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2003 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
- 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
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2003 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 2003 Saturn ION AUTOMOBILES
Air Bag System Precautions -> General Motors Corp. -> Arming -> Light Trucks & Vans -> Passenger Cars
Vehicle: 2003 Saturn ION 2.2 L4 GAS
Passenger Cars
Reverse disarming procedures to arm the Supplemental Restraint System, noting the following:
- Ensure all disconnected SRS electrical connectors are securely connected and routed.
- Install all removed fuses in proper locations.
- From a safe position at sides of or below air bag module, Turn ignition switch to ON position and observe Air Bag or SRS warning lamp.
- On all models except Prizm and 1990 Corvette, warning lamp should flash seven to nine times, then go off.
- On Prizm models, warning lamp should light for six seconds,...
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BRAKE SERVICE PROCEDURES FOR 2003 Saturn ION AUTOMOBILES
Power Brake Units -> Adjustments -> AC-Delco Single Diaphragm Type -> AC-Delco Tandem Diaphragm Type -> Air Method -> Brake Pedal -> Gauge Method -> Pushrod -> Toyota/GM Single Diaphragm Type
Vehicle: 2003 Saturn ION 2.2 L4 GAS
Brake Pedal
Toyota/GM Single Diaphragm Type
- With engine running and brake pedal in rest position, measure distance between face of pedal and floor mat.
- Distance should be 5.850-6.244 inches.
- If distance is not as specified, adjust pedal height as follows:
- Remove lefthand lower instrument panel trim section and air duct.
- Loosen stop lamp switch sufficiently to access pedal adjustment.
- Loosen locknut and rotate pedal pushrod as required to obtain specified pedal height. Tighten locknut.
- Adjust brake lamp switch position so plunger lightly contacts pedal stopper and brake lamps are off when pe...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2003 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: 2003 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 2003 Saturn ION AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2003 Saturn ION 2.2 L4 GAS
- Raise and support vehicle.
- Remove tire and wheel assembly.
- Disconnect stabilizer link.
- 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. nut can be partially reinstalled to protect threads.
- Disconnect outer tie rod assembly from steering knuckle. Do NOT loosen tie rod adjustment jamb nut.
- Disconnect electrical connect...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2003 Saturn ION AUTOMOBILES
Alternator, Replace
Vehicle: 2003 Saturn ION 2.2 L4 GAS
- Disconnect battery ground cable.
- Remove throttle body air duct and accessory drive belt.
- Disconnect alternator elec...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2003 Saturn ION AUTOMOBILES
Cabin Air Filter Service -> General Motors Corp./Saturn -> 2003-07 Ion, 2005-09 Cobalt & 2007-09 G5
Vehicle: 2003 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 2003 Saturn ION AUTOMOBILES
General Motors Corp./Saturn Cars -> Traction Control System (TCS) Warning Lamp ->
Vehicle: 2003 Saturn ION 2.2 L4 GAS
This lamp should light for a approximately 6-8 seconds when the ignition is turned on as a bulb check. If the warni...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2003 Saturn ION AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2003 Saturn ION 2.2 L4 GAS
Inlet
- Drain cooling system into a suitable container.
- Reposition inlet heater hose clamp from heater core pipe.
- Remove hose from heater core.
- Reposition heater hose clamp from engine.
- Remove inlet heater hose from engine.
- Remove hose from vehicle.
- Reverse procedure to...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2003 Saturn ION AUTOMOBILES
Serpentine Drive Belt, Replace -> Installation -> Removal
Vehicle: 2003 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 2003 Saturn ION AUTOMOBILES
Component location diagrams for most 2003 Saturn ION cars and light trucks sold in the U.S. from 1990+.
 Seat Belt Components Diagram for 2003 Saturn ION 2.2 L4 GASComponents on diagram: |
 Instrument Panel Diagram for 2003 Saturn ION 2.2 L4 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2003 Saturn ION AUTOMOBILES
OEM drawn wiring diagrams for most 2003 Saturn ION cars and light trucks sold in the U.S.
 2003 Saturn ION 2.2 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 2003 Saturn ION AUTOMOBILES
OEM TSB listings for most 2003 Saturn ION cars and light trucks sold in the U.S. from 1985+.
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Document: New Website for AFIT, TPM, and VDR Updates Vehicle: 2003 Saturn ION 2.2 L4 GAS Auto Systems: |
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Document: EVAP Emissions Small Leak Diagnosis (DTC P0442) Vehicle: 2003 Saturn ION 2.2 L4 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2003 Saturn ION AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2003 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 2003 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 2003 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 2003 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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