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 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 outer rail. 6. Locate and drill out all the necessary factory welds.
867560
7. Remove the outer rail from the vehicle.
867565
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 (11â „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.
865261
4. Position the outer rail to the vehicle using 3– dimensional measuring equipment. Clamp the outer rail in place.
867565
Plug weld accordingly. Clean and prepare all of the welded surfaces. Install all of the related panels and components. 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
5. 6. 7. 8.
867556
2003 Saturn Ion 3-65
Suspension Support Replacement - Front Removal Procedure
867622
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 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 front suspension support. 6. Locate and drill out all the necessary factory welds.
867626
3-66 2003 Saturn Ion
7. Remove the front suspension support.
867629
Installation Procedure Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (11â „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.
865265
2003 Saturn Ion
4. Position the front suspension support to the vehicle using 3–dimensional measuring equipment. Clamp the support into place.
867629
2003 Saturn Ion 3-67
5. 6. 7. 8.
Plug weld accordingly. Clean and prepare all of the welded surfaces. Install all of the related panels and components. 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.
867622
Extension Replacement Front Compartment Side Rail - Rear Removal Procedure
867632
3-68 2003 Saturn Ion
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 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 rear extension of the front compartment side rail. 6. Locate and drill out all the necessary factory welds.
867635
7. Remove the rear extension.
867636
Installation Procedure
2003 Saturn Ion
Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (11â „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.
865268
2003 Saturn Ion 3-69
4. Position the rear extension to the vehicle using 3– dimensional measuring equipment. Clamp the support into place.
867636
5. 6. 7. 8.
Plug weld accordingly. Clean and prepare all of the welded surfaces. Install all of the related panels and components. 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.
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
3-70 2003 Saturn Ion
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 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 windshield frame reinforcement. 6. Locate and drill out all the necessary factory welds.
875601
2003 Saturn Ion
7. Remove the windshield frame reinforcement.
875604
2003 Saturn Ion 3-71
Installation Procedure Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (11â „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.
875599
4. Position the windshield frame reinforcement to the vehicle.
875604
5. 6. 7. 8.
Plug weld accordingly. Clean and prepare all of the welded surfaces. Install all of the related panels and components. 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
3-72 2003 Saturn Ion
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 Dimensions - Body on page 3-7.
875620
2003 Saturn Ion
Important: Note the number and location of the factory welds for installation of the hinge pillar. 6. Locate and drill out all factory welds
875622
2003 Saturn Ion 3-73
7. Remove the damaged hinge pillar reinforcement.
875623
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.
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
3-74 2003 Saturn Ion
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 Dimensions - Body on page 3-7. 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary.
870896
870899
2003 Saturn Ion 3-75
2003 Saturn Ion
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.
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7. Remove the inner hinge pillar.
870901
Installation Procedure Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (11â „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.
870898
4. Install the baffle in the inner portion of the front inner hinge pillar.
870903
3-76 2003 Saturn Ion
5. Position the hinge pillar body to the vehicle.
870901
6. 7. 8. 9.
Plug weld accordingly. Clean and prepare all of the welded surfaces. Install all of the related panels and components. 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.
2003 Saturn Ion
870896
2003 Saturn Ion 3-77
Hinge Pillar Body Sectioning - Front Removal Procedure
874221
874304
3-78 2003 Saturn Ion
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.
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. 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary.
876963
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.
876965
2003 Saturn Ion 3-79
2003 Saturn Ion
Important: Note the number and location of the factory welds for installation of the hinge pillar. 8. Locate and drill out all factory welds.
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.
876966
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 11â „2 times the metal thickness at the sectioning joint.
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
3-80 2003 Saturn Ion