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Service bulletins for the 2006 Saturn Ion

A bulletin is a manufacturer's communication to its dealers, as NHTSA indexes it. The summary is NHTSA's. The document is the manufacturer's: read it at NHTSA. A bulletin is not a recall, and listing a model year does not mean every vehicle of it is concerned.

739 on file from NHTSA, as of 2026-10-19.

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Only bulletins with component: Fuel system are shown. Show all

Bulletins, newest first
PI14432017-08-15. Service bulletin. FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY. This preliminary informational bulletin provides technicians with infomation on fuel tank replacement and replacement/reftrofit of the matching fuel fill hose.
PIT4943C2017-08-15. Service bulletin. EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL; FUEL SYSTEM, GASOLINE; SERVICE BRAKES, HYDRAULIC. This Preliminary Information communication provides information to the technician about vehicles that have a Service Engine Soon Malfunction Indicator Lamp. Technician may find Diagnostic Trouble Code P0442. Technician will need to review Techlink article from May 2013 titled "Using the Evaporative Emissions System Tester" Technician will need to follow these steps to help diagnose the issue. First after the P0442 has been verified do not disturb any of the fuel system components. The technician now can use the scan tool to close the Evaporative Emissions System. If possible change the tank pressure sensor units from inch_H2O to milimeter_Hg for better resolution. Now the vehicle can be stared to monitor the tank pressure sensor output value for approximately two minutes. If the tank pressure sensor value does change, pressurize the fuel tank side of the purge solenoid with the GE 41413-A / J 41413-A and the necessary adaptors. Now add smoke and allow pressure to stabilize for 2 minutes. If smoke is allowed to pass through the purge solenoid, replace the purge solenoid. If the tank pressure sensor value does not change, then install CH-48096 adaptor between the purge line from the canister and the purge solenoid. With the Evaporative Emissions System closed, pressurize the system through the CH-48096 adaptor and allow the system to completely stabilize, by observing the Press / Vac Gauge for a minimum of 5 minutes. Now add smoke to the system with GE 41413-A / J 41413-A after system stabilization. Now inspect the purge solenoid, engine side, fuel cap, canister vent solenoid filter and any line quick connects. When the leak is unable to be located, test under a vacuum condition. his type of leak may be detected by using the scan tool Purge/Seal function to create a vacuum in the Evaporative Emissions System and then observe the FTP sensor parameter for vacuum decay.
