how to replace ignition housing from steering column on saturn ion?

Insert the ignition key into the Ion's ignition and turn the key to the "II" position.

Slide a 1/8-inch punch pin into the access hole under the ignition. The punch pin (also known as a "pin punch") is a long, thin metal rod with a handle on one end.

Press in on the punch pin while you pull the ignition module out of the steering column. The module contains the lock cylinder and switch.

Insert the new ignition module. You will need to make sure that the key is in the "II" position in the new ignition before sliding it into the steering column. Orient the ignition module until it slides all the way into the steering column and locks into place.

if your replacing the ignition switch it's easy, just remove the cover behind the steering wheel then unplug the switch and un screw the two torx bolts, then reverse that process. After you complete that you will need to do a "passlock relearn" it'll take 40 min. Act like your starting the car the release the key and a security lock icon should flash, wait ten minutes or untill the light stop's flashing then turn the ignition of for 3o sec, then just repeat the process for a total of 3 times. then pass lock should be relearned.

If your replacing the ignition cyclinder because your key is stuck forget it. you'll need a new housing and cyclinder.

If your replacing the ignition cylinder because the key is getting caught at times thats an easy fix. What you do is remove the ignition cover behind the steering wheel. On top of the ignition housing where the cycling is located there should be to holes. The hole fartest away from where u put the key is where you want to start first. Put the key in and turn it to ignition on but not start. put a small hex wrench inside the hole. as you put the hex wrench inside the hole turn the key towards start but don't try to start in a pull back on the key and the cylinder should move out of the housing slightly. Then go to the second hole and do the some thing and the cyclinder should come out. If the cyclinder is dry and no lube put white lythium greese on the cyclinder and reinstall. If you still have issues with it getting caught that you will need a new cyclinder

Power rack and pinion steer gear :-------

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions Section.
2. Turn the steering wheel to the straight ahead position, remove the key and lock the steering wheel.
3. Remove or disconnect the following:
   
   WARNING

   Do not rotate the intermediate shaft once it is disconnected from the gear as damage may occur.
   
   
   
   
   Negative battery cable

   Both front wheels
   
   
   
   
   Intermediate shaft from the steering gear pinch bolt

   Shaft from the gear

   Tie rods from the knuckles

   Steering gear bolts

   Steering gear through the left side wheel opening
   
   

To install:

1. Install or connect the following:
   
   
   Steering gear through the left wheel opening

   Steering gear bolts to torque the fasteners to 81 ft. lbs. (110 Nm)

   Intermediate shaft to the steering gear and torque the new pinch bolt to 18 ft. lbs. (25 Nm)

   Tie rod ends to the steering knuckle and torque the nut to 15 ft. lbs. (20 Nm) plus an additional 180 degrees

   Wheels

   Negative battery cable
   
   
2. Check the alignment and adjust if necessary.

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Steering Linkage:---

Removal & Installation

1. Raise and support the vehicle.
2. Remove the front wheel.
3. Loosen the outer tie rod to inner tie rod jam nut.
4. Remove the tie rod to steering knuckle nut and discard.
5. Using the special tool SA91100C, separate the tie rod from the steering knuckle.
6. Remove the outer tie rod from the inner tie rod. Record the number of turns used in removal to aid in the installation.
7. Remove the outer to inner tie rod jam nut and discard.

To install:

1. Thoroughly clean the inner tie rod threads.
2. Install a new outer to inner tie rod jam nut.
3. Thread the outer tie rod onto the inner tie rod using the previously recorded thread count.
4. Install the outer tie rod to the steering knuckle.
5. Install a new outer tie rod nut, and tighten the nut to 18 lb ft+90 degrees (25 Nm+90 degrees).
6. Install the front wheel.
7. Set the toe.

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Steering Wheel:-----

Removal & Installation

1. Disable the SIR system.
2. Remove the inflatable restraint steering wheel module.
3. If equipped with cruise control, disconnect the cruise control switch connector from the steering column.
4. Remove the steering wheel nut.
5. Remove the steering wheel. It may be necessary to use the special tools J1859-A and J42578 or equivalent to remove the steering wheel.

To install:

Fig. The removal and installation of the steering wheel

1. Align the steering wheel to the steering column and install the steering wheel.
2. Install the steering wheel nut and tighten the steering wheel nut to 30 ft. lbs. (41 Nm).
3. If equipped with cruise control, connect the cruise control switch connector.
4. Install the inflatable restraint steering wheel module.
5. Enable the SIR system.

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1. Disconnect the negative battery cable.
2. Disable the SIR system.
3. Remove the steering column trim covers.
4. Turn the ignition lock cylinder to the RUN position.
   NOTE There are two retainers on the ignition lock cylinder. Depress both retainers to remove the lock cylinder from the housing.
   
   
   

   Fig. Depress the first retainer through the lock housing access hole (2) and depress the second retainer through the lock housing access hole (1)
   

5. Depress the first retainer through the lock housing access hole with a small allen wrench or similar pick-type tool. The lock cylinder will back out slightly.
6. Depress the second retainer through the lock housing access hole. The lock cylinder will back out slightly again.
7. Pull the lock cylinder out enough to locate the second retainer to the lock housing access hole.
8. Depress the retainer though the access hole a second time. The ignition cylinder should release from the housing. If not, the ignition cylinder may need to be moved in and out several times to locate the retainer correctly in the hole.
9. Remove the lock cylinder from the lock housing.

To install:

1. Position the lock cylinder in the run position. Insert the cylinder into the lock housing.
2. Rotate the lock cylinder in the housing. Verify proper rotation.
3. Install the steering column trim covers.
4. Enable the SIR system.
5. Connect the negative battery cable.

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Important: There are two retainers on the ignition lock cylinder. Depress both retainers to remove the lock cylinder from the housing. Depress the first retainer through the lock housing access hole with a small allen wrench or similar pick-type tool. The lock cylinder will back out slightly.

Depress the second retainer through the lock housing access hole . The lock cylinder will back out slightly again.

Pull the lock cylinder out enough to locate the second retainer to the lock housing access hole .

Depress the retainer though the access hole a second time. The ignition cylinder should release from the housing. If not, the ignition cylinder may need to be moved in and out several times to locate the retainer correctly in the hole.

Remove the lock cylinder from the lock housing.

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whenever working in the column, you need to turn air bag off on the steering wheel . Info below for zone 3

SIR DISABLING AND ENABLING ZONE 3 DISABLING PROCEDURE

1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead.
2. Turn the ignition switch to the OFF position.
3. Remove the key from the ignition switch.
4. Locate the body control module (BCM) fuse center in the driver's side of the floor console, then remove fuse center cover.
5. Locate and remove the AIR BAG fuse from the body control module fuse center. IMPORTANT: With the AIR BAG fuse removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction.

1. Remove the driver/left outer trim cover from the instrument panel (I/P).
2. Remove the connector position assurance (CPA) from the steering wheel module coil connector.
3. Disconnect the steering wheel module coil connector from the vehicle harness connector.

ENABLING PROCEDURE

1. Remove the key from the ignition switch.

Connect the steering wheel module coil connector to the vehicle harness connector.

1. Install the CPA to the steering wheel module coil connector.
2. Install the left outer trim cover to the I/P.

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If you require under hood fuse box diagram see below :----