Lighting Systems: Removal & Installation Saturn ION I

Removal Procedure

1. Remove the accelerator pedal retaining nuts. Move the pedal aside.
2. Remove the stop lamp switch by grasping the switch and turning it counterclockwise while pulling toward the front of the vehicle.
3. Disconnect the stop lamp switch electrical connector.

Installation Procedure

1. Connect the stop lamp switch electrical connector.
2. Insert the stop lamp switch into the retainer.
3. Install the accelerator pedal to the dash panel. Install the retaining nuts. Tighten: Tighten the accelerator pedal retaining nuts to 10 N.m (89 lb in).
4. Adjust the stop lamp switch. Refer to «Stop Lamp Switch Adjustment»(ref-196945-S36190616112005101000000) .

1. Pull up on the I/P upper compartment in order to release the retaining clips.
2. Disconnect the I/P dimmer switch electrical connector.
3. Disconnect the fog lamp switch electrical connector.
4. Remove the fog lamp switch from the I/P upper compartment.

1. Install the fog lamp switch into the I/P upper compartment.
2. Connect the I/P dimmer switch electrical connector.
3. Connect the fog lamp switch electrical connector.
4. Align the retaining clips on the I/P upper compartment to the I/P top panel.
5. Push the I/P upper compartment in order to secure.

1. Pull out on the outer trim cover in order to release the retaining fasteners.
2. Slide the outer trim cover toward the rear of the vehicle.
3. Disconnect the Door Switch electrical connector.
4. Remove the Air Bag electrical connector from the outer trim panel.
5. Remove the Door Switch from the outer trim panel.

1. Install the Door Switch into the outer trim panel.
2. Install the Air Bag electrical connector to the blade on the outer trim panel.
3. Connect the door switch electrical connector.
4. Insert the tabs on the outer trim cover onto the slots on the I/P.
5. Align the retaining fasteners with the I/P.
6. Push the outer trim in order to secure.

1. Open the rear door.
2. Remove the lower garnish molding from the center pillar. Refer to «Garnish Molding Replacement - Center Pillar Lower»(ref-196949-S02949542262005101000000) .
3. Reach into the opening in the center pillar and pinch the tabs together on the door jamb switch (2). Remove the switch from the center pillar.
4. Disconnect the electrical connector (1) from the door jamb switch.

1. Connect the electrical connector (1) to the door jamb switch.
2. Press inward on the door jamb switch (2) until fully seated in the hinge pillar.
3. Install the lower garnish molding to the center pillar. Refer to «Garnish Molding Replacement - Center Pillar Lower»(ref-196949-S02949542262005101000000) .
4. Close the rear door.

1. Remove the instrument panel (I/P) accessory trim plate. Refer to «Trim Plate Replacement - Instrument Panel (I/P) Accessory»(ref-196967-S35985953092005101000000) in Instrument Panel, Gages, and Console.
2. Carefully release the retaining tabs and remove the hazard switch from the I/P accessory trim plate.

1. Install the hazard switch to the I/P accessory trim plate. Ensure that the retaining tabs are fully engaged.
2. Install the I/P accessory trim plate. Refer to «Trim Plate Replacement - Instrument Panel (I/P) Accessory»(ref-196967-S35985953092005101000000) in Instrument Panel, Gages, and Console.

1. Pull up on the I/P upper compartment in order to release the retaining clips.
2. Disconnect the I/P dimmer switch electrical connector.
3. If equipped, disconnect the fog lamp switch electrical connector.
4. Remove the I/P dimmer switch from the I/P upper compartment.

1. Install the I/P dimmer switch into the I/P upper compartment.
2. Connect the I/P dimmer switch electrical connector.
3. If equipped, connect the fog lamp switch electrical connector.
4. Align the retaining clips on the I/P upper compartment to the I/P top panel.
5. Push the I/P upper compartment in order to secure.

