Steering Wheel & Steering Column: Removal & Installation Saturn ION I

Removal Procedure

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
2. Remove the left front tire. Refer to «Tire and Wheel Removal and Installation»(ref-196968-S42694341792005101000000) in Tire and Wheel.
3. Remove the intermediate shaft to steering gear pinch bolt. Discard the bolt.
4. Disconnect the intermediate shaft from the steering gear.
5. Lower the vehicle.
6. Align the steering wheel into the straight forward position.
7. Remove the ignition key and turn the steering wheel clockwise until it locks.
8. Place scribe marks on the intermediate shaft to the steering column connection prior to removal.
9. Remove the intermediate shaft pinch bolt at the steering column. Discard the pinch bolt.
10. Slide the intermediate shaft off the steering column shaft.
11. Use a pulling, squeezing and twisting motion to unseat the intermediate shaft seal from the dash.
12. Remove the intermediate shaft/seal from the vehicle.

Installation Procedure

1. If installing a new intermediate shaft, transfer the pre-scribed alignment marks onto the new part.
2. Install the intermediate shaft/seal through the front of dash.
3. Seat the intermediate shaft seal using a pushing, squeezing and twisting motion until seal is fully seated.
4. Align the pre-scribed mark on the intermediate shaft to the pre-scribed mark on the steering column shaft.
5. Connect the intermediate shaft to the steering column shaft.
6. If the intermediate shaft was removed without the use of a scribed mark, perform the following: Place the road wheels in the straight ahead position. Install the intermediate shaft to the steering gear so the intermediate shaft bolt head faces the LH wheel well opening. Place the steering wheel in the straight ahead position. Connect the intermediate shaft to the steering column shaft.
7. Install a new intermediate shaft to steering column pinch bolt. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
8. Connect the intermediate shaft to the steering gear.
9. Install a new intermediate shaft to steering gear pinch bolt. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
10. Install the left front wheel. Refer to «Tire and Wheel Removal and Installation»(ref-196968-S42694341792005101000000) in Tire and Wheel.
11. Check for proper steering wheel alignment. If steering wheel is out of alignment perform the following: Remove the intermediate shaft pinch bolt at the steering column. Disconnect the intermediate shaft in order to rotate and reconnect as needed to straighten the steering alignment. Install a new intermediate shaft pinch bolt. Tighten: Tighten the bolt to 34 N.m (25 lb ft).

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zone 3»(ref-196951-S39158394842005101000000) in SIR.
2. Unsnap and remove the upper steering column cover.
3. Remove the lower steering column cover screws.
4. Lower the steering column adjusting handle.
5. Unsnap and remove the left lower steering column cover.
6. Remove the right lower steering column cover.

1. Install the right lower steering column cover.
2. Install the left lower steering column cover and snap into the right cover.
3. Raise the steering column adjusting handle to lock the steering column into place.
4. Install the lower steering column cover screws. Tighten: Tighten the lower steering column cover screws to 2 N.m (17 lb in).
5. Install the upper steering column cover by guiding the soft closeout under the I/P Trim Panel and aligning the retaining fasteners with the lower covers.
6. Push on the upper steering column cover to secure.
7. Enable the SIR system. Refer to «SIR Disabling and Enabling Zone 3»(ref-196951-S39158394842005101000000) in SIR.

1. Remove the steering column trim covers. Refer to «Steering Column Trim Covers Replacement»(ref-196954-S01449608982005101000000) .
2. Disconnect the ignition switch harness connector.
3. Turn the ignition switch to the run position.
4. Remove the ignition switch screws.
5. Remove the ignition switch from the steering column.

