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Ken
Ken, Saturn Mechanic
Category: Saturn
Satisfied Customers: 754
Experience:  GM & SATURN FACTORY TRAINED
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2003 Saturn ION 1: the Coolant Level Switch

Customer Question

How do I locate and remove/replace the Coolant Level Switch on a 2003 Saturn ION 1?
Submitted: 5 years ago.
Category: Saturn
Expert:  Ken replied 5 years ago.
Hi and thanks for your question! Here is the information you asked for. Let me know if you need more information. Remember to click "Accepted" or I do not get compensated for helping you today. Ken
Radiator Surge Tank Replacement

Tools Required

Removal Procedure

  1. Drain the cooling system. Lower the vehicle.
    Object Number: 873719  Size: SH
    Click here for detailed picture of above image.
  2. Reposition the surge tank inlet hose clamp.
  3. Remove the surge tank inlet hose from the surge tank.
    Object Number: 889782  Size: SH
    Click here for detailed picture of above image.
  4. Remove the under hood junction block bracket nuts (1,2).
  5. Remove the under hood junction block bracket bolt (3).
  6. Lift the under hood junction block bracket and position away from the surge tank.
    Object Number: 873720  Size: SH
    Click here for detailed picture of above image.
  7. Remove surge tank bolt. Lift surge tank and reposition the surge tank outlet hose clamp.
  8. Remove surge tank outlet hose.
    Object Number: 873721  Size: SH
    Click here for detailed picture of above image.
  9. Disconnect the coolant level sensor electrical connector.
  10. Remove surge tank.

Installation Procedure


    Object Number: 873721  Size: SH
    Click here for detailed picture of above image.
  1. Install the surge tank.
  2. Connect the coolant level sensor electrical connector.
    Object Number: 873720  Size: SH
    Click here for detailed picture of above image.
  3. With the surge tank raised, install the surge tank outlet hose.
  4. Reposition the hose clamp to secure the hose. Install the surge tank bolt.
  5. Tighten
    Tighten the bolt to 8 N·m (70 lb in).


    Object Number: 889782  Size: SH
    Click here for detailed picture of above image.
  6. Set the underhood junction block bracket into position.
  7. Install the underhood junction block bracket nuts (1,2).

    Tighten
    Tighten the nuts to 10 N·m (88 lb in).

  8. Install the underhood junction block bracket bolt (3).

    Tighten
    Tighten the bolt to 25 N·m (18 lb ft).


    Object Number: 873719  Size: SH
    Click here for detailed picture of above image.
  9. Install the surge tank inlet hose to the surge tank.
  10. Reposition the hose clamp to secure the hose.
  11. Fill the cooling system.
Customer: replied 5 years ago.
This tells me how to remove the overflow tank and disconnnect the connector to the coolant level sensor. How do I remove the coolant level sensor?
Expert:  Ken replied 5 years ago.
As far as I know it is part of the surge tank. I even went back to the R&R list and it goes to replacing the surge tank. Ken
Ken, Saturn Mechanic
Category: Saturn
Satisfied Customers: 754
Experience: GM & SATURN FACTORY TRAINED
Ken and other Saturn Specialists are ready to help you
Customer: replied 5 years ago.
Does the cooling system really need to be totally drained to remove the surge tank?
Expert:  Ken replied 5 years ago.
I do not, I pinch of the hoses or just top it off when I am done. It is better for you if you do not drain the hole system. It can be a pain to get the air out of the motor and heater core. Ken

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Ken
Ken
Saturn Mechanic
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GM & SATURN FACTORY TRAINED