Saturn 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

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

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

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

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

— — — 1243

— — — 1591

— — — 974

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

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

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

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

7. Remove the side rail bracket from the front compartment lower rail.

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.

867618

4. Position the side rail bracket to the front compartment lower rail and tie bar side panel. Clamp the bracket in place.

2003 Saturn Ion

865267

2003 Saturn Ion

867618

3-31

867612

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.

Wheelhouse Replacement - Front

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.

2. Disconnect the negative battery cable.

Important: The upper strut mounting surface is a dimensionally critical area, and 3-dimensional measuring equipment should be used to locate the front wheelhouse assembly. The front wheelhouse can be serviced as a complete assembly for both the left and right wheelhouses. A wheelhouse front panel is also available to service separately on the left or the right sides.

3. Remove the sealers and anti-corrosion materials from the repair area, as necessary.

Important: Be sure to inspect the front of the cowl and dash panel for damage. If the metal surface is damaged, the cowl panel must be repaired to restore the structural integrity of the vehicle.

4. Visually inspect the damaged area. Repair as much of the damage as possible. Refer to

Dimensions - Body on page 3-7

.

3-32 2003 Saturn Ion

867478

5. Locate and drill out all factory welds.

Important: Note the number and location of welds for installation of the front wheelhouse.

6. Remove the front wheelhouse from the vehicle.

867495

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 as necessary in the locations noted from the original assembly.

2. Prepare the mating surfaces as necessary.

3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

4. Position the front wheelhouse in the vehicle using 3-dimensional measuring equipment. Clamp the wheelhouse in place.

2003 Saturn Ion

867507

2003 Saturn Ion

865277

3-33

867495

868716

5. Plug weld accordingly.

6. Clean and prepare all of the welded surfaces.

7. Install all 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.

Wheelhouse Extension Replacement - Front

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.

.

3-34 2003 Saturn Ion

Important: Note the number and location of the factory welds for installation of the front wheelhouse extension.

6. Locate and drill out all the necessary factory welds.

7. Remove the front wheelhouse extension.

868717

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.

2003 Saturn Ion

868718

2003 Saturn Ion

865281

3-35

868718

4. Position the front wheelhouse extension to the vehicle using 3-dimensional measuring equipment. Clamp the extension in 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.

3-36 2003 Saturn Ion

868716

Rail Replacement Front Compartment Side Upper

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.

1. Disable the SIR system.

868719

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 to factory speciﬁcations. Refer to

Body on page 3-7

.

Dimensions -

5. 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 front upper rail.

7. Remove the damaged front upper rail.

2003 Saturn Ion

868721

2003 Saturn Ion

868722

3-37

868720

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 front upper rail on the vehicle using 3-dimensional measuring equipment. Clamp the rail in place.

3-38 2003 Saturn Ion

868722

5. Plug weld accordingly.

6. Clean and prepare all welded surfaces.

7. Install all related panels and components.

8. Apply the sealers and anti-corrosion materials to the repair area, as necessary.

9. Paint the repair area.

10. Connect the negative battery cable.

11. Enable the SIR system.

868719

Rail Sectioning Front Compartment Side Upper

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: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision.

Caution: Refer to SIR Caution on page 1-1 in General Information.

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 front compartment of the side upper rail.

6. Locate and drill out all the necessary factory welds.

.

868719

2003 Saturn Ion

874293

3-39

874296

7. Measure forward 50 mm (2 in) (a) of the center of the third fender bolt hole location. Mark the location.

8. Using the mark made in the previous step as a starting point, use a sliding square to transfer a line on the top, side, and bottom of the rail.

9. Cut the side upper rail at the marked location.

3-40 2003 Saturn Ion

874298

10. Remove the front portion of the side upper rail.

11. Drill 2 8 mm (5/16 in) plug weld holes 10 mm (1/2 in) rearward from the edge of the top, bottom, and outer side on the front edge of the remaining portion of the side upper rail on the vehicle.

874299

Installation Procedure

1. Measure a section on the service part that is 25 mm (1 in) (a) forward of the third fender bolt hole. Mark this section.

