Saturn 2003 Ion,2003 Ion Service Manual Supplement
2003 Saturn Ion
Description and Operation
General Body Construction (Unibody)
Description
This information pertains to unitized body construction.
The engine and transaxle, front suspension control
arms, and rack and pinion steering are supported by
the engine frame which is bolted to the vehicle at
six locations. Each mounting location is cushioned by
a thick rubber insulator. These insulators are
specifically designed for each location to give the
proper amount of structural strength while providing
maximum road noise isolation. Different insulators are
used at the various frame-to-body attaching points
to change ride and handling characteristics of
the vehicle.
Mounting provisions for the front suspension system
are also shared by the body components through
the suspension strut towers. The towers must
be dimensionally correct in relation to the underbody
to maintain proper suspension geometry.
With unitized body construction, underbody
components must be properly aligned to assure
correct suspension location. In case of collision
damage, it is important that the body dimensions be
checked thoroughly, and if necessary, realigned
in order to accurately establish proper dimensions.
Since the individual underbody components also
contribute directly to the overall strength of the body, it
is essential that the proper welding techniques be
observed during service repair operations. The
underbody components should be properly sealed and
rustproofed whenever body repair operations destroy
or damage the original sealing and rustproofing. When
rustproofing critical underbody components, it is
essential to use a quality air dry primer such as
corrosion-resistant chromate or equivalent material.
Combination type primer-surfacers are not
recommended.
Door Frame Description
The side door frame openings feature a unique
modular build sub-assembly design in order to improve
manufacturing quality. The openings are composed
of numerous individual components that are
pre-assembled and attached to the vehicle as a
single unit.
You may replace the door frame as a complete unit.
Various segments of the door frame may be sectioned,
which is usually much faster and more cost effective.
A front and rear half also are available for complete
or sectioning procedures. There are some key
structural areas where sectioning should not take
place. Service parts for sectioning must be cut from
the service assembly and modified as necessary.
2003 Saturn Ion
2003 Saturn Ion
3-1
Component Locator
Panel Identification
Legend
(1) PA + PPE
(2) ABS + PC
(3) PA + PPE
(4) ABS + PC
(5) PET
(6) Steel
(7) ABS + PC
873924
(8) TPO
(9) PET
(10) PA + PPE
(11) ABS + PC
(12) PA + PPE
(13) TPO
(14) PET
3-2 2003 Saturn Ion
Exterior body panels are constructed of various
materials, due to the increased dent and corrosion
resistance of modern composites. All vertical panels,
such as fenders, doors, quarters, and rocker
panels, are made from rigid thermoplastic. Front and
rear fascias are constructed of thermoplastic
olefin (TPO). The hood, roof, and deck are steel.
Different materials require different procedures
for preparing and refinishing. Before beginning any
repair, identify the type of material involved.
Panel Identification
Identifying Symbol
PE Polyethylene
PP Polypropylene
ABS Acrylonitrite/Butadine/Styrene
ABS+PC
E/P/TPO
PA + PPE
Chemical Composition or
Plastic “Family” Name
Acrylonitrite/Butadine-Styrene
+ Polycarbonate
Ethylene/Polypropylene
(Rubber)
Polyamide +
Polyphenylene Ether
Typical Area where Used Common or Trade Names
Inner Fender Panels,
Valances, Spoilers, Inner
Trim Panels, Seatbelt
Covers, Gas Tank Shields
Kick Panels, Deflector
Panels, Cowl Panels, Interior
Moldings, Radiator Shrouds,
Inner Fenders, Bumper
Covers
Instrument Clusters, Trim
Moldings, Consoles, Armrest
Supports, Steering Column
Jackets
Instrument Panels, Exterior
Door Panels, Rocker Panel
Covers
Bumper Covers
Fenders GTX
Dylan, Fortiflex, Marlex,
Alathon, Hi-Fax,
Hosalen, Paxon
Profax, Oleflo, Marlex, Azdel,
Novolen, Tenite, Daplen,
