GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 ION 🢒 Engine 🢒 Engine Mechanical - 2.0L (LSJ) 🢒 Engine Replacement

Removal Procedure
  1. With the tires in the straight forward position, remove the key from the ignition.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  3. Remove the air outlet duct . Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 2.0L (LSJ).

    4. Object Number: 857193 Size: SH
  4. Secure the cooling module to the upper body structure.
  5. Relieve the fuel system pressure. Refer to Fuel Pressure Relief in Engine Controls - 2.0L (LSJ).

    6. Object Number: 1387192 Size: SH
  6. Disconnect the fuel line from the fuel rail.
  7. Remove the supercharger. Refer to Supercharger Replacement .
  8. Remove the charge air radiator hose. Refer to Charge Air Cooler Inlet Hose Replacement in Engine Cooling.
  9. Remove the charge air cooler hose. Refer to Charge Air Cooler Outlet Hose Replacement in Engine Cooling.
  10. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  11. Remove the radiator inlet hose.
  12. Remove the surge tank to cylinder head pipe. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement and Radiator Surge Tank Outlet Hose/Pipe Replacement in Engine Cooling.
  13. Remove the radiator outlet hose.

    14. Object Number: 786506 Size: SH
  14. Remove the inlet (1) and outlet (2) heater hoses. Refer to Heater Inlet Hose Replacement and to Heater Outlet Hose Replacement in Heating, Ventilation and Air Conditioning.

    15. Object Number: 851553 Size: SH
  15. Disconnect the following harness connectors:
    16. • TMAP sensor
    • ETC
    • Map sensor
    • BARO sensor
    • Crankshaft sensor
    • Oil pressure sensor
    • Purge solenoid
    • Ignition coil modules
    • O2 sensor
    • Vehicle speed sensor
    • Engine temperature sensor
    • Boost solenoid
    • Back-up lamp switch
  16. Remove the engine drive belt. Refer to Drive Belt Replacement .
  17. Disconnect the charge air cooler hoses.
  18. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  19. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.

    20. Object Number: 865182 Size: SH
  20. Disconnect the compressor and condenser hose assembly from the compressor.
  21. Remove the AC compressor bolts and set the compressor aside.

    22. Object Number: 758469 Size: SH
  22. Disconnect the starter harness connectors (3,4,5).
  23. Disconnect the generator harness connectors.
  24. Drain the engine oil.
  25. Disconnect the front exhaust pipe from the exhaust manifold. Refer to Exhaust Manifold Replacement in Engine Exhaust.
  26. Disconnect the transmission shift cable from the transmission.
  27. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.
  28. Remove the engine mount. Refer to Engine Mount Replacement .

    29. Object Number: 851558 Size: SH
  29. Remove the left transmission mount. Refer to Transmission Mount Replacement - Left Side in Manual Transmission - MU3.

    30. Object Number: 851720 Size: SH
  30. Disconnect the stabilizer links from the stabilizer bar. Refer to Stabilizer Shaft Link Replacement in Front Suspension.

    31. Object Number: 854972 Size: SH
  31. Disconnect the outer tie rod ends from the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.

    32. Object Number: 851655 Size: SH

    Important: In order to prevent possible SIR system deployment, do not attempt to rotate the steering shaft.

  32. Disconnect the intermediate shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.

    33. Object Number: 851659 Size: SH
  33. Disconnect the lower control arms from the steering knuckles. Refer to Lower Control Arm Replacement in Front Suspension.

    34. Object Number: 851677 Size: SH
  34. Disconnect the drive axles from the steering knuckle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  35. Use a paint pen or magic marker in order to mark the frame to body position.

    36. Object Number: 851651 Size: SH
  36. Lower the vehicle to about 3 feet off the ground in order to position the lift table under the frame.
  37. Use wood blocks as necessary between the lift table and the frame to support the assembly.
  38. Slowly remove the frame bolts using the following sequence:
    39. 38.1. Remove the front frame bolts.
    38.2. Partially unscrew the rear frame bolts until 1.5 inches of bolt shank is exposed.
  39. Slowly lower the table to the floor.
  40. Attach the engine lift hoist to the engine lift hooks.

    41. Object Number: 758470 Size: SH
  41. Remove the starter.
  42. Remove the transmission to engine bolts.
  43. Separate the engine from the transmission.
  44. Remove the clutch pressure plate and disk.
  45. Remove the following components:
    46. • Exhaust manifold
    • Exhaust manifold studs
    • Engine mount bracket
    • Fuel rail
    • Thermostat housing and feed pipe
    • Generator
  46. Remove the engine from the engine lift.

