leaks from the fuel pump module and fuel tank, frequently accompanied by strong gasoline odors inside and outside the vehicle. The leaks occur at various points: the fuel pump module itself (which cracks or fractures), the connection between the filler neck and tank, fuel lines (including rust-through failures on hidden sections covered by protective covers), and the fuel tank seams. Many report detecting the problem early as a smell, then discovering visible leaking fuel, drips under the vehicle, or fuel streaming from the rear tire area.
Repair costs owners cite range from approximately $198 to $988, typically involving fuel pump module replacement, fuel tank replacement, or fuel line repair. Several owners report the fuel pump is designed with plastic lines molded into the assembly, which cracks under vibration—a design flaw. Complicating matters, recalls (campaign numbers 09V419000 and 12V459000) were issued for only certain states; many owners discovered their VIN was excluded despite having identical failures. A few owners report repair shops blamed impact damage or dismissed owner concerns, and some dealers refused coverage citing warranty limits or claiming the defect doesn't apply outside recall states. One owner reported a fuel pump replacement followed by fuel tank failure, allegedly caused by the technician dropping the tank during the pump service.
Same Saturn Ion fuel system reports on nearby years: 2006
Failure modes owners describe
Fuel pump module cracking/fracturing
The plastic fuel pump module develops cracks or fractures, causing fuel leakage. This is the most frequently reported failure mode.
When: Typically between 20,000 and 126,000 miles; many occur in early ownership (20k-88k range)
Symptoms owners cite: Strong gasoline odor inside and outside vehicle; Visible fuel dripping or leaking from rear tire area or under vehicle; Fuel pooling on driveway or garage floor; Engine sluggish or stalling; Check engine light illumination
Codes mentioned: P0606 (mentioned in one narrative with check engine light)
Repairs/costs cited: Fuel pump module replacement typically costs $198–$600 for parts; dealers and independent shops both perform this repair. One owner reported paying $513; another $600; another $450 at a third-party shop versus $974 at dealer.
Recalls/TSBs owners mention: Recalls issued under NHTSA campaign 09V419000 and 12V459000, but limited to certain states. Many owners' VINs excluded despite identical failures. GM sometimes refused coverage outside recall scope or beyond warranty period. One owner reported GM offered 50% compensation for out-of-warranty repair.
Fuel tank leaking/cracking at seams and filler neck
Fuel tank develops leaks at the seam where the plastic filler neck is molded or mated to the tank, or at the tank base. Some tanks show rust-through in hidden sections covered by protective shields.
When: Ranging from early ownership to 80,000 miles; one reported rust damage at 53,951 miles on hidden fuel lines
Symptoms owners cite: Strong gasoline odor; Visible fuel leak from rear tire area or under vehicle, sometimes streaming out; Fuel leak worse when tank is more than 3/4 full or during acceleration; Leaks may disappear temporarily if parked on downward incline, then reappear
Repairs/costs cited: Full fuel tank replacement costs $695–$988 depending on dealer; one owner paid $831 for tank plus labor. Fuel line rust-through repairs mentioned but costs not specified. Repairs sometimes required after fuel pump replacement service if tank was dropped by technician.
Recalls/TSBs owners mention: No manufacturer response documented in most narratives. One dealer claimed tank leak was not covered under recall and required full replacement. GM refused to pay for fuel line replacement unless compelled by NHTSA recall.
Plastic fuel lines cracking and rusting
Fuel pump assembly includes plastic fuel lines molded into the top of the pump that crack under vibration. Separately, hidden fuel lines covered by protective shields rust through despite sheltered location; exposed lines remain pristine.
When: Fuel pump plastic lines: around 70,000 miles. Fuel line rust: 53,951 miles (hidden sections)
Symptoms owners cite: Gasoline smell, initially faint; Small fuel leak at pump connection, later worsening when pressure line cracks; Fuel pooling under vehicle; Severe rust on hidden fuel line sections near fuel pump
Repairs/costs cited: Fuel pump replacement $600 in one narrative. Fuel line replacement cost not specified by owner but GM refused to cover it absent a recall. New pump had identical plastic-line design to original failure.
Recalls/TSBs owners mention: GM design unchanged: replacement pumps shipped with same plastic-line configuration as failed originals. Service manager expected eventual recall for fuel line rust damage. GM refused to pay for fuel line repair outside of recall mandate.
Engine stalling and fuel pump module electrical failure
Vehicle loses power while driving, engine stalls without warning lights, or fails to start. Some cases involve internal open wires in fuel pump harness or no power reaching the fuel pump module.
When: Various speeds and conditions; one occurred at idle (red light), another mid-drive at 55 mph with multiple dashboard lights illuminating
Symptoms owners cite: Check engine light (on some vehicles); Engine dies while driving or at rest; requires key cycling to restart; Fuel odor present; Difficulty starting; Multiple dashboard warning lights (ABS, battery, power steering, oil, odometer) illuminating simultaneously; Fuel pump module electrical harness with internal open wires
Codes mentioned: Code for fuel system (mentioned in one case; specific code not provided)
Repairs/costs cited: One repair involved fuel pump replacement, tank removal, harness inspection, and replacement of upper fuel pump due to internal open wires. Cost not specified.
Recalls/TSBs owners mention: GM suggested owner 'drive to see if it might happen again' despite frequent recurrence. Manufacturer informed some owners VIN not in recall, thus no coverage.
Fuel system odor without visible leak (transient)
Owner detects strong gasoline smell inside vehicle cabin or around exterior, but no visible leak detected initially. Smell may come and go.
When: Early in ownership or at variable mileage (reported between 40,000 and 80,000 miles); one case after recall repair
Symptoms owners cite: Overpowering gasoline smell when starting, driving, or while parked; No visible fuel leak initially; Smell sometimes resolves or becomes undetectable
Repairs/costs cited: One owner reported fuel pump replacement had no effect; smell persisted post-repair. No diagnosis of fuel leak confirmed, suggesting possible EVAP or charcoal canister issue or incomplete repair.
Recalls/TSBs owners mention: One owner reported no further manufacturer action after repair; smell continued despite pump replacement.
Synthesized from 75 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 2 most recent
Bill Dodge auto group, westbrook me 04092, invoice 841019, customer states can smell fuel check for leak, 00 diag and replace leaking fuel pump and sender. 8986 cgm $us 198.00,1 19257125 nb- (s) module kit $390.32. Parts 390.32 labor 198 other 0 total $588.32 62491 fuel sending unit found fuel leaking by tank area, removed tank and found sending unit return line broken of sending unit, will…
Tl* the contact owns a 2007 Saturn ion. The contact stated that fuel was leaking into the muffler abnormally. The vehicle was taken to a local mechanic who diagnosed that the fuel pump module fractured and would need to be replaced. The manufacturer was made aware of the failure who did not offer any assistance since the vehicle was not included in the recall under NHTSA campaign id number:…
Had fuel system trouble with your 2007 Saturn Ion?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the fuel system problem on the 2007 Saturn Ion?
It's a documented issue but not catastrophic. 75 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
At what mileage does the fuel system typically fail?
Across the 62 complaints that reported odometer mileage, most fuel system failures cluster between 47,000 and 90,000 miles, with the median around 68,000. A quarter of owners report trouble before 47,000; a quarter make it past 90,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $1,200 for fuel system repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to fuel system?
No active recalls currently cover fuel system issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2007/Saturn/Ion.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.