Escorene
ABS, Cycolac, Abson,
Kralastic, Lustran,
Absafil, Dyel
Babyland, Proloy,
Cycoloy, KHA
TPO, TPR (Thermoplastic
Rubber) EPI, EPII
2003 Saturn Ion
2003 Saturn Ion
3-3
Structure Identification
Number Description Procedure
1
2 Tie Bar Replacement
3
4
5
6
7
Impact Bar Bracket Replacement – Front Bumper
Tie Bar Replacement – Lower
Latch Primary Support Replacement – Hood
Tie Bar Replacement – Left
Tie Bar Replacement – Right
Bracket Replacement Side Rail – Front Compartment
3-4 2003 Saturn Ion
867419
Structure Identification
Impact Bar Bracket Replacement -
Front Bumper on page 3-15
Tie Bar Replacement on page 3-17
Tie Bar Replacement - Lower on
page 3-21
Latch Primary Support Replacement -
Hood on page 3-26
Tie Bar Replacement - Left on
page 3-19
Tie Bar Replacement - Right on
page 3-23
Bracket Replacement Front
Compartment - Side Rail on page 3-30
Structure Identification (cont’d)
Number Description Procedure
8
9
10
11
12
13
14 Dash Panel Replacement
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Wheelhouse Replacement – Front
Wheelhouse Extension Replacement – Front
Rail Replacement Front Compartment – Side Upper
Rail Sectioning Front Compartment – Side Upper
Plenum Panel Replacement – Upper
Plenum Panel Replacement – Lower
Cross Bar New Replacement – Floor Panel
Rail Replacement Front Compartment – Front
Rail Replacement Front Compartment – Front Half
Rail Sectioning Front Compartment – Front
Rail Replacement Front Side Underbody – Outer
Suspension Support Replacement – Front
Extension Replacement Front Compartment
Side Rail – Rear
Windshield Frame Reinforcement Replacement –
Inner Upper
Hinge Pillar Body Replacement – Front Inner
Hinge Pillar Body Reinforcement Replacement –
Front Inner
Hinge Pillar Body Sectioning – Front
Roof Panel Replacement – Outer
Windshield Frame Header Panel Replacement – Front
Rear Window Frame Header Panel Replacement – Rear
Floor Panel Replacement – Center
Rocker Panel Replacement – Inner
Rocker Panel Extension Replacement – Inner
Rocker Panel Reinforcement Replacement – Inner
Rocker Panel Reinforcement Sectioning – Inner
Wheelhouse Replacement - Front on
page 3-32
Wheelhouse Extension Replacement -
Front on page 3-34
Rail Replacement Front Compartment -
Side Upper on page 3-36
Rail Sectioning Front Compartment -
Side Upper on page 3-39
Plenum Panel Replacement - Upper on
page 3-43
Plenum Panel Replacement - Lower on
page 3-45
Dash Panel Replacement on page 3-48
Cross Bar No.1 Replacement - Floor
Panel on page 3-51
Rail Replacement Front Compartment -
Front on page 3-53
Rail Replacement Front Compartment -
Front Half on page 3-55
Rail Sectioning Front Compartment -
Front on page 3-59
Rail Replacement Front Side
Underbody - Outer on page 3-63
Suspension Support Replacement -
Front on page 3-66
Extension Replacement Front
Compartment Side Rail - Rear on
page 3-68
Windshield Frame Reinforcement
Replacement - Inner Upper on
page 3-70
Hinge Pillar Body Replacement - Front
Inner on page 3-75
Hinge Pillar Body Reinforcement
Replacement - Front Inner on
page 3-73
Hinge Pillar Body Sectioning - Front on
page 3-78
Roof Panel Replacement - Outer on
page 3-81
Windshield Frame Header Panel
Replacement - Front on page 3-85
Rear Window Frame Header Panel
Replacement - Rear on page 3-87
Floor Panel Replacement - Center on
page 3-89
Rocker Panel Replacement - Inner on
page 3-93
Rocker Panel Extension Replacement -
Inner on page 3-95
Rocker Panel Reinforcement
Replacement - Inner on page 3-97
Rocker Panel Reinforcement Sectioning
- Inner on page 3-100
2003 Saturn Ion
2003 Saturn Ion
3-5
Structure Identification (cont’d)
Number Description Procedure
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
Pillar Lock Front Door Sectioning – Outer
Pillar Lock Front Door Reinforcement Replacement
– Outer
Pillar Lock Front Door Reinforcement
Pillar Lock Front Door Replacement – Inner
Pillar Lock Front Door Sectioning Replacement – Outer
Rear Window Reinforcement Replacement – Lower Front
Rear Window Panel Replacement
Rear Window Reinforcement – Rear
Pillar Lock Rear Door Replacement – Inner
