Tommy's Project Tupperware - 2004 Saturn Ion Quad Coupe Level 2

My father bought me this as a daily driver when my Monte Carlo bent the valves (and also heavily urging me to get rid of the Monte). I call this Project Tupperware because it's a common nickname for Saturns here, due to the plastic dent-resistant body panels. My aunt even asked if I had to burp the sunroof when getting into it XD.
A little background info on Saturn for you Europeans since they're North American Market only.
Saturn was a project started by GM in the early 1980's. GM wanted to show they could make a high quality small car to take down the Japanese imports... something they weren't known for. The project started in 1982 as "Project Saturn". At the time it was just a code-name for the project. In 1985, GM Announced Saturn to the world, showing one of the development cars, and announcing Saturn would be independent from GM.
In 1988, Saturn built their factory and headquarters, a high-tech factory in Spring Hill, Tennessee.
In 1990, Saturn began building their first 2 cars, the SL sedan, and the SC coupe. The cars featured plastic body paneling heavily advertised for it's dent-resistant nature. The cars featured a platform unique to Saturn and Saturn's own engines, either a 1.9L SOHC 8 valve I4, or a 1.9L DOHC 16 valve I4, both of which shared the exact same block. Saturns were built almost entirely in their factory, with few, if any, imported parts in a manufacturing process that was both unique, efficient, and left the cars mostly hand-built. Saturn IMMEDIATELY became well-known for treating their customers great and for their no-haggle pricing. What this meant was that the price was never up or down from quoted. What you saw is what you paid. Dealers were allowed to set their own prices but most just went with the invoice pricing. Saturn was an immediate hit.
In 1992, Saturn entered the Canadian market. Saturn by now had received much praise for their customer satisfaction rating, the highest in the industry.
In 1993, Saturn built their 500,000th car, named Carla. 1993, Saturn also introduced the SW, an estate/station wagon variant.
In 1995, Saturn built their 1,000,000th car, a green SC2 coupe named "Jasper".
In 1994, Saturn hosted a "Homecoming", a 3 day "feel-good" event for Saturn owners at Saturn's factory in Tennessee, which further cemented relationships with customers and further established Saturn as caring about their customers. Saturn hosted one of these every few years after that.
In 1996 Saturn introduced the second generation SL and SW. Also in 1996, Saturn officials met with GM officials to discuss Saturn's future. Though the experiment was deemed a runaway success, the experiment had garnered much hatred inside GM. Saturn's development had drained 5 billion dollars from other projects, and Saturn's sales proved cannibalistic as 41% of Saturn's buyers already owned a GM car. GM voted to cut Saturn's development, which severely hampered the company.
In 1997, Saturn introduced the second generation SC coupe. Saturn also had found a partnership of sorts with European GM division Opel and Vauxhall, which tended to act independently from GM as well. The fruits of this partnership led to the development of the chain-drive 2.0, 2.2, and 2.4L Ecotec 4 cylinder engines in 2000.
In 1999, Saturn's SC coupe gained a door, a backwards-swinging half door on the driver's side allowing better rear seat access. The door was optional in 1999, but became standard in 2000.
2000 was a big year for Saturn. First Saturn introduced their first all-new car, a mid-size car called the L-series, in the same vain as their successful S-series car. The L-series was based on the Opel/Vauxhall Vectra, featured Saturn's trademark plastic body paneling, and featured the 2.2L Ecotec or the 3.0L DOHC V6. Saturn also introduced their third generation SL, SC, and SW cars.
In 2001, the SW was dropped due to lagging sales.
In 2002, Saturn introduced the VUE, a mid-size crossover SUV, utilizing GM's newest Theta platform and also the first public vehicle on the platform. Again, the VUE featured plastic body panels. The VUE had the same engine options as the L-series, but offered AWD. 2002 was the last year for Saturn's S-series cars.
In 2003, To replace the successful S-series cars, Saturn introduced the ION, the first car in the world to feature GM's new Delta platform (which would underpin the 2005+ Astra's). Once again, the ION featured the dent resistant panels, and the 2.2L Ecotec in base models. Saturn unveiled the cars in a large "apple" in New York City, commonly nicknamed "The Big Apple" to indicate how well it was in city's. The Ion featured 2 body-styles. A conventional 4 door sedan, and an unconventional 4 door coupe Saturn called the Quad Coupe, due to the 2 rear backwards swinging half-doors.
In 2004, Saturn introduced a new badge, "Redline", denoting a performance oriented vehicle. The first 2 vehicles to bear this badge were the VUE, which featured a 3.5L Honda SOHC V6, and the Ion, featuring a 205 HP supercharged 2.0L Ecotec. The Ion Redline was heavily promoted for it's Nurburgring tuned suspension. In 2004, The Vue also dropped the 3.0L DOHC V6 in favor of Honda's 3.5L SOHC V6, while the L-series retained the 3.0L DOHC.
In 2005, Chevrolet introduced the Cobalt, a replacement for their aging Cavalier. This car featured the same Delta platform as the Ion, and utilized Saturn's supercharged Ecotec and Nurburgring tuned suspension in the SS variant. The Cobalt SS Supercharged was heavily promoted as a world-beater. In 2005 Saturn's partnership with Opel/Vauxhall had grown stonger, as evidenced by the Saturn preVUE concept, showcasing the next generation Saturn VUE. 2005 was the last year for the L-series, and the Ion was updated to match it's Chevrolet Cobalt sibling's updates. 2005 was also the year Saturn officially merged with GM, becoming nothing more than another division. 2005 Also saw Saturn's first non-plastic bodied behicle in the lineup, the RELAY minivan (or MPV as you Europeans know it). This wasn't a true Saturn and was ACTUALLY a rebadged Chevrolet Uplander minivan. Engine options were a 3.5L Pontiac Developed OHV 12 valve 212 HP V6, and a Chevrolet developed 3.9L variant with 240 HP.
In 2006, Saturn introduced their first RWD car, a 2 seat roadster called the SKY, which was meant to do 2 things, take down the Mazda MX5 Miata and to promote Saturn's new 2.4L DOHC 16 valve VVT Ecotec. 2006 also saw a facelift for the aging VUE SUV.
2007 was another big year for Saturn. 2007 was the last year of the Ion, and the first year of the Saturn Aura, which replaced the L-series and was again heavily based on the Opel/Vauxhall Vectra. The car was so impressive it won 2007 North American Car Of The Year. Engine options in the AURA were the 2.4L Ecotec, a 2.4L Ecotec hybrid, a Pontiac Developed 212 HP 3.5L OHV 12 valve V6, and a Cadillac developed 240 HP 3.6L DOHC V6. 2007 was the last year for the Relay minivan. 2007 also saw the SKY introduced as the third REDLINE vehicle, featuring a turbocharged 2.0L Ecotec with 260 HP. This 260 HP version was sold by Opel as the Opel GT.
2008 was another big year for Saturn. Saturn introduced 3 new models. The Saturn Astra was introduced in 3 and 5 door hatch form to replace the ION. This was a rebadged Opel/Vauxhall Astra, built on the same assembly line, and even featuring the same 1.8L Ecotec engine (which was the only engine option in America). This was also the first, and only Saturn to feature a timing belt.
The Saturn Outlook was a full-size crossover SUV using GM's new Lambda platform and featured the Cadillac developed DOHC 24 valve 288 HP 3.6L V6 as the only engine option
2008 Also saw the second generation VUE, another rebadged vehicle. This time a rebadged Opel Antara. Engine options were the 2.4L Ecotec and the 3.6L V6, and a 2.4L hybrid.
2009 was a carryover year for Saturn and a sad one as well. As part of GM's bankruptcy proceedings, it was agreed that GM would shut down Saturn. As such, 2009 was the last year for the Saturn Astra, Aura, and Sky.
2010 was the last year for the Saturn Outlook and Saturn period. The end of a revolution in car sales.
In 2011, America saw the Opel Insignia rebadged as the Buick Regal here. This car was originally supposed to be the second generation Saturn Aura.

