I replace the Fuel Pump & Housing Assembly on a 2006 saturn ion 2 when i fill the tank up with gas the gauge stop just below the full mark it was working okay before i replace the Fuel Pump & Housing Assembly what i need to do to fix the problem?
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If you haven't replaced the fuel filter in the last year or so, do it now-basic maintenance.
Check if the pump is working by turning key to ON (not crank), and listen for the pump in the tank to come on for a couple of seconds. Should hear a short hum or buzz verifying tank is working. If you don't hear it come on, either the pump is bad, or power is not reaching it. May have to pull the pump connector off at tank, and check for 12 volts on pump wire when someone cranks the car. If power there, the pump must be bad. If no power there at pump, check fuses for pump and fuel pump relay.
Unfortunately......you have a gas sending unit that has failed....and yes it is located in the fuel tank...these GMs have had a very notorious tsb for the fuel tank pump and unit assembly failing due to design.....theres nothing you can do to repair this ....but you can replace this unit.....it's kind of a bear with a full tank of gas if you're gonna be doing this yourself....on the ground...this fuel tank pump unit is found quicker and more reliably at the dealership. ...HOPE I HELPED!!!!!
i just had the same issue . . .I have been having starting problems with my car (2006 Saturn Ion) and smelling gasoline. It turns out the hose connected to the fuel pump was cracked and leaking gas. The mechanic said that this is a safety issue and should be recalled. He feels that the one hose is not connected and harnessed properly and the vibration to the hose eventually caused the crack. I googled "Saturn 2006 Ion fuel leak" and several other people have had the same issue. What is also the major problem here is that the hose is configured with the fuel pump itself. So, the entire mechanism had to be replaced. It cost me 700.00 for a cracked hose because the fuel pump had to be replaced and my car only is 46,000 miles. This is a major safety issue. I drove for 2 weeks with a car that was leaking fuel. Saturn must know about this and is waiting for the same situtation to happen, but for the car to blow up instead. PLEASE IF YOU ARE READING THIS CAUSE YOU HAVE THE SAME ISSUE . . . . contact the office of defects and the NHTSA . . .This is a saftey issue and a recall needs to be in affect . . .