1. Install the ignition switch and screws on to the steering column. Tighten: Tighten the screws to 2 N.m (17 lb in).
2. Connect the ignition switch harness connector.
3. Install the steering column trim covers. Refer to «Steering Column Trim Covers Replacement»(ref-196954-S01449608982005101000000) . IMPORTANT: If the ignition switch is replaced and a learn procedure is not performed, the engine will crank but not start or will start and stall immediately.
4. Perform the vehicle theft deterrent system learn procedure. Refer to «Programming Theft Deterrent System Components»(ref-196961-S05204491162005101000000) in Theft Deterrent.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-196956-S04090516432005101000000) in Engine Electrical.
2. Disable the SIR system. Refer to «SIR Disabling and Enabling Zone 3»(ref-196951-S39158394842005101000000) in SIR.
3. Remove the steering column trim covers. Refer to «Steering Column Trim Covers Replacement»(ref-196954-S01449608982005101000000) .
4. Turn the ignition lock cylinder to the RUN position.
5. Depress the first retainer through the lock housing access hole (2) with a small Allen wrench or similar pick-type tool. The lock cylinder will back out slightly.
6. Depress the second retainer through the lock housing access hole (1). The lock cylinder will back out slightly again.
7. Pull the lock cylinder out enough to locate the second retainer to the lock housing access hole (2).
8. Depress the retainer though the access hole (2) a second time. The ignition cylinder should release from the housing. If not, the ignition cylinder may need to be moved in and out several times to locate the retainer correctly in the hole.
9. Remove the lock cylinder from the lock housing.

1. Position the lock cylinder in the run position. Insert the cylinder into the lock housing.
2. Rotate the lock cylinder in the housing. Verify proper rotation.
3. Install the steering column trim covers. Refer to «Steering Column Trim Covers Replacement»(ref-196954-S01449608982005101000000) .
4. Enable the SIR system. Refer to «SIR Disabling and Enabling Zone 3»(ref-196951-S39158394842005101000000) in SIR.
5. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-196956-S04090516432005101000000) in Engine Electrical.

1. Remove the steering wheel. Refer to «Steering Wheel Replacement»(ref-196954-S16469050772005101000000) .
2. Remove the steering column trim covers. Refer to «Steering Column Trim Covers Replacement»(ref-196954-S01449608982005101000000) .
3. Remove the inflatable restraint steering wheel module. Refer to «Inflatable Restraint Steering Wheel Module Coil Replacement»(ref-196951-S07249891472005101000000) in SIR.
4. If applicable, disconnect the ignition lock cylinder solenoid harness connector.
5. Disconnect the ignition switch harness connector.
6. Using the following procedure, remove the ignition lock cylinder case shear bolt: Use a hammer and chisel to bite into the shear bolt at a position offset from center. Tap the chisel to rotate the bolt in order to loosen it. Repeat as necessary until bolt is loose enough to remove.
7. Remove the ignition lock cylinder case housing from the steering column.
8. Remove the ignition lock cylinder from the lock cylinder case housing. Refer to «Ignition Lock Cylinder Replacement»(ref-196954-S33256823522005101000000) .

1. Install the ignition lock cylinder into the lock cylinder housing. Refer to «Ignition Lock Cylinder Replacement»(ref-196954-S33256823522005101000000) .
2. Install the lock cylinder case housing to the steering column.
3. Install the lock cylinder case housing clamp and a new shear bolt. Ensure the tab is correctly positioned.
4. Tighten the shear bolt until the head breaks off.
5. If applicable, connect the ignition lock cylinder solenoid harness connector.
6. Connect the ignition switch harness connector to the lock module.
7. Install the inflatable restraint steering wheel module. Refer to «Inflatable Restraint Steering Wheel Module Coil Replacement»(ref-196951-S07249891472005101000000) in SIR.
8. Install the steering column trim covers. Refer to «Steering Column Trim Covers Replacement»(ref-196954-S01449608982005101000000) .
9. Install the steering wheel. Refer to «Steering Wheel Replacement»(ref-196954-S16469050772005101000000) .

1. Remove the steering column trim covers. Refer to «Steering Column Trim Covers Replacement»(ref-196954-S01449608982005101000000) .
2. Disconnect the Ignition lock cylinder solenoid harness connector.
3. Remove the Ignition lock cylinder solenoid screws.
4. Remove the Ignition lock cylinder solenoid from the lock cylinder case housing.

1. Install a new spring over the ignition lock cylinder solenoid plunger.
2. Carefully install the new ignition lock cylinder solenoid over the plunger.
3. Seat the ignition lock cylinder solenoid on the lock cylinder case housing and install the screws. Tighten: Tighten the screws to 2 N.m (17 lb in).
4. Connect the lock cylinder solenoid harness connector.
5. Install the steering column trim covers. Refer to «Steering Column Trim Covers Replacement»(ref-196954-S01449608982005101000000) .
6. Check the operation of the ignition lock cylinder solenoid.