147282017-01-30. Service bulletin. FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY; EQUIPMENT. 14728 - SPECIAL COVERAGE. CERTAIN 2006 CHEVROLET COBALT, PONTIAC PURSUIT, PONTIAC G4, AND SATURN ION VEHICLES AND CERTAIN 2007 CHEVROLET COBALT, PONTIAC G5, AND SATURN ION VEHICLES AND CERTAIN 2008 CHEVROLET COBALT AND PONTIAC G5 VEHICLES MAY HAVE A CRACKED FUEL TANK INLET CONTROL VALVE. VEHICLES THAT HAVE HAD A FUEL-TANK REMOVAL PROCEDURE ARE ESPECIALLY AT RISK FOR THIS CONDITION, AS THE TANK-REMOVAL PROCESS CAN DAMAGE THE INLET CONTROL VALVE. THIS CONDITION MAY CAUSE FUEL OR FUEL VAPOR TO LEAK FROM THE FUEL TANK. A VEHICLE WITH THIS CONDITION MAY DISPLAY AN ILLUMINATED SERVICE ENGINE SOON (SES) LIGHT, LEAK FUEL ONTO THE GROUND UNDER THE REAR OF THE VEHICLE BETWEEN THE REAR TIRES DURING OR AFTER FUELING, OR EMIT A STRONG FUEL ODOR FROM THE REAR OF THE VEHICLE. DEALERS ARE TO REPLACE THE FUEL TANK AND COMPATIBLE FILL PIPE TO CORRECT THE CONDITION.
12191B2017-01-30. Service bulletin. FUEL SYSTEM, OTHER:DELIVERY:FUEL PUMP. 12191B - SPECIAL COVERAGE (REVISED PARTS). SOME 2006 MODEL YEAR PONTIAC PURSUIT, 2006-2007 MODEL YEAR SATURN ION, 2006-2009 MODEL YEAR CHEVROLET COBALT, 2007-2009 MODEL YEAR CHEVROLET EQUINOX, PONTIAC G5, AND TORRENT, AND 2008-2009 MODEL YEAR CHEVROLET UPLANDER AND PONTIAC MONTANA SV6 VEHICLES MAY HAVE A CONDITION IN WHICH THE PLASTIC SUPPLY OR RETURN PORT ON THE FUEL PUMP MODULE MAY CRACK. IF EITHER OF THESE PORTS DEVELOP A CRACK, FUEL WILL LEAK FROM THE AREA. THE CUSTOMER MAY NOTICE A FUEL ODOR WHILE THE VEHICLE IS BEING DRIVEN OR AFTER IT IS PARKED. IF THE CRACK BECOMES LARGE ENOUGH, FUEL MAY BE OBSERVED DRIPPING ONTO THE GROUND AND VEHICLE PERFORMANCE MAY BE AFFECTED. IF A VEHICLE INVOLVED IN THIS SPECIAL COVERAGE DEMONSTRATES THE CONDITION OR SYMPTOMS DESCRIBED ABOVE, DEALERS ARE TO REPLACE THE FUEL PUMP MODULE, AND ON 2006-2008 MODEL YEAR CHEVROLET COBALT, PONTIAC PURSUIT, G5, AND SATURN ION VEHICLES, DEALER ARE TO ALSO REPLACE THE FUEL TANK AND FUEL FILLER PIPE OR FILLER HOSE, IF NECESSARY, REGARDLESS OF THE VEHICLE'S AGE OR MILEAGE.
09275C2017-01-30. Service bulletin. FUEL SYSTEM, OTHER:DELIVERY:FUEL PUMP. 09275C - SPECIAL COVERAGE (REVISED PARTS). SOME 2006 MODEL YEAR CHEVROLET COBALT, PONTIAC G4, AND SATURN ION VEHICLES ORIGINALLY SOLD OR CURRENTLY REGISTERED IN ALABAMA, ARKANSAS, CALIFORNIA, FLORIDA, GEORGIA, HAWAII, LOUISIANA, MISSISSIPPI, NORTH CAROLINA, NEW MEXICO, OKLAHOMA, SOUTH CAROLINA, TENNESSEE, AND TEXAS; AND SOME 2007 MODEL YEAR CHEVROLET COBALT, PONTIAC G5, AND SATURN ION VEHICLES ORIGINALLY SOLD OR CURRENTLY REGISTERED IN ALABAMA, ARKANSAS, GEORGIA, HAWAII, LOUISIANA, MISSISSIPPI, NORTH CAROLINA, NEW MEXICO, OKLAHOMA, SOUTH CAROLINA, AND TENNESSEE MAY HAVE A CONDITION IN WHICH THE PLASTIC SUPPLY OR RETURN PORT ON THE MODULAR RESERVOIR ASSEMBLY (MRA) MAY CRACK. IF EITHER OF THESE PORTS DEVELOP A CRACK, FUEL WILL LEAK FROM THE AREA. THE CUSTOMER MAY NOTICE A FUEL ODOR WHILE THE VEHICLE IS BEING DRIVEN OR AFTER IT IS PARKED. IF THE CRACK BECOMES LARGE ENOUGH, FUEL MAY BE OBSERVED DRIPPING ONTO THE GROUND AND VEHICLE PERFORMANCE MAY BE AFFECTED. IF A VEHICLE INVOLVED IN THIS SPECIAL COVERAGE DEMONSTRATES THE CONDITION OR SYMPTOMS DESCRIBED ABOVE, DEALERS ARE TO REPLACE THE FUEL PUMP MODULE, AND IF NECESSARY, THE FUEL TANK AND FUEL TANK FILLER PIPE OR FILLER HOSE, REGARDLESS OF THE VEHICLE’S AGE OR MILEAGE.