Body Side Panel Replacement – Outer
Rear Compartment Floor Panel Sectioning
Wheelhouse Replacement – Rear Inner
Quarter Panel Sectioning – Outer
Quarter Panel Replacement – Inner
Cross Bar No. 4 Replacement – Floor Panel
Cross Bar No. 4 Extension Replacement – Floor Panel
Cross Bar No. 5 Replacement – Floor Panel Center
Cross Bar No. 5 Extension Replacement – Floor Panel
Rail Replacement Rear Side Underbody
Rail Sectioning Rear Side Underbody
Rail Side Underbody Gusset Replacement – Rear
Rail Side Underbody Reinforcement Replacement – Rear
Impact Bar Anchor Plate Replacement – Rear Bumper
Body Rear End Panel Replacement
Battery Tray Replacement
Pillar Lock Front Door Sectioning -
Outer on page 3-103
Pillar Lock Front Door Reinforcement
Replacement - Outer on page 3-107
Pillar Lock Front Door Reinforcement
Sectioning - Outer on page 3-109
Pillar Lock Front Door Replacement -
Inner on page 3-112
Pillar Lock Front Door Reinforcement
Sectioning - Outer on page 3-109
Rear Window Reinforcement
Replacement - Lower Front on
page 3-114
Rear Window Panel Replacement on
page 3-116
Rear Window Reinforcement
Replacement - Rear on page 3-119
Pillar Lock Rear Door Replacement -
Inner on page 3-121
Body Side Panel Replacement - Outer
on page 3-123
Rear Compartment Floor Panel
Sectioning on page 3-126
Wheelhouse Replacement - Rear Inner
on page 3-130
Quarter Panel Sectioning - Outer on
page 3-133
Quarter Panel Replacement - Inner on
page 3-136
Cross Bar No.4 Replacement - Floor
Panel on page 3-140
Cross Bar No.4 Extension Replacement
- Floor Panel on page 3-138
Cross Bar No.5 Replacement - Floor
Panel on page 3-145
Cross Bar No.5 Extension Replacement
- Floor Panel on page 3-143
Rail Replacement Rear Side
Underbody on page 3-147
Rail Sectioning Rear Side Underbody
on page 3-150
Rail Underbody Gusset Replacement -
Rear on page 3-155
Rail Underbody Reinforcement
Replacement - Rear on page 3-157
Impact Bar Anchor Plate Replacement -
Rear Bumper on page 3-160
Body Rear End Panel Replacement on
page 3-162
Battery Tray Replacement on
page 3-28
3-6 2003 Saturn Ion
Specifications
Dimensions - Body
Rear End
Location Description Length = x Width = y Height = z Point to Point
2 Center Line — — — x
a
b
c
d (Sedan)
d (Coupe)
All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless
otherwise specified.
Rear Tail Lamp
Pocket Hole
Rear Impact Beam
Upper Outer
Attach Hole
Rear Impact Beam
Lower Outer
Attach Hole
Rear Header Panel
Roof Attachment Hole
Rear Header Panel
Roof Attachment Hole
5162 532 683 x
5149 587 447 x
5176 439 327 x
4133 306 1326 x
4068 306 1285 x
876934
2003 Saturn Ion
2003 Saturn Ion
3-7
Coupe Side
Location Description Length = x Width = y Height = z Point to Point
a
b
c
d
e
f
g
h
i Rocker Panel Rear Hole 3780 762 250 x
j Rocker Panel Center Hole 3228 756 234 x
k Rocker Panel Front Hole 2432 762 250 x
l Front Lower Hinge Rear Hole 2260 750 396 x
m
n Body Side Control Hole 2175 745 640 x
o
p Front Upper Hinge Rear Hole 2260 739 754 x
Rear Lower Hinge
Lower Hole
Rear Lower Hinge
Upper Hole
Rear Upper Hinge
Lower Hole
Rear Upper Hinge
Upper Hole
Fascia Bracket Rear
Upper Hole
Quarter Panel Rear Inner
Lower Hole
Quarter Panel Dog Leg
Outer Attach Hole
Quarter Panel Dog Leg
Outer Attach Hole
Front Lower Hinge
Front Hole
Front Upper Hinge
Front Hole
3996 770 555 x
4046 759 649 x
4067 747 758 x
4056 738 863 x
4989 768 798 x
4822 730 445 x
3955 762 320 x
3961 762 235 x
2225 750 396 x
2225 739 754 x
876935
3-8 2003 Saturn Ion
Location Description Length = x Width = y Height = z Point to Point
q
r
All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless
otherwise specified.
Door Opening Point to Point
Measurement to Weld
Flange Die Marks
Door Opening Point to Point
Measurement to Weld
Flange Die Marks
x x x 1588
x x x 1868
Front End
Location Description Length = x Width = y Height = z Point to Point
2 Center Line — — — x
a
b
c
d
e Lower Tie Bar Outer Hole 998 314 428 x
f Center Brace Hole 1089 17 568 x
g Lower Tie Outer Slot 998 314 428 x
h
All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless
otherwise specified.