2. Using the mark made in the previous step as a starting point, use a sliding square to transfer a line on the top, side, and bottom of the rail.

3. Cut the service part at the marked location.

874296

Important: If the location of the original plug weld holes can not be determined, space the plug weld

1

holes every 40 mm (1

⁄2in) apart.

4. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted on the original panel.

5. Prepare all mating surfaces as necessary.

6. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

7. Measure 25 mm (1 in) forward from the cut area. Mark the location on top of the rail.

8. Using the mark made in the previous step as a starting point, use a sliding square to transfer a line on the top, side, and bottom of the rail.

2003 Saturn Ion

874298

2003 Saturn Ion

874290

3-41

875630

Important: Do not cut past the scribed line.

9. At the weld ﬂange areas of the rail and at each radius, cut toward the scribed line. This will aid in the ﬂange-forming process.

10. Bend the cut area of the rail inward to create a 25 mm (1 in) step ﬂange for the weld joint.

Important: Flanges on the service part will slide inside the rail portion of the vehicle.

11. Position the side upper rail to the vehicle using 3-dimensional measuring equipment. Clamp the rail in place.

3-42 2003 Saturn Ion

874299

12. Stitch and plug weld accordingly.

13. Clean and prepare all of the welded surfaces.

14. Install all of the related panels and components.

15. Apply the sealers and anti-corrosion materials to the repair area, as necessary.

16. Paint the repaired area.

17. Connect the negative battery cable.

18. Enable the SIR system.

868719

Plenum Panel Replacement - Upper

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 upper plenum panel.

6. Locate and drill out all the necessary factory welds.

.

870823

2003 Saturn Ion

870852

3-43

2003 Saturn Ion

870855

7. Remove the upper plenum panel.

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. 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.

1

⁄2in) apart.

3-44 2003 Saturn Ion

870847

4. Position the upper plenum panel to the vehicle using 3-dimensional measuring equipment. Clamp the panel in place.

870855

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.

Plenum Panel 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.

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.

.

870823

2003 Saturn Ion

3-45

870828

6. Locate and drill out all the necessary factory welds.

7. Locate and drill out all of the necessary factory welds at the following locations:

• The dash panel to the lower plenum

• The inside ends of the lower plenum

• On the top rear portion of the front upper rail to the plenum

3-46 2003 Saturn Ion

870842

8. Pull the body side panel outward and upward.

870838

9. Remove the lower plenum panel from the vehicle.

Installation Procedure

Important: The service part comes as an assembly

that includes the lower dash panel. If the repair does not require the dash panel, remove the dash panel before you install the lower plenum panel.

Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1

1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the corresponding locations noted on 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.

1

⁄2in) apart.

870834

4. Position the lower plenum panel to the vehicle.

2003 Saturn Ion

870826

2003 Saturn Ion

870828

3-47

870823

868877

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.

Dash Panel 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 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.

.

3-48 2003 Saturn Ion

Important: Note the number and location of the factory welds for installation of the dash panel.

6. Locate and drill out all the necessary factory welds.

7. Remove the dash panel.

870810

Installation Procedure

Important: The service part comes as an assembly

that includes the plenum lower panel. If the repair does not require the plenum, remove the plenum before you install the dash panel.

Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1

1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the corresponding locations noted on the original panel.

1

⁄2in) apart.

2003 Saturn Ion

870809

2003 Saturn Ion

865505

3-49

870805

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 dash panel. Clamp the dash panel in place.

3-50 2003 Saturn Ion

870809

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.

868877

Cross Bar No.1 Replacement - Floor Panel

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 cross bar #1 to the ﬂoor panel.

6. Locate and drill out all the necessary factory welds.

.

870812

2003 Saturn Ion

870816

2003 Saturn Ion

3-51

870819

7. Remove the cross 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. 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.

1

⁄2in) apart.

3-52 2003 Saturn Ion

870815

4. Position the cross bar. Clamp the cross bar in place.

870819

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.

Rail Replacement Front Compartment - Front

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 assembly is replaced at factory seams.

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.

