Hi everyone, I'm new to the forums and I just was browsing through the forums in regards to fitment issues with the throttle body. I couldn't find much of anything other than how the tube rubs on various areas in the engine bay.

I drive an '06 2.4L Saturn Ion, I installed my Injen on the 5th attempt. The fit is ridiculously tight with the stock intake seal, so I actually had to cut slits into the elbow and pried it open a little, and filed the bore to a slightly larger diameter (would have popped it in a mill, but I was too antsy) I also filed down the lip on the throttle body a little bit (It's still there, and still prevents the seal from crawling up the throttle body, just it's a little smaller now)

What I'd like to know is if anyone here has come across this problem, what did you do to overcome it? I tried Saturnfans without any luck, IonForums helped me get where I am now. I'd just like to know if there was a better way, or even other ways of doing it (other than dropping the seal into boiled water, which didn't help me)

I haven't had any issues thus far with the intake, the SRI is an excellent match up with the 2.4L, I can't wait for the spring to install the CAI portion.

Thanks guys, hopefully I didn't miss anything in my search.

 

hey you are going to get the same answers here as you did on IF.net the injen does not fit on the ion perfect. Its like they just threw the kit together and sent it to market. So as long as you got it to fit and its working you are good.

 

Hey bro when you gonna meet up with us at the next Orlando meet?

 

PM'ed

 

I simply wanted a few more ideas. Nobody on IF.net told me if what I did was right, or acceptable, so I thought maybe these guys could guide me a little better.

 

This is the easy way of getting it done. the throttl body hat is too small to fit with the rubber gromet on it. Widen the hat and promblem solved.

 

So by filing it like I did, the outcome is the same.

But nobody whatsoever has made any mention of if filing the throttle body lip will be a problem. Granted, warranty is done on it now, but mechanically that lip will do the same thing whether it is .05" deep, or .1" deep; so long as there is still a little more material at the end of the opening. Correct?