GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2005 🢒 ION 🢒 Engine 🢒 Engine Mechanical - 2.0L 🢒 Engine Replacement

Removal Procedure
  1. With the tires in the straight forward position, remove the key from the ignition.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  3. Remove the air outlet duct . Refer to Air Cleaner Outlet Resonator Replacement .

    4. Object Number: 857193 Size: SH
  4. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

    5. Object Number: 1387192 Size: SH
  5. Disconnect the fuel line from the fuel rail.
  6. Remove the supercharger. Refer to Supercharger Replacement .
  7. Remove the surge tank to cylinder head pipe. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement and Radiator Surge Tank Outlet Hose/Pipe Replacement .
  8. Remove the radiator outlet hose.

    9. Object Number: 786506 Size: SH
  9. Remove the inlet (1) and outlet (2) heater hoses. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement .

    10. Object Number: 851553 Size: SH
  10. Disconnect the following harness connectors:
    11. • TMAP sensor
    • Electronic temperature control (ETC)
    • Manifold absolute pressure (MAP) sensor
    • Barometric pressure (BARO) sensor
    • Crankshaft sensor
    • Oil pressure sensor
    • Purge solenoid
    • Ignition coil modules
    • Oxygen (O2) sensor
    • Vehicle speed sensor
    • Engine temperature sensor
    • Boost solenoid
    • Back up lamp switch
  11. Disconnect the charge air cooler hoses.
  12. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  13. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .

    14. Object Number: 758469 Size: SH
  14. Disconnect the starter harness connectors (3, 4, 5).
  15. Disconnect the generator harness connectors.
  16. Drain the engine oil.
  17. Disconnect the front exhaust pipe from the exhaust manifold. Refer to Exhaust Manifold Replacement .
  18. Disconnect the transmission shift cable from the transmission.
  19. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.

    20. Object Number: 851677 Size: SH
  20. Disconnect the drive axles from the steering knuckle. Refer to Wheel Drive Shaft Replacement .
  21. Attach the engine lift hoist to the engine lift hooks.

    22. Object Number: 758470 Size: SH
  22. Remove the starter.
  23. Remove the transmission to engine bolts.
  24. Separate the engine from the transmission.
  25. Remove the clutch pressure plate and disk.
  26. Remove the following components:
    27. • Exhaust manifold
    • Exhaust manifold studs
    • Engine mount bracket
    • Fuel rail
    • Thermostat housing and feed pipe
    • Generator

Installation Procedure
  1. Attach the engine lift hoist to the engine lift hooks.
  2. Install the following components:
    3. • Exhaust manifold--Refer to Exhaust Manifold Replacement .
    • Engine mount bracket--Refer to Engine Mount Bracket Replacement .
    • Fuel rail--Refer to Fuel Injection Fuel Rail Assembly Replacement .
    • Idler pulley
    • Drive belt tensioner--Refer to Drive Belt Tensioner Replacement - Supercharger .
    • Thermostat housing and feed pipe--Refer to Engine Coolant Thermostat Replacement .
    • Generator--Refer to Generator Replacement .
    • 
    •  Flywheel--Refer to Engine Flywheel Replacement .
    • Clutch pressure plate and disk--Refer to Clutch Pressure and Driven Plate Replacement .
  3. Align the engine to the transmission.

    4. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 851293 Size: SH
  4. Secure the engine to the transmission.

    5. Tighten
    Tighten the transmission to engine bolts to 75 N·m (55 lb ft).


    Object Number: 758470 Size: SH
  5. Install the starter. Refer to Starter Motor Replacement .

    6. Object Number: 851677 Size: SH
  6. Connect the drive axles to the steering knuckles. Refer to Wheel Drive Shaft Replacement .
  7. Remove the wood blocks between the powertrain and frame.
  8. Connect the transmission shift cable to the transmission.

    9. Object Number: 878834 Size: SH
  9. Connect the exhaust takedown pipe to the exhaust manifold.

    10. Tighten
    Tighten the nuts to 30 N·m (22 lb ft).

  10. Connect the generator harness connectors.

    11. Tighten
    Tighten the generator terminal nut to 20 N·m (15 lb ft).


    Object Number: 758469 Size: SH
  11. Connect the starter harness connectors (3, 4, 5).

    12. Tighten

        • Tighten the battery terminal nut to 17 N·m (13 lb ft).
        • Tighten the S-terminal nut to 3 N·m (27 lb in).
  12. Install the supercharger. Refer to Supercharger Replacement .
  13. Connect the charge air cooler hoses.
  14. Connect the following harness connectors:
    15. • TMAP sensor
    • ETC
    • MAP sensor
    • Crankshaft sensor
    • Oil pressure sensor
    • Purge solenoid
    • BARO sensor
    • Ignition coil modules
    • O2 sensor
    • Vehicle speed sensor
    • Engine temperature sensor
    • Boost solenoid

    Object Number: 786506 Size: SH
  15. Install the inlet heater hose (1) and outlet heater hose (2). Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement .

    16. Object Number: 1387192 Size: SH
  16. Connect the fuel line to the fuel rail.
  17. Install the surge tank to the cylinder head pipe.

    18. Tighten
    Tighten the bolt to 10 N·m (89 lb in).


    Object Number: 857193 Size: SH
  18. Release the cooling module from the upper body structure.
  19. Install the air outlet duct . Refer to Air Cleaner Outlet Resonator Replacement .
  20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  21. Fill the engine with engine oil to the proper level. Refer to Fluid and Lubricant Recommendations .
  22. Fill the cooling system. Refer to Cooling System Draining and Filling .
  23. Road test the vehicle.