1. Remove the steering column trim covers. Refer to «Steering Column Trim Covers Replacement»(ref-196954-S01449608982005101000000) .
2. Disconnect the multifunction turn signal switch harness connector.
3. Remove the multifunction turn signal switch retaining screws.
4. Remove the multifunction turn signal switch from the steering column.

1. Install the multifunction turn signal switch to the steering column. Tighten: Tighten the multifunction turn signal switch screws to 2 N.m (17 lb in).
2. Connect the multifunction turn signal switch harness connector.
3. Install the steering column trim covers. Refer to «Steering Column Trim Covers Replacement»(ref-196954-S01449608982005101000000) .

Steering Wheel Replacement

Tools Required

1. J 42578 Steering Wheel Puller Legs. See «Special Tools»(ref-196954-S12554810642005101000000) .
2. J 1859-A Steering Wheel Puller. See «Special Tools»(ref-196954-S12554810642005101000000) .

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zone 3»(ref-196951-S39158394842005101000000) in SIR.
2. Remove the inflatable restraint steering wheel module. Refer to «Inflatable Restraint Steering Wheel Module Replacement»(ref-196951-S15513241662005101000000) in SIR.
3. If equipped with cruise control, disconnect the cruise control switch connector from the steering column.
4. Remove the steering wheel nut.
5. Remove the steering wheel. It may be necessary to use the J 42578 and J 1859-A or equivalent to remove the steering wheel. See «Special Tools»(ref-196954-S12554810642005101000000) .

1. Align the steering wheel to the steering column and install the steering wheel.
2. Install the steering wheel nut. Tighten: Tighten the steering wheel nut to 41 N.m (30 lb ft).
3. If equipped with cruise control, connect the cruise control switch connector.
4. Install the inflatable restraint steering wheel module. Refer to «Inflatable Restraint Steering Wheel Module Replacement»(ref-196951-S15513241662005101000000) in SIR.
5. Enable the SIR system. Refer to «SIR Disabling and Enabling Zone 3»(ref-196951-S39158394842005101000000) in SIR.

1. Disable the SIR system. Refer to «SIR Disabling and Enabling Zone 3»(ref-196951-S39158394842005101000000) in SIR.
2. Remove the inflatable restraint steering wheel module. Refer to «Inflatable Restraint Steering Wheel Module Replacement»(ref-196951-S15513241662005101000000) in SIR.
3. Remove the steering wheel. Refer to «Steering Wheel Replacement»(ref-196954-S16469050772005101000000) .
4. Place the steering wheel face down on a clean surface.
5. Remove the steering wheel shroud screws.
6. Remove the steering wheel shroud.

1. Install the steering wheel shroud and screws. Tighten: Tighten the steering wheel shroud screws to 2.5 N.m (22 lb in).
2. Install the steering wheel. Refer to «Steering Wheel Replacement»(ref-196954-S16469050772005101000000) in Steering Wheel and Column.
3. Install the inflatable restraint steering wheel module. Refer to «Inflatable Restraint Steering Wheel Module Replacement»(ref-196951-S15513241662005101000000) in SIR.
4. Enable the SIR system. Refer to «SIR Disabling and Enabling Zone 3»(ref-196951-S39158394842005101000000) in SIR.

1. Place the steering wheel in the straight forward position.
2. Remove the steering Wheel. Refer to «Steering Wheel Replacement»(ref-196954-S16469050772005101000000) .
3. Remove the I/P lower compartment. Refer to «Compartment Replacement - Instrument Panel (I/P) - Lower»(ref-196967-S22123691462005101000000) in Instrument Panel, Gages and Console.
4. Remove the column trim covers. Refer to «Steering Column Trim Covers Replacement»(ref-196954-S01449608982005101000000) .
5. Disconnect the head lamp/turn signal harness connector from the SIR coil module assembly.
6. Disconnect the wiper/washer harness connector from the SIR coil module assembly.
7. Disconnect the SIR coil harness connector from the SIR coil module assembly.
8. Remove the SIR coil Module assembly. Refer to «Inflatable Restraint Steering Wheel Module Coil Replacement»(ref-196951-S07249891472005101000000) in SIR.
9. Disconnect the ignition lock cylinder harness connector.
10. Disconnect the ignition switch harness connector.
11. Place scribe marks on the intermediate shaft to steering column, for use during assembly.
12. Remove the intermediate shaft pinch bolt at the steering column and discard.
13. Slide the intermediate shaft off the steering column.
14. Disconnect the EPS control module power feed harness connector.
15. Disconnect the EPS control module small harness connector.
16. Remove the steering column pivot bolt.
17. Remove the steering column mounting bolts.
18. Remove the column from the vehicle and place on a bench.
19. Remove the ignition lock cylinder case from the steering column. Refer to «Ignition Lock Cylinder Case Replacement»(ref-196954-S19391417782005101000000) .