.

870812

867423

2003 Saturn Ion

3-53

867533

Important: Note the number and location of the factory welds for installation of the full rail service part.

6. Locate and drill out all the necessary factory welds.

7. Remove the full rail.

3-54 2003 Saturn Ion

867535

865235

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. 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 full rail service part to the vehicle using 3–dimensional measuring equipment. Clamp the rail in place.

1

⁄2in) apart.

5. Plug weld accordingly.

6. Clean and prepare all of the welded surfaces.

7. Apply the sealers and anti-corrosion materials to the repair area, as necessary.

8. Paint the repaired area.

9. Install all of the related panels and components.

10. Connect the negative battery cable.

11. Enable the SIR system.

Rail Replacement Front Compartment Front Half

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.

Important: The service part is developed from a

complete assembly and will require the spot weld removal at the rail mid joint. The lower rail service part comes as a complete front rail assembly, including all the brackets and the reinforcements.

Important: Loosen and protect the fuel and brake lines during rail replacement.

1. Support the engine and the transmission with suitable equipment.

2. Remove the fasteners to the engine and the transmission.

3. Remove all the other related panels and components as necessary, including the suspension and the crossmember,.

4. Visually inspect the damaged area. Repair as much of the damage as possible to factory speciﬁcations. Refer to

page 3-7

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary.

.

Dimensions - Body on

867423

2003 Saturn Ion

867423

3-55

872672

6. Locate the area where the front compartment will be separated from the rail.

7. Locate and drill the factory welds along the ﬂanges of the rail, only up to and including the rail mid joint just forward of the dash panel.

8. Drill out the factory welds.

3-56 2003 Saturn Ion

867545

9. Pry open the outer layer of the rail at the front rail mid joint to allow the front portion of the rail to be removed from the vehicle.

867551

10. Remove the damaged front lower rail.

11. Drill out the factory welds at the service rail assembly mid joint.

12. Remove the forward portion of the front rail assembly at the mid joint.

867552

13. Prepare the mating surfaces as necessary.

14. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

2003 Saturn Ion

872672

2003 Saturn Ion

865237

3-57

867552

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. 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 rail to the vehicle.

1

⁄2in) apart.

3-58 2003 Saturn Ion

867548

5. Plug weld accordingly.

6. Clean and prepare all of the welded surfaces.

7. Install all related panels and components.

8. Apply sealers and anti-corrosion materials to the repair area, as necessary.

867521

Notice:

location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identiﬁed in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless speciﬁed. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and speciﬁcations when installing fasteners in order to avoid damage to parts and systems.

9. Install the suspension crossmember.

Use the correct fastener in the correct

Tighten

Tighten the fasteners to 100 N·m (74 lb ft) + 180 degrees.

Rail Sectioning Front Compartment - Front

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: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision.

Caution: Refer to SIR Caution on page 1-1 in General Information.

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 of the related panels and the components.

4. Remove the sealers and anti-corrosion materials from the repair area, as necessary.

5. Repair as much of the damage as possible to factory speciﬁcations. Refer to

Body on page 3-7

.

Dimensions -

867588

2003 Saturn Ion

3-59

867581

6. Locate the die marks on the inner and outer halves of the front rail.

Important: Do not section the rail except where indicated.

867583

7. Measure forward of the straight line shown on the

1

die marks 7 mm (

⁄4in). Mark the rail at both die

mark locations.

8. At the marks made forward of the die marks, align a sliding square or similar tool to the bottom side of the front rail. Scribe a line 360 degrees

1

around the frame rail, 7 mm (

⁄4in) forward of the

die marks.

3-60 2003 Saturn Ion

867585

9. Cut the rail at the marked location.

10. Remove the damaged component from the vehicle.

867537

Installation Procedure

1. At the straight line on the die mark, align a sliding square or similar tool to this line and the bottom side of the front lower rail. Scribe a line completely around the frame rail.

2003 Saturn Ion

867586

2003 Saturn Ion

867585

3-61

867590

2. Cut the upper and lower inner and outer corners of the frame rail. Cut at the beginning and the end of the radius at each corner rearward 7 mm

1

⁄4in) to the scribe line.

