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2005 Saturn ION CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Saturn REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- 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
BRAKE SERVICE PROCEDURES FOR 2005 Saturn ION AUTOMOBILES
Anti-Lock Brakes -> Bosch 8.0 -> Description -> Anti-Lock Telltale Lamp & Red Brake Warning Lamp -> Low Traction Telltale Lamp -> System Operation
Vehicle: 2005 Saturn ION RED Line 2.0 L4 GAS
System Operation
The Anti-Lock Brake System (ABS) minimizes wheel lockup during heavy braking on most road surfaces. The system performs this function by monitoring wheel speed and controlling the brake fluid pressure during braking. This allows the driver to retain directional stability and better steering capability.
Anti-Lock Telltale Lamp & Red Brake Warning Lamp
The Anti-Lock Telltale lamp, located in the instrument cluster, has several functions. If the lamp comes on solid, a fault has occurred and the ABS system has been disabled and should be serviced as soon as possible. If th...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2005 Saturn ION AUTOMOBILES
General Motors Corp./Saturn Passenger Cars -> Fuel Pressure Relief -> Except Aveo, LaCrosse, LeMans (1988-93), Malibu & Malibu Maxx (2004-05), Metro, Nova, Prizm, Spectrum & Storm -> Engine Fuel Pressure Service Port -> Engines Less Fuel Pressure Service Port
Vehicle: 2005 Saturn ION RED Line 2.0 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 vehicle relearns its adaptive strateg...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2005 Saturn ION AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2005 Saturn ION RED Line 2.0 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 2005 Saturn ION AUTOMOBILES
Alternator, Replace
Vehicle: 2005 Saturn ION RED Line 2.0 L4 GAS
- Disconnect battery ground cable.
- Rotate or lift belt tensioner arm, using a suitable tool to relieve tension from drive belt.
- Remove serpentine drive belt.
- Remove supercharger assembly.
- Disconnect ...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2005 Saturn ION AUTOMOBILES
Cabin Air Filter Service -> General Motors Corp./Saturn -> 2003-07 Ion, 2005-09 Cobalt & 2007-09 G5
Vehicle: 2005 Saturn ION RED Line 2.0 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 2005 Saturn ION AUTOMOBILES
General Motors Corp./Saturn Cars -> Active Handling System Warning Lamp ->
Vehicle: 2005 Saturn ION RED Line 2.0 L4 GAS
This lamp should light for a approximately 6-8 seconds when the ignition is turned on as a bulb check. The lamp will also come on as the system is...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2005 Saturn ION AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2005 Saturn ION RED Line 2.0 L4 GAS
Inlet
- Drain cooling system into a suitable container.
- Remove radiator surge tank.
- Reposition heater hose inlet clamp at heater core.
- Remove heater inlet hose from heater core.
- Reposition heater core inlet hose clamp at thermostat housing.
- Remove hose from thermostat housing.
- Remove hose from vehicle.
- Reverse procedure to install.
Outlet
- Dra...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2005 Saturn ION AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2005 Saturn ION RED Line 2.0 L4 GAS
- Remove righthand front fender liner.
- Mark serpentine belt running direction.
- Relieve...
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COMPONENT LOCATION DIAGRAMS FOR 2005 Saturn ION AUTOMOBILES
Component location diagrams for most 2005 Saturn ION cars and light trucks sold in the U.S. from 1990+.
Right Rear Side Under Vehicle Diagram for 2005 Saturn ION RED Line 2.0 L4 GAS Components on diagram: |
Top of the Engine Diagram for 2005 Saturn ION RED Line 2.0 L4 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2005 Saturn ION AUTOMOBILES
OEM drawn wiring diagrams for most 2005 Saturn ION cars and light trucks sold in the U.S.
2005 Saturn ION RED Line 2.0 L4 GAS Wiring Diagram Components on diagram: |
2005 Saturn ION RED Line 2.0 L4 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2005 Saturn ION AUTOMOBILES
OEM TSB listings for most 2005 Saturn ION cars and light trucks sold in the U.S. from 1985+.
Document: GM of Canada New Vehicle Limited Warranty Tire Program Vehicle: 2005 Saturn ION RED Line 2.0 L4 GAS Auto Systems: |
Document: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Vehicle: 2005 Saturn ION RED Line 2.0 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2005 Saturn ION AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2005 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 2005 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 2005 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 2005 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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