2005 Saturn Ion Service and Repair Manual

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Factory-Grade Data

2005 Saturn Ion service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Built for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and use wiring diagrams and system sections to diagnose problems faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical coverage with wiring diagrams
  • Coverage across key systems: engine, transmission, brakes, steering, suspension, HVAC, and more

Trims covered

  • 1 Sedan 4-Door
  • 2 Sedan 4-Door
  • 3 Sedan 4-Door
  • 2 Coupe 4-Door
  • 3 Coupe 4-Door
  • Red Line Coupe 4-Door

Engines covered

  • 2.2L 2198CC 134Cu. In. l4 GAS DOHC Naturally Aspirated
  • 2.0L 122Cu. In. l4 GAS DOHC Supercharged

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2005 Saturn Ion Recalls & Complaints

NHTSA #14V04700010/02/2014Component: AIR BAGS

This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if

Consequence

If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a c

Remedy

GM will notify owners, and dealers will replace the ignition switch, free of charge. An interim not

NHTSA #09E01200007/04/2009Component: EXTERIOR LIGHTING

SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONF

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE S

TSB #11020816

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

TSB #11019074

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

TSB #11019073

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

TSB #11019072

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

TSB #11014455

This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the

TSB #11011782

This Preliminary Information communication provides information to the technician about the use of J-35616-64B terminal test probe, replacement terminals, and terminated leads. The J-35616-64B is the latest test probe released for checking

TSB #11009156

This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and

TSB #11008956

This service bulletin provides information for dealers/technicians on When and How to Submit a Field Product Report (FPR) (U.S. and Canada Dealers Only).

Showing the 8 most recent of 585 technical service bulletins on file with NHTSA.

20130616Component: AIR BAGSCrash reported3 injured

MY HUSBAND WAS DRIVING MY 05 SATURN ION 2 QUAD COUPE HOME FROM WORK ON THE INTERSTATE.TRAFFIC STOPPED , CAME TO COMPLETE STOP VEHICLE BEHIND DID NOT BRAKE AND REAR ENDED MY VEHICLE AT ROUGHLY 50+ MPH

20130616Component: SEATSCrash reported3 injured

MY HUSBAND WAS DRIVING MY 05 SATURN ION 2 QUAD COUPE HOME FROM WORK ON THE INTERSTATE.TRAFFIC STOPPED , CAME TO COMPLETE STOP VEHICLE BEHIND DID NOT BRAKE AND REAR ENDED MY VEHICLE AT ROUGHLY 50+ MPH

20110307Component: STEERINGCrash reported2 injured

2005 SATURN ION I POWER STEERING RECALL I HAD THE RECALL NOTICE - CALLED SATURN OF COOL SPRINGS - AND THEY POINT BLANK ASKED "IS IT DOING IT NOW" I SAID "NO" AND THEIR RESPONSE WAS "DON'T WORRY ABOUT

20070326Component: AIR BAGSCrash reported2 injured

I HIT THE REAR OF A TRUCK HARD ENOUGH THAT MY RADIATOR WAS CRUSHED AGAINST MY ENGINE BLOCK. HOWEVER, THE AIRBAGS IN MY CAR DID NOT DEPLOY AT ALL. I KNOW I HAD TO HAVE HIT THE TRUCK IN FRONT OF ME SOME

20051106Component: AIR BAGS:FRONTALCrash reported2 injured

I WAS IN A FRONT END COLLISION ON 10-7-2005 . THE OTHER DRIVER WAS DRIVING A FORD PICK--UP TRUCK F-150 RANGER. NONE OF MY AIRBAGS DEPLOYED. THE TRUCK DRIVERS DRIVER AND PASSENGER SIDE AIR BAGS DEP

Showing the 5 most serious of 755 complaints filed with NHTSA.

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