That is Saturn's history and Saturn's legacy.
Anyways, My father bought me a 2004 Ion 2 Quad Coupe to drive around in since my Monte Carlo was down and out. Featuring the 2.2L Ecotec, and getrag F23 manual, it has the same powertrain as many European Astra's and Vectra's. Sorry to say, but the 2.2L, 2.0L, and 2.4L Ecotecs were Saturn developed and borrowed from Saturn for use by Opel/Vauxhall. The Opel and Saturn developed Ecotecs tend to be easy to differentiate. Saturn developed Ecotec engines feature a timing chain. Opel developed Ecotec engines feature a timing belt. This applies only to those 3 displacements. All other Ecotec's were Opel developed. Anyways, here's photos of my Saturn Ion. I'll update this thread as the project progresses.
100111183710.jpg

100111183723.jpg

100311143901.jpg

101911144806.jpg

110611155246.jpg

110611155303.jpg

112011145032.jpg

112011150002.jpg

010612130129.jpg

010612130231.jpg

010612130151.jpg

010612130212.jpg
 
Last edited:
Last edited:
  • Like
Reactions: Loz
I hope all goes well Tommy! Awfully kind of your Dad to buy you come coilovers. The car looks great and I am following this thread with a lot of interest!

Is it me, or does the very front of the Ion look a little bit like a Hyandai coupe?
 