(

3. Bend each side of the rail inward by aligning a vice grip ﬂanging tool or similar tool to the scribe line. Bend a 7 mm (

1

⁄4in) ﬂange inward slightly.

This ﬂange is the welding backer.

4. Prepare the sectioning weld area as necessary for welding.

3-62 2003 Saturn Ion

867591

5. Locate the die marks on the service part front rail.

6. Scribe a line completely around the service rail at the line in the die mark by aligning a sliding square or similar tool to the bottom edge of the front rail service part.

7. Cut at the marked location. Remove the front portion of the rail.

8. Prepare the cut edge of the front rail section for welding.

9. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

867583

10. Position the front rail section using 3-dimensional measuring equipment. Clamp the service part in place.

11. Tack weld the part into position.

12. Inspect the service rail for proper dimensions using 3–dimensional measuring equipment.

13. Stitch weld along the entire sectioning joint. Make 25 mm (1 in) welds along the seam with 25 mm (1 in) gaps between.

14. Complete the stitch weld.

15. Clean and prepare the welded surfaces.

16. Install all of the related panels and components.

17. Apply the sealers and anti-corrosion materials to the repair area, as necessary.

18. Paint the repaired area.

19. Enable the SIR system.

20. Connect the negative battery cable.

867586

Rail Replacement Front Side Underbody - Outer

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.

1. Disable the SIR system.

2003 Saturn Ion

876346

2003 Saturn Ion

867556

3-63

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 outer rail.

6. Locate and drill out all the necessary factory welds.

867560

867565

7. Remove the outer rail from the vehicle.

3-64 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. 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 outer rail to the vehicle using 3– dimensional measuring equipment. Clamp the outer rail in place.

1

⁄2in) apart.

865261

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

867565

2003 Saturn Ion

867556

3-65

867622

Suspension Support Replacement - Front

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 front suspension support.

6. Locate and drill out all the necessary factory welds.

.

3-66 2003 Saturn Ion

867626

7. Remove the front suspension 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. 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.

1

⁄2in) apart.

867629

4. Position the front suspension support to the vehicle using 3–dimensional measuring equipment. Clamp the support into place.

2003 Saturn Ion

865265

2003 Saturn Ion

867629

3-67

867622

867632

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.

Extension Replacement Front Compartment Side Rail - Rear

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

.

3-68 2003 Saturn Ion

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 rear extension of the front compartment side rail.

6. Locate and drill out all the necessary factory welds.

7. Remove the rear extension.

867635

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. 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.

1

⁄2in) apart.

2003 Saturn Ion

867636

2003 Saturn Ion

865268

3-69

867636

4. Position the rear extension to the vehicle using 3– dimensional measuring equipment. Clamp the support 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.

3-70 2003 Saturn Ion

867632

Windshield Frame Reinforcement Replacement - Inner Upper

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.

1. Disable the SIR system.

875595

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 windshield frame reinforcement.

6. Locate and drill out all the necessary factory welds.

7. Remove the windshield frame reinforcement.

875601

2003 Saturn Ion

875604

2003 Saturn Ion

3-71

875599

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. 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 windshield frame reinforcement to the vehicle.

1

⁄2in) apart.

3-72 2003 Saturn Ion

875604

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.

875595

Hinge Pillar Body Reinforcement Replacement - Front Inner

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. Remove the sealers and anti-corrosion materials from the repair area, as necessary.

5. Repair as much of the damaged area as possible. Refer to

Important: Note the number and location of the factory welds for installation of the hinge pillar.

6. Locate and drill out all factory welds

Dimensions - Body on page 3-7

.

875620

2003 Saturn Ion

875622

3-73

875623

7. Remove the damaged hinge pillar reinforcement.

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 as 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. Align the service part using 3-dimensional measuring equipment. Clamp in place.