Front Lamp Assembly Inner
Attach Hole
Front Lamp Assembly Center
Attach Hole
Front Lamp Assembly Outer
Attach Hole
Front Lamp Assembly Lower
Attach Hole
Front Header Panel Roof
Attachment Hole
(Sedan and Coupe)
1146 327 675 x
1208 458 682 x
1271 589 676 x
1307 561 594 x
2799 297 1307 x
2003 Saturn Ion
876936
2003 Saturn Ion
3-9
Underbody
3-10 2003 Saturn Ion
876938
Location Description Length = x Width = y Height = z Point to Point
2 Center Line — — — x
a Rear Cradle Attachment Hole 2100 332 201 x
b
c
d
e
f
g
h Floor Pan Rear Drain Hole 3378 521 190 x
i
j Front Rail Hole 3826 600 184 x
k 5 Bar Outer Hole 4235 180 354 x
l Rear Rail Rear Slot 4757 487 372 x
m
t
ntoo
otop
ptoq
qtos
rtos
stot
ttor
rtof
rtoi
ftoo
otol
lton
All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless
otherwise specified.
Front Rail Outer Torque Box
Master Gage Hole
Floor Pan Drain Hole
Front Hole
Front Rail Hole Front of Rear
Portion
Floor Pan Sled Rail
Front Hole
Front Rail Hole Rear of Rear
Portion
Floor Pan Sled Rail
Rear Hole
Rear Rail Torque Box Master
Gage Hole
Rear Compartment Floor
Pan Drain Hole
Front Cradle
Attachment Hole
Rear Rail Rear Hole to Rear
Rail Master Gage Hole
Rear Rail Master Gage Hole
to Front Rail Rear Hole
Front Rail Rear Hole to Front
Rail Master Gage Hole
Front Rail Master Gage Hole
to Front Cradle
Attachment Hole
Rear Cradle Attachment Hole
to Front Cradle
Attachment Hole
Front Cradle Attachment
Hole to Front Cradle
Attachment Hole
Front Cradle Attachment
Hole to Opposite Rear
Cradle Attachment
Rear Cradle Attachment Hole
to Opposite Rear Rail
Rear Hole
Rear Cradle Attachment Hole
to Rear Rail Master
Gage Hole
Front Rail Rear Hole to
Opposite Rear Rail Master
Gage Hole
Rear Rail Master Gage Hole
to Opposite Rear Rail
Rear Hole
Rear Rail Rear Hole to Rear
Rail Rear Hole
2218 600 121 x
2420 542 190 x
2675 421 134 x
2585 162 133 x
3171 601 167 x
3374 170 144 x
3593 592 203 x
5000 40 221 x
1371 474 231 x
— — — 1174
— — — 419
— — — 956
— — — 847
— — — 742
— — — 948
— — — 1087
— — — 1756
— — — 1756
— — — 1243
— — — 1591
— — — 974
2003 Saturn Ion
2003 Saturn Ion
3-11
Engine Compartment
Location Description Length = x Width = y Height = z Point to Point
2 Center Line — — — x
a
b
c
d
e Strut Tower Center Hole 1811 553 815 x
f
g
h
i
All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless
otherwise specified.
Upper Cowl Panel Rear
Flange Hole
Front Upper Rail Rear
Fender Attach
Front Upper Rail Center
Fender Attach
Front Upper Rail Front
Fender Attach
Front Upper Tie Bar Rear
Flange Hole
Point to Point Front Fender
Attach Hole to Rear Hinge
Attach Hole
Front Engine Mount Hole
Rail Surface Not Top of Stud
Rear Engine Mount Hole Rail
Surface Not Top of Stud
2115 590 873 x
1786 698 805 x
1594 688 773 x
1425 681 739 x
1226 232 700 x
— — — 1499
1461 470 515 x
1657 465 515 x
876940
3-12 2003 Saturn Ion
Sedan Side
876943
2003 Saturn Ion
2003 Saturn Ion
3-13
Location Description Length = x Width = y Height = z Point to Point
a
b
c
d
e
f
g Rear Lower Hinge Rear Hole 3289 746 430 x
h Rear Lower Hinge Front Hole 3254 747 430 x
i Front Lower Hinge Rear Hole 2259 748 396 x
j Rear Cradle Attachment Hole 2100 332 201 x
k
l Front Rail Outer Panel Hole 1840 463 430 x
m
n
o
p Body Side Control Hole 2175 745 640 x
q
r Front Upper Hinge Rear Hole 2260 737 754 x
s
t
u
v
w
x
y
All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless
otherwise specified.
