2006 Saturn Ion Service and Repair Manual

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Factory-Grade Data

2006 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

  • 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
  • 2.4L 2384CC 145Cu. 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

2006 Saturn Ion Recalls & Complaints

NHTSA #09V41900029/10/2009Component: FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

GENERAL MOTORS IS RECALLING CERTAIN MODEL YEAR 2006 CHEVROLET COBALT AND SATURN ION VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF ARIZONA AND NEVADA; AND MODEL YEAR 2007 CHEVROL

Consequence

FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

Remedy

DEALERS WILL REPLACE THE FUEL PUMP MODULE FREE OF CHARGE. A SPECIAL COVERAGE WILL BE IMPLEMENTED IN

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 739 technical service bulletins on file with NHTSA.

20130211Component: AIR BAGSCrash reportedFire reported3 injured

MY SON LOST CONTROL OF THE CAR HITTING A POLE HEAD ON AND THEN THE CAR SPUN THREE TIMES IN A 360 AND THEN A 180... AIR BAGS DIDN'T DEPLOY AND HE AND THE PASSENGER ARE BADLY INJURED. THE AIR BAGS COULD

20140405Component: ELECTRICAL SYSTEMCrash reportedFire reported1 fatalities

PER WITNESSES MY DAUGHTER'S SATURN ION HIT THE REAR OF A SEMI TRUCK THAT HAD STOPPED ON NORTHBOUND I-81 NEAR MILE MARKER 210.5. THE WITNESSES STATE THAT THE AIR BAGS DID NOT DEPLOY. THE CAR CAUGHT FIR

20080530Component: AIR BAGS:FRONTALCrash reported4 injured

I WAS INVOLVED IN A FRONTAL CAR ACCIDENT AT ABOUT 40-45 MPH AND MY AIRBAGS DID NOT DEPLOY, INJURY COULD HAVE BEEN AVOIDED HAD THE AIRBAG DEPLOYED. MY CENSOR FOR MY PASSENGER WAS ON, BUT THE AIRBAGS D

20140520Component: VEHICLE SPEED CONTROLCrash reported3 injured

TL* THE CONTACT OWNS A 2006 SATURN ION. THE CONTACT STATED THAT AFTER STARTING THE ENGINE, THE VEHICLE ACCELERATED INDEPENDENTLY AND CRASHED INTO A CURB. THE CONTACT INDICATED THAT THE FRONT DRIVER, T

20140118Component: STEERINGCrash reported2 injured

I PURCHASED A 2006 SATURN ION IN MAY OF 2009 FROM ROCKENBACH CHEVROLET IN GRAYSLAKE ILLINOIS. THE VEHICLE WAS INSPECTED THREE TIMES FOR THIS POWER STEERING PROBLEM PRIOR TO THE ACCIDENT BY ROCKENBAC

Showing the 5 most serious of 1537 complaints filed with NHTSA.

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