2006 saturn ion stalls

Experiencing random stalling issues with your 2006 Saturn Ion can be frustrating. There could be several potential causes for this problem, and it would be best to have a qualified mechanic perform a thorough diagnosis. However, here are a few common issues to consider: 1. Faulty Ignition Switch: A faulty ignition switch can cause intermittent loss of power and result in the engine shutting off unexpectedly. If the switch is worn or damaged, it may disrupt the electrical connection to the engine, causing the stalling. Consider having the ignition switch inspected and potentially replaced if necessary. 2. Fuel Delivery Issues: Insufficient fuel supply or a malfunctioning fuel pump can lead to engine stalling. Check for fuel-related problems such as a clogged fuel filter, a failing fuel pump, or issues with the fuel injectors. A mechanic can perform fuel pressure tests to assess the fuel delivery system. 3. Electrical System Problems: Issues with the electrical system, such as loose or corroded connections, can disrupt the power supply to critical engine components, resulting in engine stalling. Have the battery, alternator, wiring, and connections inspected for any signs of damage or poor connectivity.


4.Engine Control Module (ECM) Malfunction: The interruption of power to the computer, as indicated by the check engine light, could suggest a problem with the ECM itself. It may be necessary to have the ECM thoroughly inspected or potentially reprogrammed or replaced. 5. Sensor Malfunctions: Faulty sensors, such as the crankshaft position sensor or the camshaft position sensor, can cause intermittent engine shutdown. These sensors provide crucial information to the ECM for proper engine operation. If any of these sensors fail or send incorrect signals, it can lead to stalling or engine shutdown. It's important to have a qualified mechanic perform a diagnostic scan and conduct further testing to pinpoint the exact cause of the stalling issue. They can use specialized equipment to monitor various systems, retrieve error codes, and identify any underlying problems. This will help in accurately diagnosing and resolving the issue with your Saturn Ion.

Not to sound rude, but when it says "vacuum leak", it means from the intake manifold. Get a can or two of Ether, and start the engine. Have someone run it at a steady RPM. Spray the ether around the manifold, and any hoses under the hood, until you hear the engine rev up. Spray along said section until you find the issue. Replace the offending part. As for the misfire, this should cure that, and if not, try simple things, IE, spark plug replacement, etc.

All kinds of repair manuals are available here.Have a look of this may be you will get something useful.
Saturn Ion Complete Workshop Service Repair Manual 2003 2004 2005 2006 2007

Wrong fuel? Possible bad vapor vent allowing too much fuel to throttle body, bad fuel.

It seems that cap of the tank is not letting in air to replace the volume consumed by the engine. Earlier, when it used to stall when1/4 full, there must been less blockage of air but now the air inlet must be really clogged-up,so much so that after being emptied 1/4 of fuel, the negative pressure built up inside the tank is enough to negate the fuel pumps capacity & without gas it will stall the engine which is being deprived of fuel.
One way to make sure that this IS the problem, fill the tank half, do not put the cap try a drive at least for 5 miles & if the engine does not stall, then one can be sure that he cap of the gas tank has to be replaced............sodeep

Tell me when you fill up how far do you go before it stops,,then how far does it go the second time and the 3rd time ,,Do the times get longer each time,, if so then your problem isent a big deal.
The problem you might have is that the return fuel pipe from the engine returning fuel back in to the tank,, and the TANK breather pipe which has to let air in as you cannot take fuel out and not let air back in ,,so it causes a vacuum in the tank... So check the breather before any thing else .. OR dont fill it up any more than the first click of the pumps .
Let me know how you get on Ron

you need a new ignition for sure

Sounds like a fuel issue to me. Maybe the fuel is sloshing to the right of the tank and causing air to be drawn into the fuel line. Just a guess but something to think about.

there should be a valve that prevents the fuel from traveling back dow the fuel lines when the vacum is lost. make shure this is working properly