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Saturn ION CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Saturn REPAIR SHOPS DON'T WANT YOU TO KNOW
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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about Saturn ION car and truck
repair procedures including Saturn engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Saturn ION automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR Saturn ION AUTOMOBILES
Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported Saturn ION cars and light trucks from 1990+
Component Replacement & Adjustment -> ION -> Thermostat, Replace
Vehicle: 2003 Saturn ION 2.2 L4 GAS
- Drain engine coolant into suitable container.
- Remove thermostat housing mounting bolts and feed pipe.
- Record orient...
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BRAKE SERVICE PROCEDURES FOR Saturn ION AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Saturn ION cars and light trucks from 1990+.
Power Brake Units -> Precautions
Vehicle: 2004 Saturn ION 2.2 L4 GAS
- After disassembling power brake unit, soak metal components in solvent.
- Use only alcohol on components containing rubber. After components have been thoroughly cleaned and rinsed in solvent, they should be washed again in clean alcohol before assembly.
- Use compressed air to blow dirt and cleaning fluid...
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FUEL FILTER REPLACEMENT PROCEDURES FOR Saturn ION AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported Saturn ION cars and light trucks sold in the U.S. for 1980+.
General Motors Corp./Saturn Passenger Cars -> Fuel Filter Scheduled Maintenance -> 1991-06 Saturn -> Normal Service -> Severe Service
Vehicle: 2004 Saturn ION 2.2 L4 GAS
Normal Service
Replace every 100,0...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Saturn ION AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported Saturn ION cars and light trucks from 1990+.
CV AXLE SHAFT, Replace
Vehicle: 2007 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 Saturn ION AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Saturn ION cars and light trucks from 1990+.
Alternator, Replace
Vehicle: 2004 Saturn ION 2.2 L4 GAS
- Disconnect battery ground cable.
- Remove throttle body air duct.
- Rotate or lift belt tensioner arm, using a suitable tool to relieve tension from drive belt.
- Remove serpentine drive belt.
- Disconnect ...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR Saturn ION AUTOMOBILES
Cabin air filter locations and replacement procedures with corresponding images for most domestic and imported Saturn ION cars and light trucks sold in the U.S. as equipped to the current model year.
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 Saturn ION AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported Saturn ION cars and light trucks sold in the U.S. from 1990+.
General Motors Corp./Saturn Cars -> Change Oil, Change Oil Now Or Change Oil Soon Lamp & Messages -> 2003-07 ION
Vehicle: 2003 Saturn ION 2.2 L4 GAS
- Turn ignition on, but do not start engine.
- Press and release TRIP/RESET button until OIL LIFE message is displayed.
- Press and hold TRIP/RESET butt...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Saturn ION AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Saturn ION cars and light trucks from 1990+
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2005 Saturn ION RED Line 2.0 L4 GAS
Lower
- Drain cooling system into a suitable container.
- Remove air intake duct.
- Reposition hose clamp from radiator.
- Remove radiator outlet hose from radiator.
- Remove underhood electrical center.
- Reposition hose clamp from thermostat housing.
- Remove radiator outlet hose from thermostat housing and from vehicle.
- Reverse procedure to i...
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SERPENTINE BELT SERVICE PROCEDURES FOR Saturn ION AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported Saturn ION cars and light trucks sold in the U.S. from 1990+.
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 Saturn ION AUTOMOBILES
Component location diagrams for most Saturn ION cars and light trucks sold in the U.S. from 1990+.
 Front Body Components Diagram for 2003 Saturn ION 2.2 L4 GASComponents on diagram: |
 Right Rear Door Jamb Switch in B-Pillar Diagram for 2005 Saturn ION RED Line 2.0 L4 GASComponents on diagram: |
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WIRING DIAGRAMS FOR Saturn ION AUTOMOBILES
OEM drawn wiring diagrams for most Saturn ION cars and light trucks sold in the U.S.
 2004 Saturn ION RED Line 2.0 L4 GAS Wiring DiagramComponents on diagram: |
 2003 Saturn ION 2.2 L4 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR Saturn ION AUTOMOBILES
OEM TSB listings for most Saturn ION cars and light trucks sold in the U.S. from 1985+.
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Document: PROGRAMMING ONSTAR MODULE FOR CANADIAN FRENCH VOICE RECOGNITION (ONSTAR GENERATION 5 OR GENERATION 6) - REVISED Vehicle: 2005 Saturn ION RED Line 2.0 L4 GAS Auto Systems: |
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Document: INFORMATION ON INADVERTENT TURNING OF THE KEY CYLINDER, LOSS OF ELECTRICAL SYSTEM AND NO DTCS - REVISED Vehicle: 2005 Saturn ION RED Line 2.0 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR Saturn ION AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 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 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 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 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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