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Old 04-06-2022, 01:03 AM   #1
05_ionS/C
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2005 ION-2 Sedan
Default 05 Saturn ion 2.2 l61 build (the journey to 400hp)

So a few months ago i bought a 2005 saturn ion sedan 2.2 l61 auto with full intentions of building it. Yes i know the down falls of it not being tuneable already so no need to tell me about the fact that tbe e16a ecu n stock tcm are not supported by hpt, and trifecta no longer offers tuning for these cars either. Also I am aware of other cheaper options to make more power, but my goal since the day i bought this car was to retain the 2.2 l61 gen 1 engine and make a 400hp street car. But i have the full build planned already planned out other than what i want tl do with the audio system. So the journey for 400hp 2.2 street car begins. Im starting with the under side of the car and full suspension build, brakes, wheels and tires, which i will begin to order Friday when i get paid. Full suspension build plans listed below.

Clean underside of car and paint gloss black with por 15
Clean and paint front subframe illusion purple
Zzp tubular lower control arms powder coated gloss black
Zzp ball joint heat shields powder coated illusion purple
Zzp front sway bar kit
Zzp 140mm adjustable front sway bars
Paint front knuckles gloss black
New Cobalt ss 5 lug front hubs
Zzp 12.25" brembo front brake kit
Goodridge stainless front and rear brake hose kit
Steering rack spacers
New rack and pinion and inner and outer tie rods
Paint rack and pinion and inner tie rods gloss black
Have outer tie rods powder coated illusion purple
Paint front calipers and brackets illusion purple
Ion redline rear axle beam
New Cobalt ss rear 5 lug rear hubs
Cross drilled slotted rear rotors
New cobalt ss rear calipers
Paint rear axle beam illusion purple
Red poly axle beam bushings
Paint rear calipers illusion purple
New Copper coated brake lines
New cobalt ss e brake cables
Zzp rear sway bar kit
New gas tank straps
Bc coil overs
AEM e85 compatible in tank fuel pump
Zzp billet engine mount
42 draft designs 5x110 to 5x114.3 hubcentric wheel adapters
Aodhan ds01 gold 18x8.5 +35 offset 5x114.3ug pattern wheels
Nitto neo gen 215/40zr18 tires with permanent white nitto tire decals
Purple spline lug nuts
Purpme valve caps


Once everything under the car is complete and finished and able to set it back on the ground i will begin collecting all my 5 speed swap parts. Im planning on using a f35 5 speed as i have a line on a full swap for under $200. But i will be upgrading most of it anyway.

Plan for the trans and drive train listed below

Fidanza light weight flywheel
Zzp stage 3 clutch kit
New throw out bearing, and pilot bushing
Zzp throw out bearing spacer
Zzp stage 1 axles
Zzp billet front trans mount
Zzp rear trans mount spacer
Zzp billet rotated rear trans mount
All new hydraulic clutch system
ion redline manual pedal assemblies
New shift cables
Short throw shift kit and short throw adapter
Zzp Billet shifter bushings
05 - 06 saturn 2.2 l61 manual engine harness to get rid of tcm and tcm wiring
Clean up and paint trans gloss silver

This is my starting point and current goals. Once this is done i will post the rest of my build plans
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Old 04-06-2022, 01:21 AM   #2
05_ionS/C
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2005 ION-2 Sedan
Default Re: 05 Saturn ion 2.2 l61 build (the journey to 400hp)

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Old 04-06-2022, 01:28 AM   #3
05_ionS/C
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Join Date: Apr 2022
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2005 ION-2 Sedan
Default Re: 05 Saturn ion 2.2 l61 build (the journey to 400hp)

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IMG_20220403_221240_589.jpg
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Old 04-06-2022, 01:56 AM   #4
05_ionS/C
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Join Date: Apr 2022
Location: Ohio
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2005 ION-2 Sedan
Default Re: 05 Saturn ion 2.2 l61 build (the journey to 400hp)

Curent mods are

-Lighting and electronics-
6000K LED head light bulbs
Purple LED front turn signal bulbs
Purple LED reverse light bulbs
Purple LED license plate light buib
Purple LED interior map light bulbs
Purple LED dome light bulb
Purple LED trunk light bulb
Boss audio head unit with Bluetooth

-engine n engine bay-
3" cold air intake
Cabon fiber air filter heat shield
Billet LS1 oil cap
Purple fender bolt kit

-not yet instslled-
Long tube header with catless mid pipe
New 02 sensors
New mls header gasket
New ARP header studs
New chrome 2.5" inlet/outlet high flow resonator
New chrome 2.5" inlet/ dual 3" outlet muffler
New 2.5" 2 bolt exhaust flange
2 weld on 02 sensor bungs (1 for down stream 02 and 1 for wide band sensor)
Jet performance MAF sensor
Purple 1/4" wire loom
Purple LED strips 2 for under dash for front floor, 2 for under seats for rear floor, and 2 for inside trunk
New valve cover gasket
New spark plugs

-ordering on Friday-
Zzp front sway bar kit
Zzp 140mm adjustable stabilizer links
Zzp rear sway bar kit
Zzp billet motor mount
Zzp ball joint heat shields
Zzp rack spacers
Zzp rear trans mount spacer
Zzp camber adjustment bolts
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Old 04-06-2022, 02:04 AM   #5
05_ionS/C
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05_ionS/C is on a distinguished road
 
Join Date: Apr 2022
Location: Ohio
Posts: 8

2005 ION-2 Sedan
Default Re: 05 Saturn ion 2.2 l61 build (the journey to 400hp)

FB_IMG_160128893460569637.jpg
FB_IMG_7589880152800002511.jpg
FB_IMG_8505770821353927932.jpg
FB_IMG_6930312839825871657.jpg
FB_IMG_4145860832412774625.jpg

The fiance loves the saturn as much as i do
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Old 04-06-2022, 02:10 AM   #6
05_ionS/C
New Member
05_ionS/C is on a distinguished road
 
Join Date: Apr 2022
Location: Ohio
Posts: 8

2005 ION-2 Sedan
Default Re: 05 Saturn ion 2.2 l61 build (the journey to 400hp)

FB_IMG_4092825571366150307.jpg
FB_IMG_4274573760077212904.jpg

Idk what it is about this car that's made me like it so much but cant wait to start actually building and missing this car. Have so many plans. Can't wait to get the suspension and 5 speed swap done so i can move onto building the engine and doing the engine bay.
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