Rear Upper Hinge
Upper Hole
Quarter Panel Dog Leg
Outer Attachment Hole
Fascia Bracket Rear
Upper Hole
Quarter Panel Dog Leg
Outer Attach Hole
Quarter Panel Dog Leg
Outer Attachment Hole
Quarter Panel Dog Leg
Outer Attachment Hole
Front Lower Hinge
Front Hole
Front Cradle
Attachment Hole
Weld Nut Hole Washer Bottle
Attachment
Front Upper Outer Rail
Front Hole
Front Upper Hinge
Front Hole
Front Door Latch Striker
Upper Hole
Rear Upper Hinge
Lower Hole
Rear Latch Striker
Upper Hole
Rear Door Opening Point to
Point Measurements to Weld
Flange Die Marks
Rear Door Opening Point to
Point Measurement to Weld
Flange Die Marks
Front Door Opening Point to
Point Measurement to Weld
Flange Die Marks
Front Door Opening Point to
Point Measurement to Weld
Flange Die Marks
3301 746 776 x
4226 779 768 x
4974 746 596 x
4068 767 617 x
3991 767 437 x
3780 762 250 x
2225 740 396 x
1371 500 280 x
1222 540 409 x
1880 743 760 x
2224 737 754 x
3263 748 574 x
3299 754 741 x
4145 739 736 x
— — — 1015
— — — 1188
— — — 970
— — — 1337
3-14 2003 Saturn Ion
Repair Instructions
Impact Bar Bracket Replacement - Front
Bumper
Removal Procedure
Caution: To avoid personal injury when exposed
to welding flashes or to galvanized (Zinc Oxide)
metal toxic fumes while grinding/cutting on
any type of metal or sheet molded compound, you
must work in a properly ventilated area, wearing
an approved respirator, eye protection, earplugs,
welding gloves, and protective clothing.
1. Disable the SIR system.
2. Disconnect the negative battery cable.
3. Remove all related panels and components.
4. Repair as much of the damage as possible. Refer
to
Dimensions - Body on page 3-7
5. Remove the sealers and anti-corrosion materials
from the repair area, as necessary.
Important: Note the number and location of the
factory welds for installation of the impact bar bracket
- front bumper
6. Locate and drill out all the factory welds from the
outside surface of the rail.
.
868868
2003 Saturn Ion
867608
2003 Saturn Ion
3-15
867609
7. Remove the front bumper impact bar bracket.
Installation Procedure
1. Prepare all mating surfaces as necessary.
2. Apply 3M Weld-Thru Coating P/N 05916 or
equivalent to all mating surfaces.
3-16 2003 Saturn Ion
867597
Important: Verify the location of the front rail using
3-dimensional measuring equipment.
3. Position the impact bar bracket on the rail and
clamp in place.
867609
4. Plug weld accordingly.
5. Clean and prepare all of the welded surfaces.
6. Install all of the related panels and components.
7. Apply the sealers and anti-corrosion materials
to the repair area, as necessary.
8. Paint the repaired area.
9. Connect the negative battery cable.
10. Enable the SIR system.
Tie Bar Replacement
Removal Procedure
Caution: To avoid personal injury when exposed
to welding flashes or to galvanized (Zinc Oxide)
metal toxic fumes while grinding/cutting on
any type of metal or sheet molded compound, you
must work in a properly ventilated area, wearing
an approved respirator, eye protection, earplugs,
welding gloves, and protective clothing.
1. Disable the SIR system.
2. Disconnect the negative battery cable.
3. Remove all related panels and components.
4. Repair as much of the damage as possible to
factory specifications. Refer to
Body on page 3-7
.
5. Note the location and remove the sealers and
anti-corrosion materials from the repair area, as
necessary.
Important: Do not damage any inner panels or
reinforcements.
6. Locate and drill out all factory welds. Note the
number and location of the welds for installation
of the tie bar.
Dimensions -
868868
867423
2003 Saturn Ion
2003 Saturn Ion
867488
3-17
867491
7. Remove the damaged tie bar.
Installation Procedure
Important: If the location of the original plug weld
holes can not be determined, space the plug
weld holes every 40 mm (1 1/2 in) apart.
1. Drill 8 mm (5/16 in) plug weld holes in the service
part as necessary in the locations noted from the
original panel.
2. Prepare all mating surfaces as necessary.
3. Apply 3M Weld-Thru Coating P/N 05916 or
equivalent to all mating surfaces.
3-18 2003 Saturn Ion
865271
4. Position the tie bar to the vehicle using
3-dimensional measuring equipment. Clamp the
tie bar into place.
