Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2004 Saturn ION L4-2.2L VIN FFACTORY OEM SERVICE PROCEDURE
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR REPLACEMENT
REMOVAL PROCEDURE
1. Remove the air cleaner outlet resonator.
2. Disconnect the throttle position (TP) sensor harness connector (2).
3. Remove the throttle TP sensor screw.
4. Remove the TP sensor and seal.
INSTALLATION PROCEDURE
1. With the throttle in the closed position, install the TP sensor and seal.
NOTE: Refer to Fastener Notice in Service Precautions.
IMPORTANT: Install a new TP sensor screw when replacing the TP sensor.
2. Install the TP sensor screw.
Tighten the TP sensor screw to 2 N.m (18 lb in).
3. Connect the TP sensor harness connector (2).
4. Install the air cleaner outlet resonator.
REMOVAL PROCEDURE
1. Remove the air cleaner outlet resonator.
2. Disconnect the throttle position (TP) sensor harness connector (2).
3. Remove the throttle TP sensor screw.
4. Remove the TP sensor and seal.
INSTALLATION PROCEDURE
1. With the throttle in the closed position, install the TP sensor and seal.
NOTE: Refer to Fastener Notice in Service Precautions.
IMPORTANT: Install a new TP sensor screw when replacing the TP sensor.
2. Install the TP sensor screw.
Tighten the TP sensor screw to 2 N.m (18 lb in).
3. Connect the TP sensor harness connector (2).
4. Install the air cleaner outlet resonator.
Factory Service Tools
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.