1. Remove the left and right outer trim covers. Refer to «Instrument Panel (I/P) Outer Trim Cover Replacement»(ref-196967-S06352239182005101000000) in Instrument Panel, Gages, and Console.
2. Pull out on the accessory trim plate in order to release the retaining fasteners.
3. Disconnect the accessory trim plate electrical connector(s).
4. Remove the screw retaining the cluster trim plate to the center trim panel.
5. Lift up on the cluster trim plate to release the retaining fasteners.
6. Remove the cluster trim plate.
7. Remove the left and right windshield garnish moldings. Refer to «Windshield Garnish Molding Replacement»(ref-196949-S29522542722005101000000) in Interior Trim.
8. Remove the defroster grille bolt covers.
9. Remove the defroster grille center bolts and the outer screws.
10. Lift up on the defroster grille to release the retaining fasteners.
11. Turn the ambient light sensor body clockwise to remove it from the defroster grille.
12. Disconnect the ambient light sensor electrical connector.

1. Connect the ambient light sensor electrical connector.
2. Install the ambient light sensor to the defroster grille. Turn the ambient light sensor body counterclockwise to lock it into the defroster grille.
3. Align the defroster grille retaining fasteners with the I/P.
4. Push on the defroster grille in order to secure the retaining fasteners.
5. Install the defroster grille center bolts. Tighten: Tighten the defroster grille center bolts to 10 N.m (88 lb in).
6. Install the defroster grille outer screws. Tighten: Tighten the defroster grille outer screws to 2.5 N.m (22 lb in).
7. Install the defroster grille bolt covers.
8. Install the left and right windshield garnish moldings. Refer to «Windshield Garnish Molding Replacement»(ref-196949-S29522542722005101000000) in Interior Trim.
9. Align the cluster trim plate retaining fasteners with the center trim panel.
10. Push on the outer edge of the cluster trim plate in order to secure the retaining fasteners.
11. Install the screw retaining the cluster trim plate to the center trim panel. Tighten: Tighten the cluster trim plate screw to 2.5 N.m (22 lb in).
12. Connect the accessory trim plate electrical connector(s).
13. Align the retaining fasteners with the I/P.
14. Push on the outer edge of the accessory trim plate in order to secure the retaining fasteners.
15. Install the left and right outer trim covers. Refer to «Instrument Panel (I/P) Outer Trim Cover Replacement»(ref-196967-S06352239182005101000000) in Instrument Panel, Gages, and Console.

1. Pry the rearward end of the reading lamp cover to disengage the cover clips.
2. Pull rearward to disengage the forward hooks on the lamp cover
3. Grab the reading lamp bulb and pull gently to remove the bulb.

1. Position the bulb in the socket and push on the bulb to install.
2. Insert the forward cover hooks in the slots in the back plate.
3. Push up on the lamp cover until the snap tabs engage.

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zone 2 (Coupe)»(ref-196951-S00773360792005101000000) or «SIR Disabling and Enabling Zone 2 (Sedan)»(ref-196951-S36348943332005101000000) and «SIR Disabling and Enabling Zone 6 (Coupe)»(ref-196951-S41368052052005101000000) or «SIR Disabling and Enabling Zone 6 (Sedan)»(ref-196951-S30577493352005101000000) in SIR.
2. Remove the headliner. Refer to «Headliner Replacement (w/ Sunroof)»(ref-196949-S34546525122005101000000) or «Headliner Replacement (w/o Sunroof)»(ref-196949-S16085180052005101000000) in Interior Trim.
3. Using a small, flat-bladed tool, pry the rearward end of the lamp assembly cover to release the clips.
4. Slide the lamp assembly cover rearward to disengage the forward hooks.
5. Turn the lamp assembly back plate to disengage the plate from the headliner.
6. Disconnect the lamp assembly electrical connectors.
7. Remove the lamp assembly back plate from the headliner.