5. Plug weld accordingly.
6. Clean and prepare all welded surfaces.
7. Apply the sealers and anti-corrosion materials to
the repair area, as necessary.
8. Paint the repair area.
9. Install all related panels and components.
10. Connect the negative battery cable.
11. Enable the SIR system.
867423
Tie Bar Replacement - Left
Removal Procedure
Caution: To avoid personal injury when exposed
to welding flashes or to galvanized (Zinc Oxide)
metal toxic fumes while grinding/cutting on
any type of metal or sheet molded compound, you
must work in a properly ventilated area, wearing
an approved respirator, eye protection, earplugs,
welding gloves, and protective clothing.
Caution: When performing service on or near the
SIR components or the SIR wiring, the SIR
system must be disabled. Refer to SIR Disabling
and Enabling Zones. Failure to observe the correct
procedure could cause deployment of the SIR
components, personal injury, or unnecessary SIR
system repairs.
1. Disable the SIR system.
Caution: Before servicing any electrical
component, the ignition key must be in the OFF or
LOCK position and all electrical loads must be
OFF, unless instructed otherwise in these
procedures. If a tool or equipment could easily
come in contact with a live exposed electrical
terminal, also disconnect the negative battery
cable. Failure to follow these precautions
may cause personal injury and/or damage to the
vehicle or its components.
2. Disconnect the negative battery cable.
3. Remove all related panels and components.
4. Repair as much of the damage as possible. Refer
Dimensions - Body on page 3-7
to
5. Remove the sealers and anti-corrosion materials
from the repair area, as necessary.
Important: Note the number and location of the
factory welds for installation of the tie bar-left.
6. Locate and drill out all the necessary
factory welds.
.
867423
2003 Saturn Ion
867500
3-19
2003 Saturn Ion
867504
7. Remove the left tie bar.
Installation Procedure
Important: If the location of the original plug weld
holes can not be determined, space the plug
weld holes every 40 mm (1 1/2 in) apart.
1. Drill 8 mm (5/16 in) plug weld holes in the service
part as necessary in the locations noted from the
original panel.
2. Prepare all mating surfaces as necessary.
3. Apply 3M Weld-Thru Coating P/N 05916 or
equivalent to all mating surfaces.
3-20 2003 Saturn Ion
865272
4. Position the left tie bar to the vehicle using
3-dimensional measuring equipment. Clamp the
tie bar in place.
867504
5. Plug weld accordingly.
6. Clean and prepare all of the welded surfaces.
7. Install all of the related panels and components.
8. Apply the sealers and anti-corrosion materials
to the repair area, as necessary.
9. Paint the repaired area.
10. Connect the negative battery cable.
11. Enable the SIR system.
Tie Bar Replacement - Lower
Removal Procedure
Caution: To avoid personal injury when exposed
to welding flashes or to galvanized (Zinc Oxide)
metal toxic fumes while grinding/cutting on
any type of metal or sheet molded compound, you
must work in a properly ventilated area, wearing
an approved respirator, eye protection, earplugs,
welding gloves, and protective clothing.
Caution: When performing service on or near the
SIR components or the SIR wiring, the SIR
system must be disabled. Refer to SIR Disabling
and Enabling Zones. Failure to observe the correct
procedure could cause deployment of the SIR
components, personal injury, or unnecessary SIR
system repairs.
1. Disable the SIR system.
Caution: Before servicing any electrical
component, the ignition key must be in the OFF or
LOCK position and all electrical loads must be
OFF, unless instructed otherwise in these
procedures. If a tool or equipment could easily
come in contact with a live exposed electrical
terminal, also disconnect the negative battery
cable. Failure to follow these precautions
may cause personal injury and/or damage to the
vehicle or its components.
2. Disconnect the negative battery cable.
Important: This panel is replaced at factory seams or
can be unbolted for removal.
3. Remove all related panels and components.
4. Repair as much of the damage as possible. Refer
Dimensions - Body on page 3-7
to
5. Remove the sealers and anti-corrosion materials
from the repair area, as necessary.
.
867423
867423
2003 Saturn Ion
2003 Saturn Ion
3-21
867424
Important: Note the number and location of the
factory welds for installation of the lower tie bar.
6. Locate and drill out all the necessary
factory welds.
7. Remove the lower tie bar.
3-22 2003 Saturn Ion
867470
Installation Procedure
Important: If the location of the original plug weld
holes can not be determined, space the plug
weld holes every 40 mm (1 1/2 in) apart.
1. Drill 8 mm (5/16 in) plug weld holes in the service
part as necessary in the locations noted from the
original panel.
