2004 Saturn Ion Red LineFACTORY OEM SERVICE PROCEDURE

Installation Procedure

WARNING: This page is about a different car, the 2004 Saturn Ion 3, 2004 Saturn Ion 2, and 2004 Saturn Ion 1. However, it is still accessible from the selected car via links, so may be relevant.
  1. Connect the accelerator cable end to the accelerator pedal assembly. Ensure that the cable end retainer is fully seated to the accelerator pedal.
    2. Fig 1: View Of Accelerator Cable
    GM878827Courtesy of GENERAL MOTORS CORP.
  2. Connect the cruise control cable, if equipped, to the accelerator pedal assembly.
    3. Fig 2: Locating Cruise Control Cable
    GM878823Courtesy of GENERAL MOTORS CORP.
  3. Install the accelerator pedal assembly to the dash panel.
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the accelerator pedal retaining nuts.

    Tighten:  Tighten the nuts to 10 N.m (89 lb in).

    5. Fig 3: View Of Accelerator Pedal
    GM878828Courtesy of GENERAL MOTORS CORP.
  5. Ensure that the carpet is positioned correctly in relation to the accelerator pedal in full closed and wide open throttle positions.
    6. IMPORTANT: The throttle should operate freely and without binding between full closed and wide open throttle positions.
  6. Verify the complete throttle opening and closing positions by operating the accelerator pedal assembly.
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.

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