Saturn Ion Repair Manual 2003-2007

SKU: HY87011-007
Saturn Ion Repair Manual 2003-2007
Saturn Ion Repair Manual 2003-2007
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This DIY repair and workshop manual by Haynes, covers 2003-2007 Saturn Ion FWD automobile models, 4-door sedans and 2-door coupes, powered by 2.0L, 2.2L and 2.4L transversely-mounted 4-cylinder engines.

Power is transmitted to the front wheels through a 5-speed manual, a 4-speed or a 5-speed continuosly variable ratio automatic transaxle.

If you'd like to take proper care of your Ion, from basic maintenance chores to more advanced service tasks, all the way to complete engine rebuilding, this Haynes manuals is the guide you want!

Book Excerpt: 2003-2007 Saturn Ion Repair Manual


  1. The one-piece rear main oil seal is pressed into engine block and the crankcase reinforcement section. Remove the transaxle (see Chapter 7), the clutch components, if equipped (see Chapter 8) and the flywheel (see Section 15).
  2. Pry out the old seal with a special seal removal tool or a flat-blade screwdriver. Caution: To prevent an oil leak after the new seal is installed, be very careful not to scratch or otherwise damage the crankshaft sealing surface or the bore in the engine block.
  3. Clean the crankshaft and seal bore in the block thoroughly and de-grease these areas by wiping them with a rag soaked in lacquer thinner or acetone. Lubricate the lip of the new seal and the outer diameter of the crankshaft with engine oil.
  4. Position the new seal onto the crankshaft. Make sure the edges of the new oil seal are not rolled over. Note: When installing the new seal, if so marked, the words THIS SIDE OUT on the seal must face out, toward the rear of the engine.

    Use a special rear main oil seal installation tool or a socket with the exact diameter of the seal to drive the seal in place. Make sure the seal is not off-set; it must be flush along the entire circumference of the engine block and the crankcase reinforcement section.

  5. The remainder of installation is the reverse of removal.



  1. Engine mounts seldom require attention, but broken or deteriorated mounts should be replaced immediately or the added strain placed on the driveline components may cause damage or wear.
  2. During the check, the engine must be raised slightly to remove the weight from the mounts.
  3. Raise the vehicle and support it securely on jackstands, then position a jack under the engine oil pan. Place a large block of wood between the jack head and the oil pan, and then carefully raise the engine just enough to take the weight off the mounts.

    WARNING: DO NOT place any part of your body under the engine when it's supported only by a jack!

  4. Check the mounts to see if the rubber is cracked, hardened or separated form the bushing in the center of the mount.
  5. Check for relative movement between the mount and the engine or frame (use a large screwdriver or prybar to attempt to move the mounts). If movement is noted, lower the engine and tighten the mount fasteners.

(Refer to illustrations 8.7 and 8.10)
  1. Set the parking brake. Remove the wheel cover or hubcap.
  2. Loosen the driveaxle/hub nut with a large socket and breaker bar, but don't remove it yet.
  3. Loosen the front wheel lug nuts, raise the vehicle and support it securely on jackstands. Remove the wheel.
  4. Remove the driveaxle/hub nut.
  5. Disconnect the stabilizer bar end link, and then disconnect the tie-rod end from the steering knuckle (see Chapter 10).
  6. Disconnect the ABS wheel speed sensor (see Chapter 9). Separate the control arm from the steering knuckle (see Chapter 10).
  7. To loosen the driveaxle form the hub splines, tap the end of the driveaxle with a soft-faced hammer (see illustration). If the driveaxle is stuck in the hub splines and won't move, it may be necessary to push it from the hub with a puller.
  8. Pull out on the steering knuckle and detach the driveaxle from the hub. Suspend the outer end of the driveaxle on a bungee cord or piece of wire.
  9. Before you remove the driveaxle, look for lubricant leakage in the area around the differential seal. If there's evidence of a leak, you'll want to replace the seal after removing the driveaxle (see Chapter 7B).
  10. Position a prybar against the inner joint and carefully pry the joint off the transaxle side gear shaft (see illustration) or, if you're removing the right-side driveaxle, off the intermediate shaft.

    Do not use the driveaxle to pull the on the inner joint. Doing so might damage the inner joint components. Remove the driveaxle assembly, being careful not to overextend the inner joint or damage the axleshaft boots.

  11. Should it become necessary to move the vehicle while the driveaxle is out, place a large bolt with two large washers (one on each side of the hub) through the hub and tighten the nut securely.

Subject: 2003, 2004, 2005, 2006, 2007 Saturn Ion service, maintenance, repair. ISBN-10: 1563926644 | ISBN-13: 9781563926648 | Haynes 87011

  • Publisher: Haynes Manuals
  • Pages: 298 - Hundreds of b&w photos and illustrations
  • Binding: Paperback - 8.5 x 11 inches
  • ISBN: 978-1-56392-664-8
  • Years: 2003 - 2007
Table of Contents
  • Introduction: Vehicle identification numbers; Buying parts; Maintenance techniques, and more.
  • Tune-up and routine maintenance
  • Engine and overhaul procedures
  • Cooling, heating and air-conditioning systems
  • Fuel and exhaust systems
  • Engine electrical systems
  • Emissions control systems
  • Automatic transaxle
  • Manual transaxle
  • Driveline
  • Brakes
  • Suspension and steering systems
  • Body
  • Chassis electrical system
  • Wiring diagrams
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