2. Prepare all mating surfaces as necessary.
3. Apply 3M Weld-Thru Coating P/N 05916 or
equivalent to all mating surfaces.
865257
4. Position the tie bar on the vehicle using
3-dimensionial measuring equipment. Clamp the
tie bar into place.
5. Plug weld accordingly.
6. Clean and prepare all of the welded surfaces.
7. Install all of the related panels and components.
8. Apply the sealers and anti-corrosion materials
to the repair area, as necessary.
9. Paint the repaired area.
10. Connect the negative battery cable.
11. Enable the SIR system.
867470
Tie Bar Replacement - Right
Removal Procedure
Caution: To avoid personal injury when exposed
to welding flashes or to galvanized (Zinc Oxide)
metal toxic fumes while grinding/cutting on
any type of metal or sheet molded compound, you
must work in a properly ventilated area, wearing
an approved respirator, eye protection, earplugs,
welding gloves, and protective clothing.
Caution: Refer to SIR Caution on page 1-1 in
General Information.
Important: The graphic shows the left hand procedure.
The right hand procedure is similar.
1. Disable the SIR system.
2003 Saturn Ion
867423
2003 Saturn Ion
867423
3-23
Caution: Before servicing any electrical
component, the ignition key must be in the OFF or
LOCK position and all electrical loads must be
OFF, unless instructed otherwise in these
procedures. If a tool or equipment could easily
come in contact with a live exposed electrical
terminal, also disconnect the negative battery
cable. Failure to follow these precautions
may cause personal injury and/or damage to the
vehicle or its components.
2. Disconnect the negative battery cable.
3. Remove all related panels and components.
4. Repair as much of the damage as possible. Refer
Dimensions - Body on page 3-7
to
.
5. Remove the sealers and anti-corrosion materials
from the repair area, as necessary.
Important: Note the number and location of the
factory welds for installation of the right tie bar.
6. Locate and drill out all the necessary
factory welds.
867500
867504
7. Remove the right tie bar panel from the vehicle.
3-24 2003 Saturn Ion
Installation Procedure
Important: If the location of the original plug weld
holes can not be determined, space the plug
weld holes every 40 mm (1 1/2 in) apart.
1. Drill 8 mm (5/16 in) plug weld holes in the service
part as necessary in the locations noted from the
original panel.
2. Prepare all mating surfaces as necessary.
3. Apply 3M Weld-Thru Coating P/N 05916 or
equivalent to all mating surfaces.
4. Position the right tie bar panel to the vehicle using
3-dimensional measuring equipment. Clamp the
tie bar in place.
865272
5. Plug weld accordingly.
6. Clean and prepare all of the welded surfaces.
7. Install all of the related panels and components.
8. Apply the sealers and anti-corrosion materials
to the repair area, as necessary.
9. Paint the repaired area.
10. Connect the negative battery cable.
11. Enable the SIR system.
2003 Saturn Ion
867504
2003 Saturn Ion
867423
3-25
867423
Latch Primary Support
Replacement - Hood
Removal Procedure
Caution: To avoid personal injury when exposed
to welding flashes or to galvanized (Zinc Oxide)
metal toxic fumes while grinding/cutting on
any type of metal or sheet molded compound, you
must work in a properly ventilated area, wearing
an approved respirator, eye protection, earplugs,
welding gloves, and protective clothing.
Caution: When performing service on or near the
SIR components or the SIR wiring, the SIR
system must be disabled. Refer to SIR Disabling
and Enabling Zones. Failure to observe the correct
procedure could cause deployment of the SIR
components, personal injury, or unnecessary SIR
system repairs.
1. Disable the SIR system.
Caution: Before servicing any electrical
component, the ignition key must be in the OFF or
LOCK position and all electrical loads must be
OFF, unless instructed otherwise in these
procedures. If a tool or equipment could easily
come in contact with a live exposed electrical
terminal, also disconnect the negative battery
cable. Failure to follow these precautions
may cause personal injury and/or damage to the
vehicle or its components.
2. Disconnect the negative battery cable.
3. Remove all related panels and components.
4. Repair as much of the damage as possible. Refer
Dimensions - Body on page 3-7
to
5. Remove the sealers and anti-corrosion materials
from the repair area, as necessary.
Important: Note the number and location of the
factory welds for installation of the latch primary
support.
6. Locate and drill out all the necessary
factory welds.
.
3-26 2003 Saturn Ion
867511
7. Remove the latch primary support.
Installation Procedure
Important: If the location of the original plug weld
holes can not be determined, space the plug
weld holes every 40 mm (1 1/2 in) apart.