14728A2017-01-30. Service bulletin. FUEL SYSTEM, OTHER. 14728A - SPECIAL COVERAGE (REVISED PART INFORMATION). CERTAIN 2006 CHEVROLET COBALT, PONTIAC PURSUIT, PONTIAC G4, AND SATURN ION VEHICLES AND CERTAIN 2007 CHEVROLET COBALT, PONTIAC G5, AND SATURN ION VEHICLES AND CERTAIN 2008 CHEVROLET COBALT AND PONTIAC G5 VEHICLES MAY HAVE A CRACKED FUEL TANK INLET CONTROL VALVE. VEHICLES THAT HAVE HAD A FUEL-TANK REMOVAL PROCEDURE ARE ESPECIALLY AT RISK FOR THIS CONDITION, AS THE TANK-REMOVAL PROCESS CAN DAMAGE THE INLET CONTROL VALVE. THIS CONDITION MAY CAUSE FUEL OR FUEL VAPOR TO LEAK FROM THE FUEL TANK. A VEHICLE WITH THIS CONDITION MAY DISPLAY AN ILLUMINATED SERVICE ENGINE SOON (SES) LIGHT, LEAK FUEL ONTO THE GROUND UNDER THE REAR OF THE VEHICLE BETWEEN THE REAR TIRES DURING OR AFTER FUELING, OR EMIT A STRONG FUEL ODOR FROM THE REAR OF THE VEHICLE. DEALERS ARE TO REPLACE THE FUEL TANK AND COMPATIBLE FILL PIPE TO CORRECT THE CONDITION.
09275B2016-06-09. Service bulletin. FUEL/PROPULSION SYSTEM. SUMMARY TO BE PROVIDED ON A FUTURE DATE.
SB-0000164-141-A2016-03-31. Service bulletin. FUEL SYSTEM, OTHER:DELIVERY:FUEL PUMP; FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP. SUMMARY TO BE PROVIDED ON A FUTURE DATE.
SB-12191-A2016-03-16. Service bulletin. FUEL SYSTEM, OTHER:DELIVERY:FUEL PUMP; FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP. SUMMARY TO BE PROVIDED ON A FUTURE DATE.
SB-12191-A2016-03-16. Service bulletin. FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP. SUMMARY TO BE PROVIDED ON A FUTURE DATE.
SB-121912013-04-22. Service bulletin. FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP; FUEL SYSTEM, OTHER:DELIVERY:FUEL PUMP. CHEVROLET/PONTIAC/SATURN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. ON FUEL PUMP MODULE, PLASTIC SUPPLY OR RETURN PORT MAY BE CRACK AND WILL DEVELOP A FUEL LEAKAGE WHEREBY FUEL ODOR IS NOTICED, WHEN DRIVEN OR PARKED. PARTS AVAILABILITY WILL DONE IN PHASES. 2006-2009 COBALT, 2007-2009 G5, 2006-2007 ION, 2006 PURSUIT AND THEN 2008-2009 EQUINOX, UPLANDER, MONTANA SV6, TORRENT. *PE UPDATED 10/17/13. *PE UPDATED 11/6/15. *PE
SB-092752010-06-25. Service bulletin. FUEL SYSTEM, OTHER:DELIVERY:FUEL PUMP; FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP. SATURN/PONTIAC/CHEVROLET: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. SPECIAL COVERAGE ADJUSTMENT; FUEL ODOR OR SPOTTING ON GROUND; REPLACE FUEL PUMP MODULE. SOME VEHICLES MAY HAVE A CONDITION IN WHICH PLASTIC SUPPLY OR RETURN PORT ON MODULAR RESERVOIR ASSEMBLY (MRA) MAY CRACK. MODELS 2006-07 COBALT, G4, ION, 2007 G5. *PE UPDATED 7/1/10. *PE UPDATED 6/26/13. *PE UPDATED 10/30/15. *PE
36452006-02-23. Service bulletin. FUEL SYSTEM, OTHER:STORAGE:FUEL GAUGE SYSTEM. SATURN ONLY-FUEL GAUGE READS BELOW FULL AFTER FILLING THE FUEL TANK. *AK
36272006-01-09. Service bulletin. FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP. FUEL TANK IS SLOW TO FILL AND/OR DTC P0446 - INSPECT EVAP VENT PIPE. THE SES LAMP MAY BE ILLUMINATED DUE TO A P0466 DTC. *TT UPDATED 08-15-07. *KB

The summaries are NHTSA's. Each bulletin's page links NHTSA's copy of the manufacturer's document.