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Old 07-16-2018, 07:52 PM   #1
uluz2a6
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Default 03 Ion P0032 & P0135

So i have the codes P0032 & P0135 on my 2005 Ion 2.2. I have verified that the ERLS fuse is good. I have traced the wiring as best I can to the box with no evidence of damage. The connector and prongs within appear perfect on both the sensor side and harness side. After those tests/inspections I swapped in another O2 sensor from another Ion in my garage. Zero change.

I do not know where it receives its ground from nor do I know which relay (if any) provides its power.

I would love a hint or better yet a "hey, just ___________ and it will cure it" message.

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Old 07-17-2018, 11:33 AM   #2
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Default Re: 03 Ion P0032 & P0135

I have 12V with ignition on at the harness connector. Ground also present. Anyone one have a diagram showing the wiring?

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Old 07-17-2018, 12:35 PM   #3
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2007 ION-2 Quad Coupe
Default Re: 03 Ion P0032 & P0135

Was the oxygen sensor you changed mounted in the exhaust manifold? That is the upstream sensor. I think you already knew this, but couldn't say beyond a reasonable doubt.

The upstream oxygen sensor heater gets fed +12V through the pink wire from the ERLS fuse. The heater circuit ground is the dark green wire which goes to pin 75 at the ECM connector.

You need to make sure the dark green wire isn't "shorted" to ground. If it is, the heater circuit may still function properly, because it's still getting a ground connection (which would also test fine when testing for resistance to ground at the connector), but the ECM won't be able to control/monitor it. This seems like the most likely scenario.

The only other possibilities would be a bad ECM or a bad ECM ground connection. The ECM is grounded at G107 which located on the rear left part of the cylinder head as shown in picture below. The picture's source says it is for a 2006 Ion (and the presence of cam solenoids in the diagram indicates a 2.4L), but a 2003's ground should be in the same location. A bad ECM ground is possible, but doesn't seem likely since it appears to be functioning properly aside from the oxygen sensor faults.

I've attached a couple diagrams so you can view them.

2003-2004_Saturn_Ion_engine-controls-3-of-4.pdf
2003-2004_Saturn_Ion_engine-controls-4-of-4.pdf
2006_Saturn_Ion_2.4L_engine_harness.jpg

...
2007 Ion 2 Quad Coupe 5-speed manual 178K miles
2007 Chevy Equinox LT 185K miles

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Old 07-17-2018, 08:39 PM   #4
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Default Re: 03 Ion P0032 & P0135

Thank you so much. I have confirmed that all is as it should be, yet doesn't work. I had a helper move the fuse box as I monitored it on the Tech 2. Haywire best describes what I saw. Plan to get a replacement box at Pic a Part tomorrow morning. I will update.

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Old 07-17-2018, 11:50 PM   #5
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Default Re: 03 Ion P0032 & P0135

Before you get a new fuse box, unplug the connectors at the ECM and fuse box to inspect them if you haven't done so already.

You can also take apart the fuse box and inspect it. This is much easier than you might think.

First, remove the negative battery terminal. Then take a picture of the top where all the fuses & relays go, then remove all of them. The picture makes putting them all back go much faster. You can then proceed to remove the fuse box and take it apart without worrying about shorting anything.

I had to do this a few years ago to fix a couple fuse terminals. I stupidly forced my voltmeter's test probes into them which spread them too far apart for the fuse. I was able to take apart the fuse box, and squeeze the terminals back together. Start to finish it took less than an hour.

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2007 Ion 2 Quad Coupe 5-speed manual 178K miles
2007 Chevy Equinox LT 185K miles

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Old 07-18-2018, 09:27 PM   #6
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Default Re: 03 Ion P0032 & P0135

Fuse box had several fuses that were corroded. I was lucky, the harnesses were easily cleaned up and connectors were not damaged. New fuse box cured the issue(s). Thanks again

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Old 07-18-2018, 09:49 PM   #7
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Default Re: 03 Ion P0032 & P0135

Fuse box had several fuses that were corroded. I was lucky, the harnesses were easily cleaned up and connectors were not damaged. New fuse box cured the issue(s). Thanks again

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Old 07-18-2018, 11:28 PM   #8
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2007 ION-2 Quad Coupe
Default Re: 03 Ion P0032 & P0135

Glad to hear you got it fixed!

...
2007 Ion 2 Quad Coupe 5-speed manual 178K miles
2007 Chevy Equinox LT 185K miles

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