This Chilton repair and service manual covers all U.S. and Canadian models of Saturn Ion, 2003 through 2007.
Book Excerpt: 2003-2007 Saturn Ion Repair Manual
TIMING CHAIN AND SPROCKETS
COOLING, HEATING AND AIR CONDITIONING
- Before installing the timing chain, make sure the timing mark (round dot) on the crankshaft sprocket is pointing to the 5 o?clock position (see illustration).
- Install the intake camshaft sprocket onto the camshaft. Be sure to install a new bolt. Tighten the intake camshaft sprocket bolt lightly, finger tight at this time.
NOTE: Do not turn the camshaft more than « turn to avoid any valve/piston contact. The camshafts should be positioned correctly before the timing chain is installed.
- Install the timing chain by lowering it from the top through the opening. Be sure the timing chain drops down around both sides of the cylinder block bosses. Be sure the bright colored link (copper) on the chain is aligned with the INT designation and diamond shape on the camshaft sprocket.
The Copper link will be installed at the intake camshaft sprocket (front) while the silver links will be installed at the crankshaft sprocket and the exhaust camshaft sprocket (rear).
- Drape the timing chain over the crankshaft sprocket and engage the plated link (silver) on the chain with the crankshaft sprocket timing mark located in the 5 o?clock position (see illustration 8.23).
- Install the adjustable timing chain guide. Install the bolts and tighten them to the torque listed in this Chapter?s Specifications.
- Install the exhaust camshaft sprocket onto the camshaft. Be sure to install a new bolt. Be sure the plated link (silver) on the chain is aligned with the EXH designation and diamond shape (which should be pointing to the 10 o?clock position) on the camshaft sprocket.
Tighten the exhaust camshaft sprocket bolt lightly, finger tight at this time.
- Install the fixed timing chain guide. Tighten the bolts to the torque listed in this Chapter?s Specifications.
- Install the upper timing chain guide. Tighten the bolts to the torque listed in this Chapter?s Specifications.
- Hold the intake camshaft with a wrench on the camshaft?s hex to prevent it from turning, then tighten the intake camshaft bolt to the torque listed in this Chapter?s Specifications.
THERMOSTAT | CHECK AND REPLACEMENT
- Before assuming the thermostat is to blame for a cooling system problem, check the coolant level, drivebelt tension (see Chapter 1) and temperature gauge operation.
- If the engine seems to be taking a long time to warm up, based on heater output or temperature gauge operation, the thermostat is probably stuck open. Replace the thermostat with a new one.
- If the engine runs hot, use your hand to check the temperature of the lower radiator hose. If the hose isn?t hot, but the engine is, the thermostat is probably stuck closed, preventing the coolant inside the engine from escaping the radiator.
Replace the thermostat. Note: Don?t drive the vehicle without a thermostat. The computer may stay in open loop and emissions and fuel economy will suffer.
- If the lower radiator hose is hot, it means that the coolant is flowing and the thermostat is open. Consult the Troubleshooting section at the front of this manual for cooling system diagnosis.
2005 AND EARLIER 2.2L MODELS
NOTE: The thermostat housing is located on the firewall-side of the engine block.
- Disconnect the cable from the negative battery terminal. Raise the front of the vehicle and support it securely on jackstands.
- Drain the cooling system (see Chapter 1). If the coolant is relatively new and still in good condition, save it and reuse it.
- Remove the water pump drain bolt and drain the remaining coolant into a container.
- Remove the bolts that hold the water pump pipe/thermostat housing cover to the thermostat housing, then separate the cover from the housing and the a=water pipe from the water pump, using a twisting motion.
Subject: 2003, 2004, 2005, 2006, 2007 Saturn Ion service, maintenance, repair. ISBN-10: 156392675X | ISBN-13: 9781563926754 | Chilton 62305