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2004 Saturn ION CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Saturn REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 2004 Saturn ION AUTOMOBILES
Vacuum & Wiring Diagrams -> Passenger Cars -> Cavalier & Sunfire
Vehicle: 2004 Saturn ION 2.2 L4 GAS
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BRAKE SERVICE PROCEDURES FOR 2004 Saturn ION AUTOMOBILES
Drum Brakes -> Saturn -> Tightening Specifications
Vehicle: 2004 Saturn ION 2.2 L4 GAS
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Saturn ION AUTOMOBILES
General Motors Corp./Saturn Passenger Cars -> Fuel Filter Replacement -> Except Aveo, Chevette 1.8L Diesel, Corvette, GTO, LaCrosse, Malibu (2004-06) & Malibu Maxx, Vibe, XLR, 2004-05 Corvette & 1998-2002 Metro & Prizm
Vehicle: 2004 Saturn ION 2.2 L4 GAS
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while the v...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 Saturn ION AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2004 Saturn ION 2.2 L4 GAS
- Raise and support vehicle.
- Remove tire and wheel assembly.
- Remove wheel drive shaft nut. Insert a drift or a flat-bladed tool into caliper and rotor to prevent rotor from turning.
- Carefully loosen wheel drive shaft splines from wheel bearing/hub assembly using a wood block and a hammer. The nut can be partially reinstalled to protect threads.
- Be sure that wheel speed sensor wiring harness is repositioned away from ball joint after disconnecting electrical connector from sensor. Disconnect ball joint from steering k...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 Saturn ION AUTOMOBILES
Starter, Replace
Vehicle: 2004 Saturn ION RED Line 2.0 L4 GAS
- Disconnect battery ground cable.
- Raise and support vehicle.
- Remove mounting bolts and intercooler pump outer bracket.
- Disconnect electrical connectors and position aside.
- Remove mo...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2004 Saturn ION AUTOMOBILES
Cabin Air Filter Service -> General Motors Corp./Saturn -> 2003-07 Ion, 2005-09 Cobalt & 2007-09 G5
Vehicle: 2004 Saturn ION 2.2 L4 GAS
On 2003 models, under normal operating conditions the cabin air filter should be replaced every 24 months or 18,000 miles. In dusty areas change the cabin air filter more often.
On 2004-09 models, under normal operating conditions the cabin air filter should be replaced every 12 months or 15,000 miles or at Maintenance II as indicated on the DIC (Driver Information Center). In dusty areas change the cabin air filter more often.
- Open the glove compartment.
- Push inward at each side of the g...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Saturn ION AUTOMOBILES
General Motors Corp./Saturn Cars -> Check Gauge Warning Lamp ->
Vehicle: 2004 Saturn ION RED Line 2.0 L4 GAS
The Check Gauge warning lamp will light to warn the driver to inspect the oil pressure gauge, engine coolant temperature ga...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Saturn ION AUTOMOBILES
Radiator, Replace
Vehicle: 2004 Saturn ION RED Line 2.0 L4 GAS
- Remove surge tank cap.
- Raise and support vehicle.
- Place suitable drain pan below righthand side of radiator lower mount.
- Open petcock and drain coolant into suitable container.
- Place drain pan below water pump drain plug.
- Open drain plug and drain coolant into suitable container.
- After all coolant has drained, close petcock hand tight.
- Torque water pump drain plug to 16 ft. lbs.
- Lower vehicle and remove air cleaner outlet resonator.
- Disconnect radiator inlet and outlet hoses from radiator.
- On models equipped with automatic or VTi transaxle, proceed as follows:
- Disconnect transaxle upper ...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Saturn ION AUTOMOBILES
Serpentine Drive Belt, Replace -> Installation -> Removal
Vehicle: 2004 Saturn ION 2.2 L4 GAS
Removal
- Depress tensioner arm using suitable 3/8 inch drive breaker bar.
- Remove belt from idler or air conditioning compressor pulley and accessory pulleys.
Inst...
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COMPONENT LOCATION DIAGRAMS FOR 2004 Saturn ION AUTOMOBILES
Component location diagrams for most 2004 Saturn ION cars and light trucks sold in the U.S. from 1990+.
Engine Components Diagram for 2004 Saturn ION 2.2 L4 GAS Components on diagram: |
Front Body Components Diagram for 2004 Saturn ION 2.2 L4 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2004 Saturn ION AUTOMOBILES
OEM drawn wiring diagrams for most 2004 Saturn ION cars and light trucks sold in the U.S.
2004 Saturn ION RED Line 2.0 L4 GAS Wiring Diagram Components on diagram: |
2004 Saturn ION 2.2 L4 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2004 Saturn ION AUTOMOBILES
OEM TSB listings for most 2004 Saturn ION cars and light trucks sold in the U.S. from 1985+.
Document: New Website for AFIT, TPM, and VDR Updates Vehicle: 2004 Saturn ION RED Line 2.0 L4 GAS Auto Systems: |
Document: EVAP Emissions Small Leak Diagnosis (DTC P0442) Vehicle: 2004 Saturn ION RED Line 2.0 L4 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2004 Saturn ION AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 Saturn ION cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2004 Saturn ION cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2004 Saturn ION cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2004 Saturn ION cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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