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Old 09-01-2017, 09:48 AM   #1
WrightMan
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Location: Muskego, WI
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2004 ION-2 Sedan
Happy 2004 DIY Cold Air Intake

I just picked up a 2004 Saturn Ion which I think is a level 3 since it has the sun roof, key less entry, power windows, aluminum rims, and everything but no white gauges. The first thing I plan on doing is a CAI but would rather not pay over $200 for one. Does anyone have any suggestions on how to make one for my year? I was thinking about cutting out part of the air box and adding a gasket material to the right side to prevent hot air from the engine. The tube is oddly shaped oval though.
Any tips would be appreciated for this or any other items I should be doing with this car. Next I was looking for a larger TB but have not seen any for this. Otherwise I might just do a port and polish.
Thanks!

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

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Old 09-16-2017, 10:52 PM   #2
NoDisassemble#5
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Location: Fort Wayne, IN
Posts: 21

2004 ION-3 Quad Coupe
Default Re: 2004 DIY Cold Air Intake

Don't waste your money. CAI is just for looks. Check out Mighty Car Mods myth bust on this subject. It not only provides zero improvement to your horse power, but it takes away a small fraction. You're more efficient with your factory air box. If you're going for looks grab a can of engine paint ($7) and clean + shoot your air box. Good luck

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Old 12-03-2018, 11:30 PM   #3
Satuneez
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Default Re: 2004 DIY Cold Air Intake

Did you push through with the CAI?

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Old 12-04-2018, 10:44 AM   #4
WrightMan
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2004 ION-2 Sedan
Default Re: 2004 DIY Cold Air Intake

I ended up making one but it doesn't look that great but over winter I am planning on making a new air box out of stainless steel sheet metal and putting that around the AEM CAI to protect it from the engine bay. I decided to just buy the CAI since the piping I made doesn't look as good but wanted something to block the air from the engine like the systems I have on my other vehicles from K&N. Still debating on if I want to do ceramic coating or keep it as bare stainless steel and am planning on using a decent gauge kitchen grade stainless that my brother can get from his work as scrap pieces. Stainless steel dissipates heat well and should provide a decent shield on it's own but the ceramic coating would add to that and give it a painted look that I can match to the valve cover which I am planning on having redone when I replace the head. Initially I wasn't sure how long term I would be keeping the car which is why I was going to limit my spending on it but since I was forced to sell my built up crown vic this is going to be my new project car to build up.

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

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Old 12-08-2018, 04:37 AM   #5
19boneatock88
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2004 ION-2 Sedan
2006 ION-2 Quad Coupe
Default Re: 2004 DIY Cold Air Intake

I'm working on increasing the breathing capacity of the stock airbox instead of doing an exposed filter element and having to try and isolate it from the engine bay... I figure that since the airbox pulls air at close to ambient air temp, it is already a fairly efficient CAI, but I found that it's lacking in airflow potential in stock form...

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(M86), 139k...
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

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