General Information: Other Saturn ION I

Arrows and Symbols

This service manual uses various symbols in order to describe different service operations.

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RPO Code List

The following table provides the description of the Regular Production Option (RPO) codes that are available on the vehicle. The vehicle's RPO list is printed on the Service Parts Identification Label.

RPO Code List

Metric Fasteners

This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength.

A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive® or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive® recess head screws.

GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches.

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The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face.

The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following

1. Lower strength
2. No numbered head marking system
3. Wrong thread pitch

The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications

1. M6.0 X 1
2. M8 X 1.25
3. M10 X 1.5
4. M12 X 1.75
5. M14 X 2.00
6. M16 X 2.00

Adhesive Coated Fasteners

These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener.

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A prevailing torque fastener may be reused ONLY if

1. The fastener and the fastener counterpart are clean and not damaged
2. There is no rust on the fastener
3. The fastener develops the specified minimum torque against its counterpart prior to the fastener seating

Metric Prevailing Torque Fastener Minimum Torque Development

English Prevailing Torque Fastener Minimum Torque Development

Thread Inserts

General purpose thread repair kits. These kits are available commercially.

Repair Procedure

1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth.
2. Drill out the damaged threads. Clean out any chips.
3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads.
4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel.
5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert.
6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift.

Registered and Non-Registered Trademarks

Listed below are Registered Trademarks (®) or Non-Registered Trademarks (™) which may appear in this service manual.

Registered and Non-Registered Trademarks

Cutting Keys

The key code can be obtained from the four-digit number on the key tag that accompanies the original master keys. The four-digit key code cross- references to the cut and tumbler sequence. The keys have 10 key cut positions (1) and five key cut depths (2). Key cut positions are numbered 1-10, counting from the head of the key to the tip. The key cut depths are 1-5, cut depth number 5 is the deepest cut.

1. Cut a blank key to the proper depth and sequence of each of the tumbler positions.
2. Inspect the mechanical operation of the key in the lock cylinders in the doors, the ignition switch and the rear compartment. With each side of the key pointing up inside the lock, inspect the operation of the lock in both directions.

Removing the Ignition Lock from the Column

1. There are two retainers on the ignition lock. One is to retain the lock to the column driver and the other is to retain the lock in the column.
2. Rotate lock to the run position.
3. Depress two retainers to remove the lock from the column housing.
4. Though the poke hole depress the first retainer. The lock will back out slightly.
5. Pullout lock about 3/4 of an inch.
6. Depress the second retainer to release the lock from the column. If the lock cylinder can not be rotated to remove, the lock module must be replaced.

Lifting and Jacking the Vehicle

Note. Perform the following steps before beginning any vehicle lifting or jacking procedure: Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents.

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Front Lift Pads

When lifting the vehicle with a frame-contact lift, place the front lift pads 6.69 in (170 mm) from the front pinchweld flanges.

Rear Lift Pads

When lifting the vehicle with a frame-contact lift, place the rear lift pads 2.17 in (55 mm) from the rear pinchweld flanges.

Under the Center of the Rear Suspension

Lift the rear of the vehicle by placing the floor jack lift pad at the center of the rear suspension.

Supporting the Vehicle with Jackstands