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Home >> Saturn >> 2005 >> Ion Red Line >> Repair and Diagnosis >> External Pages >> Different car >> Section 45 (Front Suspension System) >> Repair Instructions >> Strut, Strut Component and/or Spring Replacement >> Assembly Procedure
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Assembly Procedure

WARNING: This page is about a different car, the 2004 Saturn Ion Red Line, 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. Install the spring into the J 45400  . See Special Tools and Equipment . Make sure the spring is level.
  2. Use the J 45400  to compress the spring evenly. See Special Tools and Equipment .
    3. Fig 1: Compressing Spring
    GM851646Courtesy of GENERAL MOTORS CORP.
  3. Install the lower spring seat insulator.
    4. Fig 2: View Of Lower Spring Seat Insulator
    GM851640Courtesy of GENERAL MOTORS CORP.
  4. Extend the strut shaft to the upper limit of its travel.
  5. Insert the jounce bumper into the dust shield.
  6. Slide the dust shield assembly onto the strut shaft.
  7. Load the strut through the coil spring and theJ 45400  . See Special Tools and Equipment .
  8. Firmly align the lower spring coil in the spring seat pocket.
    9. Fig 3: Aligning Lower Spring Coil In Spring Seat Pocket
    GM855305Courtesy of GENERAL MOTORS CORP.
  9. Place the upper spring insulator and spring seat onto the top of the coil spring.
  10. Place the bearing and strut mount on the top of the spring seat.
    11. Fig 4: View Of Upper Strut Mount Assembly & Mount Bearing
    GM851630Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  11. Install the upper strut shaft nut.

    Tighten:  Tighten the nut to 70 N.m (52 lb ft).

    12. Fig 5: View Of Strut Shaft Nut
    GM851628Courtesy of GENERAL MOTORS CORP.
  12. Using the J 45400  , remove the spring tension. See Special Tools and Equipment .
  13. Remove the strut assembly from the J 45400  . See Special Tools and Equipment .
  14. Install the upper strut cap.

    Tighten:  Tighten the cap screws to 14 N.m (124 lb in).

    15. Fig 6: View Of Strut Cap
    GM851625Courtesy of GENERAL MOTORS CORP.
  15. Install the strut assembly. Refer to Strut Assembly Replacement .
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