I hope all goes well Tommy! Awfully kind of your Dad to buy you come coilovers. The car looks great and I am following this thread with a lot of interest!

Is it me, or does the very front of the Ion look a little bit like a Hyandai coupe?
Thanks!... I don't see the resemblence between the 2 to be honest.
Congrats Tommy! :D

What's your plans after graduation?

Hopefully, I can get a job as a technician at a dealership. If not, I'll try and get one at an oil change place and go back to school to go after a degree in Journalism (for a career in automotive journalism).

Updates:

I also decided NOT to do a write up on these. Because this kit will not work on any other car I know of. Though the Opel/Vuaxhall Astra share the Delta Platform with the Saturn Ion, the two have completely different strut towers, which makes this kit incompatible. Besides. It's the same procedure as any normal strut/damper replacement. these are just lower and are height adjustable.
0417121411.jpg

0417121826.jpg

0417121826a.jpg
 
Last edited:
Looks smart buddy. Automotive journelism!? The next Jeremy Clarkson! :lol:

Seeing a picture of the above Saturn fitted a with a Supercharger, decided if yours will head down that route?
 
Looks smart buddy. Automotive journelism!? The next Jeremy Clarkson! :lol:

Seeing a picture of the above Saturn fitted a with a Supercharger, decided if yours will head down that route?

Jeremy Clarkson is my IDOL.

All the parts to supercharge it bolt right on my 2.2L from the 2.0L. The issue, for me, is the computer. My car's a 2004 model and 2004 cumpters are un-tuneable. Even the GM designed scantools have trouble with 2003-2004 Ion ECMs. I would either need to swap to a standalone ECU and have a custom tune done, or I'd have to swap the ECM, engine wiring harness, intake and pedal assembly to that of the 2005 revisions so I could order programming to tune the computer. Leaning towards the 2005 ECM conversion as it's cheaper than the standalone. But beyond that, a supercharger is in the future plans. I refuse to go turbo.

I don't necessarily hate turbos, I just feel they have no place on tiny engines like this, due to the heavy amount of lag involved. Superchargers have no lag, but the downside is a small parasitic effect, which I'm fine with. That and I prefer a supercharger whine over the whistle of a turbo any day.
Video's are of the Ion's supercharged sister, the Cobalt SS.
http://www.youtube.com/watch?v=icRSMo5T4uo
http://www.youtube.com/watch?v=8g-tSXfatzQ
http://www.youtube.com/watch?v=66AFDMhEnxg
 
Last edited:
Coilover install is done. And good thing too. While doing it, I found that my original dampers and struts were SHOT. Springs were doing all the work. It's not set to the lowest setting, just one I was comfortable with. The handling difference should be night and day. Now I just need to bleed the brakes and get an alignment.
Before:
030912123347.jpg

After:
0421121910.jpg

0421121913.jpg

0421121915.jpg
 
Last edited:
I haz an update here! Went to a Chevy Cobalt meet (meet for cobaltss.net) at a local fast food drive in restaurant called Sonic (It's a chain over here in the states). Got matching rear seat skins for my Saturn. installed them in the Sonic parking lot (visible in one of the following pics). The seat foam was changed in 2005 and the covers are from a 2006 car so they physically fit but it doesn't match the foam contours. oh well. looks better! Now to hunt down some black door panels.
DSC_0277.jpg

DSC_0278.jpg

DSC_0279.jpg

IMG_20120603_133041.jpg

IMAG0235.jpg

IMAG0233.jpg

IMAG0232.jpg

e9cda1b8.jpg

aa27edbe.jpg

74f60a93.jpg

22dd6450.jpg

09f889c0.jpg
 
Really? I like the Cobalt, decent performance for a small price.

That was the main point of the Cobalt. Even the base model automatic (the slowest of all Cobalts) was faster than every one of it's comparable competitors. And then the high performance SS model came with the supercharged 2.0L Ecotec (think a Saab 2.0L turbo ecotec with the turbo replaced with an Eaton M62 roots type supercharger), which had the same displacement as it's rival, the Honda Civic Si at 2.0L (K20 engine), but made slightly more power and was easier to get more from. And the aftermarket exploded around the Cobalt.
http://www.youtube.com/watch?v=Rd4yEyF3K0s

And the SS Supercharged was replaced by the SS Turbocharged in 2008 featuring an updated 2.0L Ecotec with direct injection and variable valve timing. Power was up from 205 HP to 260 HP and 260 ft-lbs. The reason for the switch from supercharger to turbo is that in 2008, the US toughened it's emissions standards and the supercharged LSJ couldn't meet the demands.
http://www.youtube.com/watch?v=pnVK6WOTVmI


Though I drive the sister car, the Ion, i still want a Cobalt. it's just not the same. I've lusted after the Cobalt since I turned 15 in late 2004 (birthday in December) and I'm 22 now. Still want a Cobalt.
 
