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


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

Reply
 
Thread Tools Display Modes
Old 08-12-2015, 08:42 PM   #1
rusted
New Member
rusted is on a distinguished road
 
Join Date: Jun 2008
Posts: 4
Default Original 2003 ion cat converter

I'm finally replacing my original cat converter. I hit a snag with the connection between the cat and the resonator. How does this come apart? It almost looks like the bolts and nuts have weld on them. This is straight from the factory so no one has touched the exhaust. Any info or advice ,as always, is appreciated.

Rusted

REWARD EXCELLENCE!

Add to rusted's Reputation
Rate the quality of this post and help rusted reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
rusted is offline   Reply With Quote
SaturnFans.com Sponsored Links
Old 08-12-2015, 09:02 PM   #2
mitche
Junior Member
mitche has a spectacular aura aboutmitche has a spectacular aura aboutmitche has a spectacular aura about
 
mitche's Avatar
 
Join Date: May 2015
Location: Long Island
Posts: 44

2006 ION-3 Sedan
Default Re: Original 2003 ion cat converter

If it's the same as my 06, the bolts have a button head and the bolt is splined so it doesn't turn in the flange, no wrench on bolt, only on nut, but that's most likely rusted beyond recognition. Torch or use cutoff wheel on nut side, front of car, just cut the nut as close to flange as possible. Then after cat is out hammer out the rest of bolt. Unless you can get the nut off with a tool but by the looks of mine I didn't even bother. Up to you if you want to look for oem bolts or normal ones after that.

...
I don't speed much anymore but I don't slow down for turns much either to keep the fun factor.

REWARD EXCELLENCE!

Add to mitche's Reputation
Rate the quality of this post and help mitche reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
mitche is offline   Reply With Quote
Old 08-13-2015, 12:24 AM   #3
goaliemo
Member
goaliemo is on a distinguished road
 
Join Date: Mar 2014
Location: Louisiana
Posts: 382
 

2003 ION-1 Sedan
2006 ION Red Line
Default Re: Original 2003 ion cat converter

Jack the car up, get it on stands, soak the bolts with WD40 for about 15 min.

I believe it was 2 15mm bolts, put your cresent wrench on it, and tap with a hammer. I got them right off, no issue. same with the top flange. Although it is easier to just unbolt the header and pull the whole thing out as space is tight.

...
I'm just a guy that enjoys my Ions.
Try Google, first. Then ask.

REWARD EXCELLENCE!

Add to goaliemo's Reputation
Rate the quality of this post and help goaliemo reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
goaliemo is offline   Reply With Quote
Old 08-13-2015, 10:40 PM   #4
2006 ion2
Master Member
2006 ion2 has a spectacular aura about2006 ion2 has a spectacular aura about2006 ion2 has a spectacular aura about
 
Join Date: Jun 2007
Location: Da U.P, EH!
Posts: 8,863
 

2007 ION-2 Sedan
Default Re: Original 2003 ion cat converter

Protect them bolts from water, good idea. To get them loose, you might want to try a penetrating fluid like pb blaster.

...
2007 Saturn Ion 2
2003 Chevrolet venture lt

trifecta dealer for the U.P. and WI. There is no two door ion. Proudly driving one of the last saturns produced before gm killed the brand.

REWARD EXCELLENCE!

Add to 2006 ion2's Reputation
Rate the quality of this post and help 2006 ion2 reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
2006 ion2 is offline   Reply With Quote
Old 08-14-2015, 04:52 PM   #5
kevin.st56
Senior Member
kevin.st56 has a spectacular aura aboutkevin.st56 has a spectacular aura about
 
kevin.st56's Avatar
 
Join Date: Apr 2012
Location: South Louisiana
Posts: 1,019
 

2003 ION-2 Sedan
Default Re: Original 2003 ion cat converter

Quote:
Originally Posted by goaliemo View Post
Jack the car up, get it on stands, soak the bolts with WD40 for about 15 min.

I believe it was 2 15mm bolts, put your cresent wrench on it, and tap with a hammer. I got them right off, no issue. same with the top flange. Although it is easier to just unbolt the header and pull the whole thing out as space is tight.
03 2.2 ions will have 3 bolts between DP and TP, not 2.
I think they are 12 or 13mm nuts

any 2.0, 05+ 2.2, and all 2.4, will have 2 bolt flange at the end of the DP.
at least this is what I found when I was DP shopping, and having a stainless catback with a 3 bolt to connect to the DP.

...
03 ion-2 Sedan 5sp
94 Honda civic automatic "VTEC yo"
05 Santa Fe 2.7L (Fefe)

"A problem clearly stated, is a problem half solved."

♕KCCO

REWARD EXCELLENCE!

Add to kevin.st56's Reputation
Rate the quality of this post and help kevin.st56 reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
kevin.st56 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
Catalytic converter 2003 6cyl AWD dabears06082 Vue General 1 05-07-2013 12:13 PM
2003 Ion Catalytic Converter Questions / HELP jess3292 Ion General 3 12-25-2009 10:26 PM
2003 L300 going to California -- needs new catalytic converter solemneyed L-Series General 13 12-04-2008 11:34 AM
Original 2003 Ion Owners? Jaseball Ion General 12 05-31-2007 02:06 AM
2006 Vue original seat covers fit 2003 vue?? Vuebots Vue General 1 07-09-2006 11:32 AM


All times are GMT -5. The time now is 10:49 PM.

Advanced Forum Search | Advanced Photo Search


Powered by vBulletin® Version 3.8.9
Copyright ©2000 - 2017, vBulletin Solutions, Inc.
SaturnFans.com. The Saturn Enthusiasts Site.