1. Position the reading lamp back plate on the headliner.
2. Turn the back plate until the tabs engage.
3. Connect the electrical harness.
4. Slide the lamp assembly cover forward to engage the hooks.
5. Push up on the rearward end of the cover in order to seat the cover clips.
6. Install the headliner. Refer to «Headliner Replacement (w/ Sunroof)»(ref-196949-S34546525122005101000000) or «Headliner Replacement (w/o Sunroof)»(ref-196949-S16085180052005101000000) .
7. Enable the SIR system. Refer to «SIR Disabling and Enabling Zone 2 (Coupe)»(ref-196951-S00773360792005101000000) or «SIR Disabling and Enabling Zone 2 (Sedan)»(ref-196951-S36348943332005101000000) and «SIR Disabling and Enabling Zone 6 (Coupe)»(ref-196951-S41368052052005101000000) or «SIR Disabling and Enabling Zone 6 (Sedan)»(ref-196951-S30577493352005101000000) in SIR.

1. Remove the front floor console. Refer to «Console Replacement - Front Floor»(ref-196967-S37494995742005101000000) in Instrument Panel, Gages, and Console.
2. Remove the transmission shift control indicator lamp.

1. Install the transmission shift control indicator lamp.
2. Install the front floor console. Refer to «Console Replacement - Front Floor»(ref-196967-S37494995742005101000000) in Instrument Panel, Gages, and Console.

1. With a flat-bladed tool remove the dome lens from the dome lamp.
2. With a flat-bladed non-metalic tool disengage the dome lamp retainers.
3. Remove the dome lamp from the headliner.
4. Disconnect the electrical connector from the dome lamp.

1. Connect the electrical connector (1) to the dome lamp.
2. Align the dome lamp retaining fasteners (3) into the fastener holes.
3. Press the dome lamp (2) firmly and evenly to engage the retainers.
4. Install the dome lens to the dome lamp.

1. Remove the dome lamp lens by disengaging the side tabs with a small flat-bladed tool.
2. Remove the dome lamp bulb.

1. Install the bulb in the dome lamp.
2. Position the dome lamp lens on the dome lamp assembly.
3. Push on the lens to install.

1. Open the hood.
2. Pull up on the headlamp retaining pins. Remove the pins.
3. Position the headlamp assembly away from the vehicle to access the electrical connectors.
4. Disconnect the electrical connectors from the headlamp bulb/socket and the park/turn bulb, if necessary.
5. Remove the headlamp from the vehicle.
6. Remove the headlamp bulb retaining nut by rotating the nut counterclockwise.
7. Remove the headlamp bulb from the housing.

1. Install the headlamp bulb into the housing.
2. Install the headlamp bulb retaining nut by rotating the nut clockwise.
3. Position the headlamp to the vehicle.
4. Connect the headlamp bulb and the park/turn bulb electrical connectors.
5. Install the headlamp retaining pins by pushing the pins downward.
6. Close the hood.

1. Open the hood.
2. Pull up on the headlamp assembly retaining pins. Remove the pins. IMPORTANT: Hold the headlamp to prevent damage to the headlamp or to the fascia.
3. Position the headlamp assembly away from the vehicle to access the bulb electrical connector.
4. Disconnect the electrical connector from the headlamp assembly.
5. Remove the headlamp assembly away from the vehicle, if necessary.
6. Remove the headlamp bulb access cover by rotating the headlamp bulb access cover counterclockwise, if necessary
7. Disconnect the headlamp bulb electrical connector, if necessary.
8. Remove the headlamp bulb retaining nut by rotating the nut counterclockwise, if necessary.
9. Remove the headlamp bulb from the housing, if necessary.
10. Remove the park/turn bulb access cover by rotating the cover counterclockwise, if necessary.
11. Remove the park/turn bulb socket from the housing by rotating the socket counterclockwise, if necessary.
12. Gently pull the park/turn bulb from the socket, if necessary.
13. To replace the wiring harness, perform the following steps: Remove the 6-pin headlamp wiring harness connector from the tab on the headlamp housing (2). Push the rubber grommet into the headlamp assembly. Push the 6-pin connector through the opening that previously held the grommet (1). IMPORTANT: Remove the headlamp bulb and the headlamp retaining nut from the headlamp assembly/connector prior to the wiring harness removal. Carefully remove the wiring harness through the park/turn bulb access opening (3)