Installation Procedure
  1. Attach the engine lift hoist to the engine lift hooks.
  2. Install the following components:
    3. • Exhaust manifold
    • Refer to Exhaust Manifold Replacement in Engine Exhaust.
    • Engine mount bracket
    • Refer to Engine Mount Bracket Replacement .
    • Fuel rail
    • Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 2.0L (LSJ).
    • Idler pulley
    • Drive belt tensioner
    • Refer to Drive Belt Tensioner Replacement - Supercharger .
    • Thermostat housing and feed pipe
    • Refer to Engine Coolant Thermostat Replacement in Engine Cooling.
    • Generator
    • Refer to Generator Replacement .
    •  Flywheel
    • Refer to Engine Flywheel Replacement .
    • Clutch pressure plate and disk
    • Refer to Clutch Pressure and Driven Plate Replacement in Clutch.
    • AC Compressor
    • Refer to Air Conditioning Compressor Replacement in Heating, Ventilation, and Air Conditioning.
  3. Align the engine to the transmission.

    4. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 851293 Size: SH

    Important: The number 3 bolt location is not used.

  4. Secure the engine to the transmission.

    5. Tighten
    Tighten the transmission to engine bolts to 75 N·m (55 lb ft).


    Object Number: 758470 Size: SH
  5. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
  6. Remove the engine lift from the engine.

    7. Object Number: 851651 Size: SH
  7. Raise and position the frame and powertrain assembly to the vehicle.
  8. Hand start all the frame bolts while aligning the frame to the paint marks.
  9. Tighten the frame bolts.

    10. Tighten
    Tighten the frame bolts to 100 N·m (74 lb ft) plus 180 degrees.

  10. Remove the lift table.

    11. Object Number: 851677 Size: SH
  11. Connect the drive axles to the steering knuckles. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.

    12. Object Number: 851659 Size: SH
  12. Connect the lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement in Front Suspension.

    13. Object Number: 851655 Size: SH
  13. Connect the intermediate steering shaft to the steering gear. Refer to Steering Gear Replacement in Power Steering System.

    14. Object Number: 854972 Size: SH
  14. Connect the outer tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.

    15. Object Number: 851720 Size: SH
  15. Connect the stabilizer links to the stabilizer bar. Refer to Stabilizer Shaft Link Replacement in Front Suspension.

    16. Object Number: 851558 Size: SH
  16. Install the left transmission mount. Refer to Transmission Mount Replacement - Left Side in Manual Transmission -  MU3.

    17. Object Number: 851553 Size: SH
  17. Install the engine mount. Refer to Engine Mount Replacement .
  18. Remove the wood blocks between the powertrain and frame.
  19. Connect the transmission shift cable to the transmission.

    20. Object Number: 878834 Size: SH
  20. Connect the exhaust takedown pipe to the exhaust manifold.

    21. Tighten
    Tighten the nuts to 30 N·m (22 lb ft).

  21. Connect the generator harness connectors.

    22. Tighten
    Tighten the generator terminal nut to 20 N·m (15 lb ft).


    Object Number: 758469 Size: SH
  22. Connect the starter harness connectors (3,4,5).

    23. Tighten
    Tighten the battery terminal nut to 17 N·m (13 lb ft).

    Tighten
    Tighten the S-terminal nut to 3 N·m (27 lb in).

  23. Install the compressor and condenser hose assembly to the compressor. Refer to Compressor Hose Assembly Replacement in Heating, Ventilation, and Air Conditioning.
  24. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.
  25. Install the supercharger. Refer to Supercharger Replacement .
  26. Install the engine drive belt. Refer to Drive Belt Replacement .
  27. Connect the charge air cooler hoses.
  28. Connect the following harness connectors:
    29. • TMAP sensor
    • ETC
    • Map sensor
    • Crankshaft sensor
    • Oil pressure sensor
    • Purge solenoid
    • BARO sensor
    • Ignition coil modules
    • O2 sensor
    • Vehicle speed sensor
    • Engine temperature sensor
    • Boost solenoid

    Object Number: 786506 Size: SH
  29. Install the inlet heater hose (1) and outlet heater hose (2). Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement in Heating, Ventilation, and Air Conditioning.
  30. Install the radiator outlet hose. Refer to Radiator Inlet Hose Replacement in Engine Cooling.

    31. Object Number: 1387192 Size: SH
  31. Connect the fuel line to the fuel rail.
  32. Install the surge tank to the cylinder head pipe.

    33. Tighten
    Tighten the bolt to 10 N·m (89 lb in).


    Object Number: 857193 Size: SH
  33. Release the cooling module from the upper body structure.
  34. Install the air outlet duct . Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 2.0L (LSJ).
  35. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  36. Fill the engine with engine oil to the proper level. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
  37. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  38. Road test the vehicle.