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Old 07-19-2014, 11:02 AM   #1
cajun1965
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2007 ION-3 Quad Coupe
Default fuel leak when tank is full

2007 ION bought it used, am happy with the way it handles and drives. I noticed when Ifill the gas tank completely full that gas will leak out of the tank and I am not sure why. once it gets around 3/4 full the leak stops. I thought there was a recall on the fuel pump or something like that. would love some advice I am new to the Saturn world.

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Old 07-19-2014, 01:33 PM   #2
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Default Re: fuel leak when tank is full

Call the nearest Chevy dealer VIN in hand and ask if the fuel system recall has been done.

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Old 07-19-2014, 02:14 PM   #3
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Default Re: fuel leak when tank is full

Did you try looking under the car to examine for any severe rust/corrosion anywhere related to the fuel system?

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Old 07-19-2014, 08:24 PM   #4
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Default Re: fuel leak when tank is full

sounds like you have a rusted pump retaining ring...

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Old 07-20-2014, 10:36 AM   #5
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Default Re: fuel leak when tank is full

Quote:
Originally Posted by 2006 ion2 View Post
sounds like you have a rusted pump retaining ring...
Good call. I've seen that in other makes-easy place to collect moisture/corrode. Time for someone to take a closer look.

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Old 07-20-2014, 10:42 AM   #6
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Default Re: fuel leak when tank is full

Quote:
Originally Posted by eneloop View Post
Call the nearest Chevy dealer VIN in hand and ask if the fuel system recall has been done.
This issue?
http://www.autoblog.com/2009/11/04/g...ontiac-g5-mod/
"
The problem involves 2006 Cobalt and Ion model models sold or registered in Arizona and Nevada and 2007 Cobalt, G5 and Ion models sold or registered in Arizona, California, Texas, Florida and Nevada.

NHTSA says the plastic supply or return port on the cars' modular reservoir assembly may crack, potentially leading to a fuel leak that could cause cause decreased efficiency and performance. Worse, if that leaking gasolinecomes into contact with an ignition source of any kind, you could be looking at a Delta platform car-b-que.

To fix the fuel leak problem, company dealerswill replace the fuel pump module of affected vehicles free of charge. GM is also providing a special coverage for 2006 and 2007 Cobalt, G5 and Ion models in other warm weather states, and you can hit the jump to read over the NHTSA press release to see if you live in a participating location. GM hasn't yet provided a time frame for owner notification, but if you have questions you can read the official press release after the jump or call 1-800-630-2438 (Cobalt), 1-800-972-8876 (Ion) or 1-800-620-7668 (G5).

[Source: NHTSA]"
http://www-odi.nhtsa.dot.gov/owners/SearchSafetyIssues

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Old 07-20-2014, 07:02 PM   #7
cajun1965
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2007 ION-3 Quad Coupe
Default Re: fuel leak when tank is full

Thank you for the reply, I have not filled the tank up full again but will do so soon to see if I can tell where the gas is coming from. I did call local Chevy dealership that use to sell the Saturns, says they don't know about the fuel leak issue recall, but I will have verify where the car was originally sold at.

I will post again when I find out something with the gas issue. Once again thanks for the reply.

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Old 07-20-2014, 07:16 PM   #8
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Default Re: fuel leak when tank is full

Could also be a loose/cracked filler neck

...
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Old 07-22-2014, 10:33 AM   #9
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2007 ION-3 Quad Coupe
Default Re: fuel leak when tank is full

All right, just came from under the car to look at fuel tank to find where the fuel is leaking from. It appears that it is coming from the filler neck on the fuel tank.
is there a fix for this or will i need to find a new / used tank to fix the issue.

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Old 07-22-2014, 12:04 PM   #10
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2007 ION-3 Quad Coupe
Default Re: fuel leak when tank is full

fuel tank.jpg

Here is an image of the fuel filler neck.

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Old 07-23-2014, 08:27 PM   #11
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2004 ION-3 Quad Coupe
Default Re: fuel leak when tank is full

You can buy a two part fuel tank repair mix from advance auto. I did that to a lawn mower gas tank and it has held up well and it is advertised for vehicles. 10.00 but honestly it might be just as easy to get the new tank. If it is covered under a recall then have them fix it.

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Old 07-23-2014, 10:12 PM   #12
2006 ion2
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Default Re: fuel leak when tank is full

There is no recall for the filter neck cracking. It's not even a common/known issue with ions/cobalts.

...
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2003 Chevrolet venture lt

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Old 07-25-2014, 08:48 AM   #13
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Wrench Re: fuel leak when tank is full

Thanks for all the input and advice on the fuel tank issue. I have been digging around for replacement tanks and have not found a good source for the tank. If you know of any good web sites for replacement tanks would greatly appreciate it. i have found some used tanks but not sure if I want to go that way just yet.
I am going to try to patch the leak, just to see if I can, in the mean time I will be looking for a new replacement tank.

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Old 07-26-2014, 12:14 AM   #14
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Default Re: fuel leak when tank is full

Rock auto, all the major parts stores, dealerships. Anywhere else is a crap shoot for fit and quality.

...
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Old 08-09-2014, 01:07 AM   #15
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2007 ION-2 Quad Coupe
Default Re: fuel leak when tank is full

Add me to this list. I've been noticing a fuel smell for the last month or so. I just got around to inspecting for leaks tonight. Sure enough, there is a crack right along the seam where the plastic spout (the extension that the rubber section attaches to) is mated/molded to the main reservoir on the fuel tank.

The only new replacement fuel tank is that is available is the OEM part from a GM stealership. The part number is 20870462 and it retails for $695 ($481.05 discounted price). When I get a chance, I hope to patch it up good with some two-part fuel tank repair epoxy without dropping the tank, but I may need to drop the tank so I can properly prep the surface. I've had great results with the repair epoxy in the past.

...
2007 Ion 2 Quad Coupe 5-speed manual 175K miles
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Old 08-09-2014, 07:55 AM   #16
2006 ion2
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Default Re: fuel leak when tank is full

Everybody file complaints with nhtsa. There should bea recall on this if it's a widespread problem.

...
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Old 08-09-2014, 10:07 AM   #17
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Default Re: fuel leak when tank is full

Quote:
Originally Posted by 2006 ion2 View Post
Everybody file complaints with nhtsa. There should bea recall on this if it's a widespread problem.
I just submitted a complaint last night.

I have access to a plastic welder, so I'm tempted to use that instead of the repair epoxy. I probably won't get to it until sometime this next week.

...
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Old 08-17-2014, 11:46 AM   #18
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Default Re: fuel leak when tank is full

I went ahead and installed a used fuel tank. I believe it was also leaking from the area circled in the first picture below. I was also happy to see that the fuel pump/module had already been replaced by a previous owner.

old leaky tank.jpg


The two round parts you see in the picture below are molded into the fuel tank and are not serviceable. I'm not exactly sure what they are, but they appeared to be EVAP system check valves that let air/vapor (but not liquid fuel) vent from one side of the tank to the other as necessary. The purge canister also connects to these parts.

used_tank.jpg


My car has federal emissions (option code NT7). All 2006-2007 Ions use this same fuel tank EXCEPT those with option code NU6. The 2003-2004, and 2005 fuel tanks are different from each other and different from 2006-2007 fuel tanks.

Another interesting thing that I learned was there is a check valve that resides in the fuel tank for the the filler neck spout. Once fuel goes in, it can't come back out.

...
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