Scheme 35

1. To replace the wiring harness, perform the following steps: Install the wiring harness through the park/turn bulb access opening starting with the headlamp connector (3). Push the headlamp connector up into the headlamp opening. Pull the 6-pin connector through the grommet opening in the headlamp assembly. Pull the grommet. Seat the grommet into the opening (1) Fasten the 6-pin connector to the tab on the headlamp housing (2)
2. Install the park/turn bulb into the bulb socket.
3. Install the park/turn bulb socket into the headlamp housing by rotating the socket clockwise.
4. Install the park/turn bulb access cover by rotating the cover clockwise.
5. Install the headlamp bulb into the headlamp housing.
6. Install the headlamp bulb retaining nut over the headlamp bulb. Rotate the nut clockwise until the nut is locked.
7. Connect the headlamp bulb electrical connector.
8. Install the headlamp bulb access cover by rotating the cover clockwise.
9. Position the headlamp assembly to the vehicle.
10. Connect the electrical connector to the headlamp assembly.
11. Install the headlamp assembly retaining pins by pushing down on the pins. IMPORTANT: Ensure that the retaining pins are fully seated in the headlamp bracket.
12. Close the hood.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
2. Disconnect the electrical connector from the front fog lamp assembly.
3. Twist the bulb about 1/4 turn counterclockwise.
4. Remove the fog lamp bulb from the lamp housing.
5. Remove the nuts mounting the front fog lamp assembly to the lower grille.
6. Remove the fog lamp assembly from the lower grille.

1. Install the fog lamp assembly to the lower front grille.
2. Install the front fog lamp mounting nuts. Tighten: Tighten the nuts to 3 N.m (27 lb in).
3. Install the fog lamp bulb into the lamp housing.
4. Twist the bulb about 1/4 turn clockwise to lock the bulb into the housing.
5. Connect the electrical connector to the fog lamp assembly.
6. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
2. Disconnect the electrical connector from the front fog lamp assembly.
3. Twist the bulb about 1/4 turn counterclockwise.
4. Remove the fog lamp bulb from the lamp housing.
5. Remove the lower grille from the fascia. Refer to «Fascia Grille Replacement - Front Bumper - Lower»(ref-196969-S14500439112005101000000) in Bumpers.
6. Remove the nuts mounting the front fog lamp assembly to the lower grille.
7. Remove the fog lamp assembly from the lower grille.

1. Install the fog lamp assembly to the lower front grille.
2. Install the front fog lamp mounting nuts. Tighten: Tighten the nuts to 2.5 N.m (22 lb in).
3. Install the lower grille into the fascia. Refer to «Fascia Grille Replacement - Front Bumper - Lower»(ref-196969-S14500439112005101000000) in Bumpers.
4. Install the fog lamp bulb into the lamp housing.
5. Twist the bulb about 1/4 turn clockwise to lock the bulb into the housing.
6. Connect the electrical connector to the fog lamp assembly.
7. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
2. Disconnect the electrical connector.
3. Twist the bulb about 1/4 turn counterclockwise.
4. Remove the fog lamp bulb from the lamp housing.

1. Install the fog lamp bulb into the lamp housing.
2. Twist the bulb about 1/4 turn clockwise to lock the bulb into the housing.
3. Connect the electrical connector.
4. Lower the vehicle.

1. Open the hood.
2. Remove the headlamp assembly. Refer to «Headlamp Assembly or Headlamp Bulb Replacement»(ref-196945-S22366714082005101000000) .
3. Remove the side marker bulb/socket from the housing by rotating the socket counterclockwise.
4. Remove the side marker retaining screw from the front of the lamp.
5. Slide the lamp forward. Remove the lamp from the fender.

1. Position the side marker lamp to the fender.
2. Install the side marker lamp retaining screw. Tighten: Tighten the screw to 2.5 N.m (22 lb in).
3. Install the side marker bulb/socket into the lamp housing by rotating the socket clockwise.
4. Install the headlamp assembly. Refer to «Headlamp Assembly or Headlamp Bulb Replacement»(ref-196945-S22366714082005101000000) .
5. Close the hood.

