Just replace and hope for the best.
I replaced the TB gasket, s/c gasket, IM gasket, and still have a weird idle (along with checking every vacuum hose) So I guess that's all that's left.
Don't take the route of replacing everything though...I spent like 125 on that...

 

How hard are the O-rings to replace?

 

Theyre not. Pull the injectors out (I believe 2 10mm on the fuel rail, and 2 t25s on the cover) and they pop off like rubber bands.

 

So, my Redline is down, again... This time, it's the alternator... I went to two different parts stores, and gave them the correct info(2004 ION, 2.0L, VIN-P) and they ordered me an L61(2.2L base model) alt instead... I've been debating with Goalie about whether or not to go to a 2.7 pulley since i have to take the belt and blower off already...I asked ZZP what the inner diameter was, and the guy refused to give me the info, saying that for gasoline, my 2.8 was likely already too small... So I guess I have to buy one and see if it fits, or just stick with the 2.8...

 

stick w the 2.8....if it's not broke, don't fix it
You have enough boost....for now....and 162K on the clock
And I damn well better get to drive it before you blow it up.

There's a reason the factory boost was 12.
Have you achieved more? Absolutely.
How much can it handle before you wreck the turbine bearings or punch the block?
Do you really want to find out?
After all the $$$ you've spent?

And a looming medical condition in semi unknown status?
_______________
Save yourself the trouble of replacing overpriced DuraCrap lifetime warranteed parts..... every 2-3 years...for a lifetime.....

And buy your parts off rockauto.com

almost any part you can find at a store that is not a store-brand you can buy from rock auto for $15 less including the shipping.
If they don't have it it usually isn't to be had BUT

In those situations I go to partstrain.com
If that fails I search the entire internet

 

Yeah, but... But... But... Goalies running a 2.7! (Sniffle sniffle) on a semi serious note, a 2.7 is considered semi safe with the cooling mods that both Goalie and myself are running... I'm still not 100% sure, but it stands to reason that now would be the time to do it if I wanted to...Probably gonna pay for some help(also getting injector o-rings changed) on the alt, and I just ordered a reman Denso (same brand that's in the car) alt for it... $204 later(NOT $251), it will be in my hands in a few business days... In the meantime I'm driving my Ranger... Which I can fill with cheap fuel and go further on a tank...

 

RockAut.com
2004 IRL
Alternator

DENSO Part # 2100666 reman $191.79
Core charge:$68
Net cost after core return: $123.79
(I know, your 204 doesn't account for the core)

As for the 2.7, that's your call -- was just trying to help w ith a reality check of sorts.

Plus I want to make sure I get to drive it before you blow it up.

Did you ever send me a music swap? I need new old tunes.....

 

Aww, crap... I haven't sent you any music yet, due to forgetting under stress from other stuff...

It's all good... I might stick with the 2.8, as I'm reading that people start to have belt trouble when they go to 2.7 and smaller, and I don't wanna buy the oversize tensioner... Besides, smaller than a 2.8 and tuning becomes difficult... Might build up my water injection and then find somebody with HPT and get the tune dialed in a little closer...

... And that alternator was the exact one I ordered... I also had a shipping charge...

How long after receiving the part do I have to make the core return? I know ZZP gave me 30 days on my PCM...

 

Cool -- you've discovered the wonder of rockauto.

Time frame for return of core : it's in there (the package or on the invoice)---usually 14 or 30 days but they'll send the info w the fine print so make sure you read it.

How's serp belt? And pullies for everything it rides on?

 

They appear fine, if a little greasy(remember the PCV issue I recently band-aided?)... I might grab a can of de-greaser and clean the crap outta everything before the new alt gets here... There's a nasty oil/dirt film all over everything because of the oil being blown out of the dipstick tube...

To be honest, I've been a little leery of RockAuto since I heard about the site(years ago), but I figured I was out nothing by trying, and I might save on the repair...