1. If replacing the steering column duplicate the scribed mark placed on the old column.
2. Install the ignition lock cylinder case to the steering column. Refer to «Ignition Lock Cylinder Case Replacement»(ref-196954-S19391417782005101000000) .
3. Position the steering column in the vehicle.
4. Hand start the steering column mid-pivot bolt.
5. Hand start the steering column mounting bolts.
6. Tighten the column bolts using the following order: Tighten: Tighten the mid-pivot bolt to 25 N.m (18 lb ft). Tighten the RH column mounting bolt to 25 N.m (18 lb ft). Tighten the LH column mounting bolt to 25 N.m (18 lb ft).
7. Connect the EPS control module power feed harness connector.
8. Connect the EPS control module small harness connector.
9. Slide the intermediate shaft onto the steering column while aligning the previously scribed marks.
10. If the steering column to intermediate shaft was not previously scribed. Refer to «Intermediate Steering Shaft Replacement»(ref-196954-S15128393302005101000000) .
11. Install a new intermediate shaft pinch bolt. Tighten: Tighten bolt to 34 N.m (25 lb ft).
12. Connect the ignition lock cylinder harness connector.
13. Connect the ignition switch harness connector.
14. Install the SIR coil module assembly. Refer to «Inflatable Restraint Steering Wheel Module Coil Replacement»(ref-196951-S07249891472005101000000) in SIR.
15. Connect the SIR coil harness connector to the SIR coil module assembly.
16. Connect the wiper/washer harness connector to the SIR coil module assembly.
17. Connect the head lamp/turn signal harness connector to the SIR coil module assembly.
18. Install the upper and lower shroud. Refer to «Steering Wheel Shroud Replacement»(ref-196954-S15429397442005101000000) .
19. Install the I/P lower compartment. Refer to «Compartment Replacement - Instrument Panel (I/P) - Lower»(ref-196967-S22123691462005101000000) .
20. Install the steering wheel. Refer to «Steering Wheel Replacement»(ref-196954-S16469050772005101000000) .

1. Place the steering wheel in the straight forward position.
2. Remove the steering wheel. Refer to «Steering Wheel Replacement»(ref-196954-S16469050772005101000000) .
3. Remove the column trim covers. Refer to «Steering Column Trim Covers Replacement»(ref-196954-S01449608982005101000000) .
4. Remove the SIR coil module assembly. Refer to «Inflatable Restraint Steering Wheel Module Coil Replacement»(ref-196951-S07249891472005101000000) in SIR.
5. Remove the ignition lock cylinder case. Refer to «Ignition Lock Cylinder Case Replacement»(ref-196954-S19391417782005101000000) .
6. Remove the steering column mounting bolts.
7. Support the lower column as necessary.
8. Remove the jacket attaching bolts.
9. Remove the upper jacket from the steering column.

1. Clean the column shaft splines
2. Use the supplied grease to apply 2 grams (0.07 oz) of grease to the column shaft splines.
3. Install the new jacket on the steering column.
4. Install the jacket attaching bolts. Tighten: Tighten the bolts to 11 N.m (97 lb in).
5. Install the steering column mounting bolts. Tighten: Tighten the RH bolt to 25 N.m (18 lb ft). Tighten the LH bolt to 25 N.m (18 lb ft).
6. Install the ignition lock cylinder case. Refer to «Ignition Lock Cylinder Case Replacement»(ref-196954-S19391417782005101000000) .
7. Install the SIR coil module assembly. Refer to «Inflatable Restraint Steering Wheel Module Coil Replacement»(ref-196951-S07249891472005101000000) in SIR.
8. Install the column trim covers. Refer to «Steering Column Trim Covers Replacement»(ref-196954-S01449608982005101000000) .
9. Install the steering wheel. Refer to «Steering Wheel Replacement»(ref-196954-S16469050772005101000000) .