1. Open the hood.
2. Remove the headlamp assembly. Refer to «Headlamp Assembly or Headlamp Bulb Replacement»(ref-196945-S22366714082005101000000) .
3. Remove the side marker bulb/socket from the housing by rotating the socket counterclockwise.
4. Remove the bulb by gently pulling the bulb from the socket.

1. Insert the bulb into the socket.
2. Install the side marker bulb/socket into the lamp housing by rotating the socket clockwise.
3. Install the headlamp assembly. Refer to «Headlamp Assembly or Headlamp Bulb Replacement»(ref-196945-S22366714082005101000000) .
4. Close the hood.

1. Reach behind the headlamp from the hood opening.
2. Remove the park/turn bulb/socket from the headlamp housing by rotating the socket counterclockwise.
3. Gently pull the bulb from the socket. Remove the bulb.

1. Install the park/turn bulb into the socket.
2. Install the park/turn bulb/socket into the headlamp housing by rotating the socket clockwise.

Note. Do not pull on the edges of the center high-mounted stop lamp cover. Damage to the cover may result. Slide your fingers between the cover and the lamp, and carefully pull the cover down.

1. Remove the center high-mounted stop lamp cover.
2. Disconnect the electrical harness only if you are removing the center high-mounted stop lamp.
3. If you are removing the bulbs, twist the sockets out of the stop lamp. Remove the bulbs.
4. Remove the center high-mounted stop lamp retainer screws.
5. Remove the center high-mounted stop lamp from the vehicle.

1. Install the center high-mounted stop lamp with screws. Tighten: Tighten the center high-mounted stop lamp screws to 2.5 N.m (19 lb in).
2. Connect the electrical connector to the center high-mounted stop lamp.
3. Install the cover by placing the tabs in the slots. Gently press the cover into place.

1. Open the rear compartment.
2. Remove the rear compartment lamp from the rear shelf using a small flat-bladed tool to release the retainers.
3. Disconnect the electrical connector (3) from rear compartment lamp (2).
4. Remove the bulb from the rear compartment lamp.

1. Install the bulb to the rear compartment lamp (1).
2. Connect the electrical connector (3) to the rear compartment lamp.
3. Install the rear compartment lamp to the rear shelf pressing into place until fully seated.
4. Close the rear compartment.

1. Remove the screws from the license lamp.
2. Remove the license lamp from the rear compartment lid applique.
3. Remove the bulb/socket from the license lamp by rotating the socket counterclockwise.
4. Remove the license lamp bulb from the socket, if required.

1. Install the license lamp bulb to the socket, if required.
2. Install the license lamp socket to the license lamp by rotating the socket clockwise.
3. Install the license lamp to the rear compartment lid applique.
4. Install the license lamp screws to the license lamp. Tighten: Tighten the license lamp screw to 2 N.m (18 lb in).

1. Open the rear compartment.
2. Remove the screws from the tail lamp.
3. Pull the tail lamp rearward to disengage the tail lamp from the quarter panel.
4. Disconnect the electrical connector from the tail lamp wiring harness.
5. Remove the tail lamp and backup lamp sockets by depressing the locking tab and rotating the sockets counterclockwise.
6. Remove the side marker lamp socket from the tail lamp by rotating the socket counterclockwise.
7. Remove the bulbs from the tail lamp, backup lamp and/or side marker lamp sockets.

1. Install the bulbs to the tail lamp, backup lamp, and/or side marker lamp sockets.
2. Install the tail lamp and/or backup lamp sockets to the tail lamp. Rotate the sockets clockwise until the locking tabs are fully seated.
3. Install the side marker lamp socket to the tail lamp. Rotate the socket clockwise until the socket is fully seated.
4. Connect the electrical connector to the tail lamp wiring harness.
5. Position the tail lamp to the quarter panel.
6. Install the tail lamp screws to the tail lamp. Tighten: Tighten the tail lamp screw to 2 N.m (18 lb in).
7. Close the rear compartment.