Last edited:
Nice car all together mate :)

We do have those engines over here but they are called Z22SE I think...
Company called Courtenay Sport do a supercharger conversion which is based on the OEM kit off the 2.0, they do it for all the Z22SE motors including the VX220.... beasty, they got 240hp and about the same for torque with standard cams and internals albeit with a slight decomp.

You need some better wheels and tyres now to go with that suspension...

Also if you do like Peugeots then check my project thread (click the sig)
 
Nice car all together mate :)

We do have those engines over here but they are called Z22SE I think...
Company called Courtenay Sport do a supercharger conversion which is based on the OEM kit off the 2.0, they do it for all the Z22SE motors including the VX220.... beasty, they got 240hp and about the same for torque with standard cams and internals albeit with a slight decomp.

You need some better wheels and tyres now to go with that suspension...

Also if you do like Peugeots then check my project thread (click the sig)

Those rims were a birthday present. For the rims I want, I need to convert the car to a 5x110mm lug set. Here's the rims I want.
http://www.crateenginedepot.com/18-2008-Cobalt-SS-Wheel-9598541-P10754C833.aspx

And them on an Ion:
39117594018_large.jpg


For tires: I'm thinking Goodyear Eagle GT's, Goodyear Eagle F1 Supercar's, or Firestone Firehawk's

And the suspension isn't done yet. 2005 rear axle swap, rear disc conversion, larger sway bars, FE5 control arms and shorter front end links are all planned. ;) Thinking of switching AWAY from the coilovers to a set of FE5 struts and dampers on Pedders lowering springs. All depends on how my research turns out.

The engine is the Z22SE as you call them. Over here, it's called the L61. And it's a Saturn designed motor. And a company over here also sells a supercharger kit for them, ZZPerformance. However, I have the GM performance build book for the car and though the pistons and connecting rods are rated to 250 HP, it's recommended to swap them out for aftermarket forged units at 220 HP to maintain reliability.
 
Last edited:
No real update, but I'm quite proud of the Saturn.
0718121817-2.jpg

80,000 miles. 128,747.52 kilometers. Just hit it about a week or so ago.

Also, come September, cobaltss.net is planning another meet in my area. And there's whispers of a group dyno day. 3 pulls for $60. If you're lucky, I may be able to get a video of it on the dyno (rolling road).
 
Last edited:
Cobalt meet coming up on August 18th at Forced Induction Motorsports in South Windsor, Connecticut, USA. It is a dyno day. $60 for 3 pulls. If all goes according to plan, I'll have a dyno video of the Saturn to post here. I'll be happy with 110 FWHP. I'll be ecstatic at 120 FWHP or higher. It's rated at 140 HP at the crank from the factory.

I actually looked at the curb weight of my car according to the sticker and was shocked. Curb weight of this car is 2602 lbs with no one in it. That's lighter than the new Scion FRS/Toyota GT-86/Subaru BRZ.
 
1180 kg, thats pretty much the same as my 306 (1155kg) it probably weighs more with the bigger engine...

You lot over the pond always like to the at the wheels reading which is probably the correct way to do it.... we obviously do but always look at the calculated flywheel horsepower
 
Actually I think the weight rating is spot on. Although it has a bigger engine, all body panels except the roof, boot lid and bonnet are dent resistant plastic, which for years was Saturn's calling card.

I do prefer the at the wheels rating. My reasoning is that saying you've got 140 HP (at the crank/flywheel) is a lie. All 140 horses don't make it to the front wheels. A lot is lost through heat, friction, and rotational inertia through the drivetrain. I only care about the use-able power. Besides, This'll be a good way to judge any gains I get from future modifications.
 
Think of it this way. Because they used the plastic body panels, they had to compensate somewhere. On most cars, the outer body panels are structurally integral to the car's safety cell. Because of the plastic body panels, Saturn couldn't do that so all the strength is in the unibody chassis under the body panels. While the car isn't stellar in side impact crash tests (no duh. There's no center pillar on the coupe I have and not much there to begin with with the plastic), It DID earn a 5 star rating for frontal crash tests.
 
Updates. The August dyno day ended up not happening because the shops dyno computer broke/caught a virus/something along those lines. We tried setting up another one at a different shop on a different day but couldn't get enough people to sign up.

So we settled for a Sonic meet where we went go-karting afterwards. Be prepared. I'm about to upload a lot of photos.
 
Last edited by a moderator:

Similar threads


Please watch this on my YouTube channel & Subscribe.


Back
Top