3-74 2003 Saturn Ion

875621

5. Plug weld accordingly.

6. Clean and prepare all of the welded surfaces.

7. Apply the sealers and anti-corrosion materials to the repair area, as necessary.

8. Paint the repaired area.

9. Install all of the related panels and components.

10. Connect the negative battery cable.

11. Enable the SIR system.

875620

Hinge Pillar Body Replacement Front Inner

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 damaged area as possible. Refer 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 inner hinge pillar.

6. Locate and drill out all the necessary factory welds.

Dimensions - Body on page 3-7

.

870896

2003 Saturn Ion

870899

3-75

2003 Saturn Ion

870901

7. Remove the inner hinge pillar.

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. 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.

1

⁄2in) apart.

3-76 2003 Saturn Ion

870898

4. Install the baffle in the inner portion of the front inner hinge pillar.

870903

5. Position the hinge pillar body to the vehicle.

6. Plug weld accordingly.

7. Clean and prepare all of the welded surfaces.

8. Install all of the related panels and components.

9. Apply the sealers and anti-corrosion materials to the repair area, as necessary.

10. Paint the repaired area.

11. Connect the negative battery cable.

12. Enable the SIR system.

870901

2003 Saturn Ion

870896

2003 Saturn Ion

3-77

874221

Hinge Pillar Body Sectioning - Front

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: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision.

The sedan body side outer panel is available either in one piece or in front or rear portions. The front and the rear halves are cut about half way across the rear door opening. You can perform any one of these replacement procedures separately or in any combination, depending upon the extent of damage to the vehicle. Sectioning must take place in speciﬁed areas only. Stay away from the door and window opening radius areas. Section only in straight areas of the openings.

The coupe body side outer panel is available as a one-piece panel only. You can perform any one of these replacement procedures separately or in any combination, depending upon the extent of the damage to the vehicle. Sectioning must take place in speciﬁed areas only. Stay away from the door and window opening radius areas. Section only in straight areas of the openings.

3-78 2003 Saturn Ion

874304

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 damaged area as possible. Refer to

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary.

Important: Sectioning can be done anywhere in the straight areas of the windshield pillar and along the rocker panel.

6. Locate the area on the panel where sectioning will be performed.

7. Measure from any trim attachment hole within the recommended sectioning areas. Mark the location for section cutting on the vehicle at the windshield pillar and rocker panel locations.

Important: Note the number and location of the factory welds for installation of the hinge pillar.

8. Locate and drill out all factory welds.

Dimensions - Body on page 3-7

.

876963

2003 Saturn Ion

876965

2003 Saturn Ion

3-79

876966

Important: Do NOT damage any other panels or reinforcements when cutting at the marked locations.

9. Cut the panel at the location laid out in the previous steps.

10. Remove the damaged hinge pillar.

Installation Procedure

1. Locate the area on the service panel where you will perform sectioning.

2. Measure and mark the cut line location on the service part at the same location as on the vehicle layout.

3. Cut the outer front hinge pillar in corresponding locations to ﬁt the remaining original panel. The sectioning joint should be trimmed to allow a gap of 1 sectioning joint.

1

⁄2times the metal thickness at the

3-80 2003 Saturn Ion

876964

4. Create a 50 mm (2 in) backing plate from the unused portion of the service part for the windshield area.

5. Create a 100 mm (4 in) backing plate from the unused portion of the service part for the rocker area.

6. Trim the backing plates as necessary to ﬁt behind the panel at the sectioning joint.

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.

7. Drill 8 mm (5/16 in) plug weld holes along the sectioning area in the service part, and at the locations noted from the original panel.

876967

8. Prepare all mating surfaces as necessary.

9. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

10. Fit the backing plates halfway into the sectioning joints, 25 mm (1 in) at the windshield pillar and 50 mm (2 in) at the rocker panel areas. Clamp the plates in place, and plug weld to the section joint

11. Position the outer front pillar to the vehicle using 3-dimensional measuring equipment. Clamp the pillar in place.

12. Plug weld accordingly.

13. Plug weld accordingly.

14. Stitch weld the butt weld locations.

15. To create a solid weld with minimum heat distortion, make a 25 mm (1 in) stitch weld along the seam with gaps of 25 mm (1 in). Go back and complete the stitch weld.

