SaturnFans.com
what's new (beta) - classifieds - forums - photos


Go Back   SaturnFans.com Forums > Models > Saturn Ion > Ion Mods
Register FAQ Members List Groups Calendar Chat Room Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Display Modes
Old 07-18-2019, 12:18 PM   #1
19boneatock88
Member
19boneatock88 is on a distinguished road
 
Join Date: Sep 2018
Location: Glenville WV
Posts: 114

2004 ION-2 Sedan
2006 ION-2 Quad Coupe
Default Preparing to do a header and full exhaust, what to expect?

So I’ve had some intermittent exhaust related problems with the car, decided the best way to fix it is to replace everything from the exhaust port, out to the bumper cover. I’m all set to do the pipe up in 2.25” tube and have my muffler and resonator already (waiting on header, flex pipe/downpipe flange, and O2 bungs), is there anything I need to expect when removing the manifold from a 15 year old Ion?

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(FY1 swap), 178K
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

REWARD EXCELLENCE!

Add to 19boneatock88's Reputation
Rate the quality of this post and help 19boneatock88 reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
19boneatock88 is offline   Reply With Quote
SaturnFans.com Sponsored Links
Old 08-05-2019, 01:18 PM   #2
WrightMan
Member
WrightMan is on a distinguished road
 
Join Date: Aug 2017
Location: Muskego, WI
Posts: 96

2004 ION-2 Sedan
Default Re: Preparing to do a header and full exhaust, what to expect?

I was thinking about adding a shorty header since I have already done the rest of the exhaust but how did it go? Did any of the studs break?

...
2004 Saturn Ion AEM CAI, Aftermarket Head and Taillights, ZZP 2.5" Cat and Custom 2.5" Complete Exhaust
2000 F150 Off-Road 3" Duals and K&N Intake SCT Livewire Tuner
2013 Escape 2.0T AWD CAI

REWARD EXCELLENCE!

Add to WrightMan's Reputation
Rate the quality of this post and help WrightMan reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
WrightMan is offline   Reply With Quote
Old 08-05-2019, 03:47 PM   #3
hudypete1
Member
hudypete1 is a jewel in the roughhudypete1 is a jewel in the roughhudypete1 is a jewel in the rough
 
Join Date: Mar 2016
Location: Lansing MI
Posts: 108

2007 ION-3 Sedan
2008 VUE 2.4L
Default Re: Preparing to do a header and full exhaust, what to expect?

Soak your exhaust manifold studs/bolts with Kroil for a couple of days. You don't want to bust a stud in the head.

To soak them, you probably have to remove the heat shield, which could be a pain if you do it for a couple of days, but it is worth it.

I have a 2.4L ecotec head that I am working on in which the previous owner/mechanic busted an exhaust stud and then did a piss poor job drilling it out and actually drilled into the oil journal. Do now I have a slow oil leak around their even worse patch job around that bolt. Don't be that person.

You might want to get extra OEM studs (from a junk yard) just in case.

The 2.4L and 2.2L ecotec share the same head so it is about the same process regardless.

...
Peter

CURRENT:
08 Vue XE Black 2.4L
07 Ion 3 Savannah Green Metallic 2.4L
04 Ion 2 Berry Red 2.2

PREVIOUS:
99 SL2 Silver Plum
99 SL2 Dark Blue
95 SL2 Lilac Metallic
94 SW2 White

REWARD EXCELLENCE!

Add to hudypete1's Reputation
Rate the quality of this post and help hudypete1 reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
hudypete1 is offline   Reply With Quote
Old 08-06-2019, 02:02 PM   #4
WrightMan
Member
WrightMan is on a distinguished road
 
Join Date: Aug 2017
Location: Muskego, WI
Posts: 96

2004 ION-2 Sedan
Default Re: Preparing to do a header and full exhaust, what to expect?

If you are doing this on the 04 what header did you get or did you find a way to modify the thermostat to make it work?

...
2004 Saturn Ion AEM CAI, Aftermarket Head and Taillights, ZZP 2.5" Cat and Custom 2.5" Complete Exhaust
2000 F150 Off-Road 3" Duals and K&N Intake SCT Livewire Tuner
2013 Escape 2.0T AWD CAI

REWARD EXCELLENCE!

Add to WrightMan's Reputation
Rate the quality of this post and help WrightMan reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
WrightMan is offline   Reply With Quote
Old 10-23-2019, 11:37 PM   #5
19boneatock88
Member
19boneatock88 is on a distinguished road
 
Join Date: Sep 2018
Location: Glenville WV
Posts: 114

2004 ION-2 Sedan
2006 ION-2 Quad Coupe
Default Re: Preparing to do a header and full exhaust, what to expect?

I wanted to update this, forgot to lol. We ended up installing the header I got from eBay from blackhorse racing. It didn’t fit at first but we reshaped the number three exhaust runner to clear the thermostat housing and it worked fine, has yet to leak. Used a ZZP downpipe flange/flex pipe and all was good. Used a 18” Thrush glasspack as a resonator and a Thrush welded muffler and poked the tip through the bumper cover with a Thrush engraved plate above for decoration and to make my car unique

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(FY1 swap), 178K
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

REWARD EXCELLENCE!

Add to 19boneatock88's Reputation
Rate the quality of this post and help 19boneatock88 reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
19boneatock88 is offline   Reply With Quote
Old 10-26-2019, 12:06 PM   #6
WrightMan
Member
WrightMan is on a distinguished road
 
Join Date: Aug 2017
Location: Muskego, WI
Posts: 96

2004 ION-2 Sedan
Default Re: Preparing to do a header and full exhaust, what to expect?

Did you look into if a newer thermostat would fit or have a way to modify that before cutting up that nice new header? What size exhaust did you all go with?

...
2004 Saturn Ion AEM CAI, Aftermarket Head and Taillights, ZZP 2.5" Cat and Custom 2.5" Complete Exhaust
2000 F150 Off-Road 3" Duals and K&N Intake SCT Livewire Tuner
2013 Escape 2.0T AWD CAI

REWARD EXCELLENCE!

Add to WrightMan's Reputation
Rate the quality of this post and help WrightMan reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
WrightMan is offline   Reply With Quote
Old 10-30-2019, 06:55 AM   #7
19boneatock88
Member
19boneatock88 is on a distinguished road
 
Join Date: Sep 2018
Location: Glenville WV
Posts: 114

2004 ION-2 Sedan
2006 ION-2 Quad Coupe
Default Re: Preparing to do a header and full exhaust, what to expect?

We didn’t check on modifying the thermostat, it was one of those things where we just instinctively made it all fit. I used 2.25” tubing for the entire system

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(FY1 swap), 178K
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

REWARD EXCELLENCE!

Add to 19boneatock88's Reputation
Rate the quality of this post and help 19boneatock88 reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
19boneatock88 is offline   Reply With Quote
Reply



Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
full exhaust white ion quad Ion General 5 12-30-2009 10:12 PM
Just installed full exhaust, header ajs_saturn S-Series Mods 59 07-21-2007 12:13 PM
Full Exhaust Borntohula S-Series Mods 11 12-07-2006 12:30 AM
Full exhaust gain Sony Mods and Performance 15 10-13-2005 03:32 PM
help, i'm trying to find a full exhaust pic... amazinghl General Saturn Discussion 4 02-07-2003 06:59 PM


All times are GMT -4. The time now is 04:24 PM.

Advanced Forum Search | Advanced Photo Search


Powered by vBulletin® Version 3.8.9
Copyright ©2000 - 2020, vBulletin Solutions, Inc.
SaturnFans.com. The Saturn Enthusiasts Site.