03 ion sedan lsj turbo swap
 

Ill go ahead and bring some life to this section.

2003 Saturn Ion 1

It has been a full bolt on car up until 2 or 3 years ago. If you dont know what bolt one are decent for the base models, ask. I don't wanna get into that.

I've accumulated a lot of parts and done a lot of labor for parts over the last few years.
Original plan was a 2.4 bottom end with an lsj head until I got an lsj as partial payment on a motor swap.

My plans are:
Bones ported and polished head
Zzp valve springs
Viton valve seals
LNF valves
Stock cams

Lsj short block
Balance shaft delete
new oem pistons and rods
wiseco rings (if the new pistons don't come with rings)
modified le5 oil pan for return line

Ottp turbo manifold
Hx35 from a 90s Cummins
(might keep the stock wastegate since its good for the psi I plan to run, but I'm not 100% yet)
3 in Catless down pipe to a side exit
custom 3in turbo piping (similar to the saab routing)
Custom 3.5 in intake
I found a universal blow off valve at the yard ill use (why not for $5?)

Intake manifold, as badly as I want a log style no one has proven gains from them. So the $500+ isnt really worth it to me.
Ill either get a saab 9-3 manifold and heavily port it or ill use the stock lsj manifold and use the blown supercharger as my "log manifold".
zzp sells an adapter plate, but I kinda want the charge pipes hidden.
I'm also thinking a TR10 inter cooler with a custom bumper support beam

This will be attached to a heavily ported lsj throttle body (or maybe even an ls4)

Suspension:
I already have fe3 on the car and its okay.
I think its time to either put the fe5 on it to match my redline or spend some money and get the bilstein/koni combo that's recently been released.
I will for sure use fe5 control arms with the ottp bushings.

Trans:
I'm sticking with an f23.
it will be the 4.41 from my vue parts car.
Modified for my ottp front rotated mount.
my top ottp mount will fit fine.
And the rear mount is a stock lnf with the zzp spacer to raise it 1/4 in.

Since the lsj has an 8 bolt crank and l61 has a 6 bolt crank, I have to scrap my brand new exedy clutch for my l61.
Ill get a stock lsj flywheel and a GMPP clutch. Imma stick with an f23 slave since they don't die every few thousand miles like the f35 in the redline.
Also converting to the cobalt clutch line/clutch master/clutch pedal. Any ion owner knows why. Lmao

This will be fueled by a cavalier return style fuel system, with ID1000cc injectors, ottp billet injector cups, and an aem high flow pump. Ill throw the ottp fuel pump rewire kit on it too. 93 octane (until e85 is available).

Now, the most fun out of all this.
Bones and I have been talking a lot lately.
we are doing a lot of trading so he can continue his green build.

He is supplying me with the engine harness, fuse box, bcm, ignition, and body harness.
ill be keeping my manual windows and lock.

Engine harness will be cut up and bare minimal will be used. Pcm will have a lot of tweaking done to make the lack of sensors okay. Will also be tucked with the fuse box. Probably in the fender.

End goal is 450-500whp.

I know I missed a few things. Car won't get brought to my property until after the new year since my accident is costing me almost $800 between repairs and fines. So far.

Id like to have it ready by this time next year.

Ill get some pictures shortly. Engine is getting put on a stand this week for the tear down. Trans is also getting detailed for storage this week as well.

Help fund this. Buy my spare parts. Lmao

Do you have a second gen S car rust free subframe? I've read they are really easy to swap out

I Don't anymore. Scrapped my s car years ago.

Theyre like 6 bolts. Could source one if you need a nice southern one.

get out. 6 bolts hold it to everything else?

including the cradle?

Pretty sure its like 6 bolts to hold the cradle to chassis

My car needs to be out of storage by Friday. Ill start breaking it down this weekend.

2.4 manifold and p&p tb is going to bones

if anyone with an ion on here sees this, ill cut a forum deal before stuff goes to eBay.

Brand new DNA 2in drop springs- 75 shipped

fe3 strut/spring/shock combo- 150 shipped

brand new fe1 control arms (were mounted)
75 shipped

Mounted brand new exedy clutch, no slave- 100 shipped

Brand new drilled and slotted rotors with ceramic pads- 60 shipped

Jbody f23 shift cables( 2in longer than ion but works perfect)- 30 shipped

Zzp shorty manifold- 50 shipped (see other add)

Valve cover- 50 shipped

Cassette coil pack- 35 shipped

ICM- 15 shipped

Balancer- 30 shipped

F23 shifter- 40 shipped

f35 shifter- 60 shipped

F23 trans- 125 picked up

Lsj 34# injectors- 45 shipped

B207l 27.4# injectors- 45 shipped

Deka 42# injectors (2 sets)- 50 shipped each

Lots and lots of parts. Make offers on everything. Package deals will be made as well. I seriously have cases of parts.
I'm gutting the interior as well. I'm putting a roll bar in. For once im considering my own safety.
https://cimg1.ibsrv.net/gimg/www.sat...599e4a20c7.jpg
2in springs in the rear, 0 miles
https://cimg6.ibsrv.net/gimg/www.sat...a55dcabcf4.jpg
My lsj donor
https://cimg9.ibsrv.net/gimg/www.sat...fb1bbc8076.jpg
2in springs.
https://cimg0.ibsrv.net/gimg/www.sat...2b40b6715d.jpg
All for sale
https://cimg1.ibsrv.net/gimg/www.sat...9421f7c98a.jpg
Stock vs lsj Ottp billet cups sold
https://cimg3.ibsrv.net/gimg/www.sat...1823cd807c.jpg
F35 shifter
https://cimg5.ibsrv.net/gimg/www.sat...49edb89a47.jpg
Ottp clamo
https://cimg6.ibsrv.net/gimg/www.sat...1fc0e1a5b9.jpg
Its a mess. Sat like this for years. Tucked in a storage building now.

Cars moved. Steering rack got destroyed somehow. But its home now. Its a mess. I know only a couple of you know how clean it used to be once upon a time.

it looks like it will be a full on resto car now along with the swap. Which I'm honestly okay with.

https://cimg4.ibsrv.net/gimg/www.sat...98e246660a.jpg

Did you remember to lock the steering column before you towed it?
Did you run over a small child / black sheep/ Zamboni pump handle?

I think the inner tie rod gave out. I was turning the wheel puahing it out of storage and the driver wheel almost hits 90°

It did fall off the dolly pulling into the property. No clue how. Both wheel straps were secure and still in place. Car is just suicidal at this point from neglect.

That's one hell of a steering mod....

Those straps are for show -- to convince other drivers that your vehicle is safely attached. Did it hit the ground with the straps still on or did it go free wheelin'?

I recommend one of the SSRI's for starters Paxil, Zoloft......
After two attempts (1/2 broken neck (tie rod) + jumping off dolly), you need to keep an eye on it.

Please tell me you are not doing the swap in that parking lot