16. Clean and prepare all of the welded surfaces.

17. Apply the sealers and anti-corrosion materials to the repair area, as necessary.

18. Paint the repaired area.

19. Install all of the related panels and components.

20. Connect the negative battery cable.

21. Enable the SIR system.

876968

Roof Panel Replacement - Outer

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.

1. Disable the SIR system.

2003 Saturn Ion

787665

2003 Saturn Ion

870880

3-81

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. Take note of the gap sizes along the perimeter of the roof panel to the headers, the glass, and the doors.

4. Remove all related panels and components.

5. Repair as much of the damaged area as possible. Refer to

Dimensions - Body on page 3-7

.

6. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary.

7. Remove the 4 nuts that retain the front and rear of the roof panel to the front and rear header panels.

Important: Do not damage any inner panels or reinforcements.

8. Locate and cut the urethane adhesive holding the roof panel to the vehicle. Note the location of the adhesive for installation of the roof panel.

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9. Remove the damaged roof panel.

Installation Procedure

1. Prepare all mating surfaces as necessary.

2. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

870883

Important: Place the urethane adhesive on the outboard side of the roof panel stud hole locations.

3. Place a 10 mm (3/8 in) diameter bead of urethane adhesive GM P/N 12346392 on the perimeter of the vehicle roof attachment points.

2003 Saturn Ion

870876

2003 Saturn Ion

874273

3-83

870880

4. Position the roof panel on the vehicle.

5. Verify the ﬁt of the roof panel to the front edge of the front header panel and to the rear edge of the rear header panel.

6. Verify the ﬁt of the roof panel at the gap along the top of the door frame to the roof panel. Adjust the panel if necessary.

Notice:

Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identiﬁed in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless speciﬁed. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and speciﬁcations when installing fasteners in order to avoid damage to parts and systems.

7. Install the 4 nuts at the front and rear header panels.

Tighten

Tighten the nuts to 8–12 N·m (3.1–4.7 lb in).

8. Apply the sealers and anti-corrosion materials to the repair area, as necessary.

9. Paint the repair area.

10. Install all related panels and components.

11. Connect the negative battery cable.

12. Enable the SIR system.

3-84 2003 Saturn Ion

870875

Windshield Frame Header Panel Replacement - Front

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 damaged area as possible. Refer 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 header panel.

6. Locate and drill out all the necessary factory welds.

Dimensions - Body on page 3-7

.

870858

2003 Saturn Ion

870860

3-85

870867

7. Remove the header panel.

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. 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.

1

⁄2in) apart.

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870858

4. Position the header panel to the vehicle using 3-dimensional measuring equipment. Clamp the front header panel in place.

870867

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.

Rear Window Frame Header Panel Replacement - Rear

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 damaged area as possible. Refer to

Dimensions - Body on page 3-7

.

870857

870868

2003 Saturn Ion

3-87

870870

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 rear window frame header panel.

6. Locate and drill out all the necessary factory welds.

7. Remove the rear window frame header panel.

3-88 2003 Saturn Ion

870872

870869

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. 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.

1

⁄2in) apart.

4. Position the rear window frame header panel to the vehicle using 3-dimensional measuring equipment. Clamp the rear header panel in 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.

870872

Floor Panel Replacement - Center

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.

1. Disable the SIR system.

2003 Saturn Ion

870868

2003 Saturn Ion

870895

3-89

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 damaged area 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 center ﬂoor panel.

Important: Do NOT damage or drill through adjacent panels.

6. Locate and drill out the #2 and #3 bar attachments to the inner rocker panel.

7. Bend the upper weld ﬂange up and away from the inner rocker panel.

870890

870892

Important: The rear portion of the front compartment lower rail is a multi-layered assembly.

8. Note the layering (1,2,3,4) of the weld ﬂanges.

• The rear portion of the front rail to rail assembly

• The rear upper reinforcement of the front rail to ﬂoor pan

• The intermediate portion of the front rail to rear upper reinforcement of the front rail

• The intermediate reinforcement to the ﬂoor pan

3-90 2003 Saturn Ion

9. Drill out all plug welds in the rear portion of the front rail connected to the center ﬂoor panel. If the rail portion is undamaged, keep the portion for reinstallation.