1. Drill 8 mm (5/16 in) plug weld holes in the service
part as necessary in the locations noted from the
original panel.
2. Prepare all mating surfaces as necessary.
3. Apply 3M Weld-Thru Coating P/N 05916 or
equivalent to all mating surfaces.
867514
4. Position the latch primary support on the vehicle
using 3-dimensional measuring equipment. Clamp
the support into place.
2003 Saturn Ion
865273
2003 Saturn Ion
867514
3-27
867423
872730
5. Plug weld accordingly.
6. Clean and prepare all of the welded surfaces.
7. Install all of the related panels and components.
8. Apply the sealers and anti-corrosion materials
to the repair area, as necessary.
9. Paint the repaired area.
10. Connect the negative battery cable.
11. Enable the SIR system.
Battery Tray Replacement
Removal Procedure
Caution: To avoid personal injury when exposed
to welding flashes or to galvanized (Zinc Oxide)
metal toxic fumes while grinding/cutting on
any type of metal or sheet molded compound, you
must work in a properly ventilated area, wearing
an approved respirator, eye protection, earplugs,
welding gloves, and protective clothing.
Caution: When performing service on or near the
SIR components or the SIR wiring, the SIR
system must be disabled. Refer to SIR Disabling
and Enabling Zones. Failure to observe the correct
procedure could cause deployment of the SIR
components, personal injury, or unnecessary SIR
system repairs.
1. Disable the SIR system.
Caution: Before servicing any electrical
component, the ignition key must be in the OFF or
LOCK position and all electrical loads must be
OFF, unless instructed otherwise in these
procedures. If a tool or equipment could easily
come in contact with a live exposed electrical
terminal, also disconnect the negative battery
cable. Failure to follow these precautions
may cause personal injury and/or damage to the
vehicle or its components.
2. Disconnect the negative battery cable.
Important: This panel is replaced at factory seams.
3. Remove all related panels and components.
4. Repair as much of the damaged area as possible.
Refer to
5. Remove the sealers and anti-corrosion materials
from the repair area, as necessary.
Dimensions - Body on page 3-7
.
3-28 2003 Saturn Ion
Important: Note the number and location of the
factory welds for installation of the battery tray.
6. Locate and drill out all the necessary
factory welds.
7. Remove the battery tray.
Installation Procedure
Important: If the location of the original plug weld
holes can not be determined, space the plug
weld holes every 40 mm (1 1/2 in) apart.
1. Drill 8 mm (5/16 in) plug weld holes in the service
part as necessary in the locations noted from the
original panel.
2. Prepare all mating surfaces for welding as
necessary.
3. Apply 3M Weld-Thru Coating P/N 05916 or
equivalent to all mating surfaces.
4. Position the battery tray to the vehicle. Clamp the
battery tray in place.
872732
5. Plug weld accordingly.
6. Clean and prepare all of the welded surfaces.
7. Install all of the related panels and components.
8. Apply the sealers and anti-corrosion materials
to the repair area, as necessary.
9. Paint the repaired area.
10. Connect the negative battery cable.
11. Enable the SIR system.
2003 Saturn Ion
872732
2003 Saturn Ion
872730
3-29
867612
Bracket Replacement Front Compartment
- Side Rail
Removal Procedure
Caution: To avoid personal injury when exposed
to welding flashes or to galvanized (Zinc Oxide)
metal toxic fumes while grinding/cutting on
any type of metal or sheet molded compound, you
must work in a properly ventilated area, wearing
an approved respirator, eye protection, earplugs,
welding gloves, and protective clothing.
Caution: When performing service on or near the
SIR components or the SIR wiring, the SIR
system must be disabled. Refer to SIR Disabling
and Enabling Zones. Failure to observe the correct
procedure could cause deployment of the SIR
components, personal injury, or unnecessary SIR
system repairs.
1. Disable the SIR system.
Caution: Before servicing any electrical
component, the ignition key must be in the OFF or
LOCK position and all electrical loads must be
OFF, unless instructed otherwise in these
procedures. If a tool or equipment could easily
come in contact with a live exposed electrical
terminal, also disconnect the negative battery
cable. Failure to follow these precautions
may cause personal injury and/or damage to the
vehicle or its components.
2. Disconnect the negative battery cable.
3. Remove all related panels and components.
4. Repair as much of the damage as possible. Refer
Dimensions - Body on page 3-7
to
5. Remove the sealers and anti-corrosion materials
from the repair area, as necessary.
Important: Note the number and location of the
factory welds for installation of the bracket side
rail-front compartment.
6. Locate and drill out all the necessary
factory welds.
.
3-30 2003 Saturn Ion
867617
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