Recently, a 2006 Cobalt LT 2.2, 5 speed, 105,000 mi, was given to me. It sat for 3 years with no use and needed some attention by me to be useable again. It responded well to treatment and I love driving it. However, it's undercarriage is terminal with rust and driving it is no longer safe.
So, I went looking for a better bodied Cobalt to put the drivetrain into. Couldn't find one within a reasonable distance. So I put the word out at the local junkyard. Time went by...nothing showed up.
Was driving by the 'yard, decided to stop in. No, I was told, nothing Cobalt has come in. I left the office and noticed a familiar looking car sitting in the receiving lot; I didn't know then what it was, but I was certain it was a GM Delta Platform car of some type. I checked it out as best I could right then-- it was a 2007 Saturn Ion 2.2 automatic and marked on the windshield was '125,000' miles. The interior showed neglect and abuse; the exterior looked good.
After further checking out the undercarriage rust damage in another visit, I bought the car from the 'yard and had it flatbedded to my shop.
My goal is to at first get the car back on the road and see what its suspension and steering is like. But, I want to deal with the undercarriage rust and then swap in the Cobalt's engine/manual transmission. I'm aware that will be a daunting task. I'm presently stripping the wiring and electronics out of the Cobalt.

 

When there's a will there's a way.

Please keep us updated with a build thread. If you want I can change the title of this thread to something else you choose

 

As received, the Ion didn't have its alternator, A/C compressor, and--as I was later to find out-- its keys.
I wasn't too concerned about the key at first. The car was unlocked, had a battery with a charge, so I had complete access to it as I was checking it out at ð junkyard. I figured the key was no issue and was available if I needed it during my look over. At that point I was mostly concerned about the undercarriage rust.
However, somebody had romped hard, very hard, on the steering wheel as if to make it unlock. The wheel had a slop factor that indicated damage to me. I wasn't too concerned at this point; I figured my Cobalt would have whatever was necessary if I chose to buy the Ion. But he steering column was locked and I asked for the key. As it turned out, there was no key. How the car got delivered, nobody knew. I tried every key the 'yard had, but no luck. But I discovered that any key that would fit into the ignition would allow the lock to release momentarily if side pressure were applied to the key at the steering wheel lock up point. But the wheel would lock again when it could, so side pressure on the key was continuously necessary to steer the car. Getting the car out of park was easy; a long screwdriver must've been used to depress the park locking lever thru the console access hole.
I was at a loss as what to do about the key. With no other option, I decided to take the VIN and the title to the local Chevy dealer. I felt it was a long shot, but worth a try.
Bingo. In short order I had a working ignition key. The VIN had the key cutting information, and the title proved ownership. Cost: $24.
However, the key doesn't open the trunk. Curiously, the key for my 06 Cobalt won't open its trunk, either. Something is up with that, but I'm clueless.

 

Took a break from ð Cobalt disassembly in order to attempt starting the Ion; I really want know what the engine sounds like, even though I fully intend to swap in the Cobalt's drivetrain.
The new key was used and the engine cranked, but with no attempt at an engine start. The smell of gasoline became very strong; a look under ð car showed a massive fuel leak in the vicinity of ð fuel filter. I'll need to get the car up on blocks to investigate that.
I later happened to be looking under the hood and found that the wiring harness to the fuel injectors was disconnected, too. So, even if there had been no fuel leak, the Ion couldn't have started. I definitely need to get the Cobalt stripped and out of my shop so the Ion can be put inside.

 

Has anyone out there reprogrammed a 2007 Ion's PCM to delete the automatic transmission?

 

I know they are tunable. Don't know if it's that tunable. Usually you substitute an ECM that is Vin matched if you put in an ECM with a tune. I'm not sure what your intentions are long-term but I'm not sure that having the automatic trans programmed into the ECM is something you can change. I would think it's got to be possible.
Are you going to swap it for a 5-speed?
@oldmarine @DropDead ?

 

Yes, I want to install the 5 speed manual from my '06 Cobalt into the '07 Ion.
But I now see that I've got a lot of research to do before that happens. In the meantime, I need to get the Ion running as it now is so to assess what shape the car's in.
Rob

 

Ok, it's been a while, but I've made progress on ð Ion. Did get it up on blocks so I could wiggle underneath it. Pulled the fuel tank and found that the massive fuel leak was caused by the return line at the fuel pump which had broken off from the pump itself. Got a new pump from Rock Auto-- it was stated to be a GM pump, but the box was labeled ACDelco. However, the pump itself is Bosch. I would not have boughten a Bosch pump, but I installed it anyway. Parts for Saturn Ions are getting scarce on Rock Auto; this pump was listed as manufacturer discontinued and priced at $32. I can't complain about that, it looked identical to what was there in the tank and fit perfectly. I replaced the fuel filter, too, and added fresh gasoline.
It took some cranking, but ð engine lit and settled quickly into a good sounding idle--that was a relief. I removed the blocks and took it around the block.
There's a massive clunking in the front end when hitting any size of road bump, but the engine ran great and the auto transmission was working very well. Brakes worked well, too, but need to be serviced as the pedal has more travel than I would prefer. I noted that the front left turn signal bulb was burned out. The big annoyance is that the doors won't automatically unlock when the car is put into Park.
All in all, I'm pleased with how the Ion runs considering that it was awaiting its fate at the junkyard. I've replaced the turn signal bulb and have found that both CV joints are wasted, especially on the passenger side, and one of the sway bar end links is also shot. The bushings for the front sway bar also need replaced. All are ample places for the front end clunking, so the front end repair is next on the list.
I'm trying my hand at adding photos, so here's one of the Ion on blocks. Looks like I should've cropped the photo on the bottom.

 

My L series cars unlock the doors when you remove the key from the ignition. Your car may be the same.

 

Hey, thanks for the suggestion. After reading your response, I ran down to my shop to check it out. Unfortunately, no dice. Would've been nice, though. I've got to dig into the Ion's prints and see what's up.