10. Drill out all plug welds that attach the rear portion of the front rail to the intermediate portion of the front rail.

Important: Remove the rear section of the rail before you remove the center ﬂoor panel.

11. Using a 90 degree bent pry tool, pry the intermediate portion of the front rail apart from the rear portion of the rail far enough to allow the rear portion to slide free of the intermediate portion. Remove the rear portion of the front compartment rail.

870893

12. Locate and drill out all of the spot welds that attach the center ﬂoor pan to the following components:

• The dash and panel

• The #1 bar area

• The lower inner rockers

• The rear ﬂoor pan

13. Remove the center ﬂoor panel by lowering the rear edge ﬁrst and pulling down and rearwards until the ﬂoor pan is free from the vehicle.

2003 Saturn Ion

870891

2003 Saturn Ion

870894

3-91

870888

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. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the corresponding locations noted on 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 center ﬂoor panel to the vehicle using 3-dimensional measuring equipment. Clamp the panel in place.

1

⁄2in) apart.

3-92 2003 Saturn Ion

870894

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.

870886

Rocker Panel Replacement - Inner

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 damaged area as possible. Refer 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 inner rocker panel.

6. Locate and drill out all the necessary factory welds.

Dimensions - Body on page 3-7

.

870905

2003 Saturn Ion

870908

2003 Saturn Ion

3-93

870909

7. Remove the inner rocker panel.

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. 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.

1

⁄2in) apart.

3-94 2003 Saturn Ion

870906

4. Position the inner rocker panel and clamp the panel in place.

870909

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.

Rocker Panel Extension Replacement - Inner

Removal Procedure

This assembly is available as part of the rear side rail underbody assembly. If only the inner rocker panel extension is required, remove the extension from the complete assembly before installation.

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.

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 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

.

870905

870910

2003 Saturn Ion

3-95

870914

Important: Note the number and location of the factory welds for installation of the inner rocker panel extension.

6. Locate and drill out all the necessary factory welds.

7. Remove the inner rocker panel extension.

3-96 2003 Saturn Ion

870915

870911

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 corresponding locations noted on the original panel.

2. Prepare all mating surfaces for welding as necessary.

3. Apply 3M equivalent to all mating surfaces.

®

Weld-Thru Coating P/N 05916 or

4. Position the inner rocker panel extension.

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.

870915

Rocker Panel Reinforcement Replacement - Inner

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.

1. Disable the SIR system.

2003 Saturn Ion

870910

2003 Saturn Ion

870916

3-97

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 damaged area 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 rocker panel reinforcement-inner.

6. Locate and drill out all the necessary factory welds.

870918

870919

7. Remove the rocker panel reinforcement-inner.

3-98 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 for welding as necessary.

3. Apply 3M equivalent to all mating surfaces.

4. Position the rocker panel reinforcement-inner on the vehicle. Clamp the panel in place.

®

Weld-Thru Coating P/N 05916 or

870917

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

870919

2003 Saturn Ion

870916

3-99

870926

Rocker Panel Reinforcement Sectioning - Inner

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: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision.

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 damaged area as possible. Refer to

5. Remove the sealers and anti-corrosion materials from the repair area, as necessary.

Important: Do NOT section through any holes in the inner rocker panel.

6. Measure from any key feature on the panel. Lay out the cut line location on the inner rocker panel reinforcement.

Important: Note the number and location of the factory welds for installation of the inner rocker panel reinforcement.

7. Locate and drill out all the necessary factory welds.

Important: When you multi-layer sectioning areas in 2 or more panels, place the sectioning cut lines at least 100 mm (4 in) apart.

8. Cut at the laid out cut line location.

Dimensions - Body on page 3-7

.

3-100 2003 Saturn Ion

870920

Saturn 2003 Ion Service Manual Supplement

Specifications and Main Features

Frequently Asked Questions

User Manual