Page 1

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.


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


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.

876968

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.

787665

Roof Panel Replacement - Outer Removal Procedure

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

870880

2003 Saturn Ion 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.

874270

3-82 2003 Saturn Ion


9. Remove the damaged roof panel.

870883

Installation Procedure 1. Prepare all mating surfaces as necessary. 2. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

870876

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

2003 Saturn Ion

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.

874273

2003 Saturn Ion 3-83


870880

870875

3-84 2003 Saturn Ion

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.


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 Dimensions - Body on page 3-7. 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary.

870858

2003 Saturn Ion

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.

870860

2003 Saturn Ion 3-85


7. Remove the header panel.

870867

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 3MÂŽ Weld-Thru coating P/N 05916 or equivalent to all mating surfaces.

870858

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

870867

3-86 2003 Saturn Ion


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.

870857

Rear Window Frame Header Panel Replacement - Rear Removal Procedure

870868

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 damaged area as possible. Refer to Dimensions - Body on page 3-7.

2003 Saturn Ion 3-87


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.

870870

7. Remove the rear window frame header panel.

870872

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 3MÂŽ Weld-Thru coating P/N 05916 or equivalent to all mating surfaces.

870869

3-88 2003 Saturn Ion


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

870872

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.

870868

Floor Panel Replacement - Center Removal Procedure

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

870895

2003 Saturn Ion 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

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

870892

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.

870893

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.

870891

2003 Saturn Ion

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.

870894

2003 Saturn Ion 3-91


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 corresponding locations noted on the original panel. 2. Prepare all mating surfaces as necessary. 3. Apply 3MÂŽ Weld-Thru coating P/N 05916 or equivalent to all mating surfaces.

870888

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

870894

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.

870886

3-92 2003 Saturn Ion


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 Dimensions - Body on page 3-7. 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary.

870905

870908

2003 Saturn Ion 3-93

2003 Saturn Ion

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.


7. Remove the inner rocker panel.

870909

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 3MÂŽ Weld-Thru coating P/N 05916 or equivalent to all mating surfaces.

870906

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

870909

3-94 2003 Saturn Ion


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.

870905

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. 870910

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 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.

2003 Saturn Ion 3-95


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.

870914

7. Remove the inner rocker panel extension.

870915

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

870911

3-96 2003 Saturn Ion


4. Position the inner rocker panel extension.

870915

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.

870910

Rocker Panel Reinforcement Replacement - Inner Removal Procedure

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

870916

2003 Saturn Ion 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

7. Remove the rocker panel reinforcement-inner.

870919

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

870917

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

870919

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.

870916

2003 Saturn Ion 3-99


Rocker Panel Reinforcement Sectioning - Inner Removal Procedure

870926

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 Dimensions - Body on page 3-7. 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.

3-100 2003 Saturn Ion

870920


9. Remove the damaged portion of the inner rocker panel reinforcement.

870919

Installation Procedure 1. Measure and lay out the cut line on the service panel in the same location as the original panel. 2. Cut the panel at the lines laid out in the previous step.

870923

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.

2003 Saturn Ion

3. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the corresponding locations noted on the original panel. 4. Prepare all mating surfaces for welding as necessary. 5. Apply 3MÂŽ Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 6. Drill 8 mm (5/16 in) plug weld holes in the inner rocker panel reinforcement at the cut line location and 10 mm (0.4 in) rearward of the edge of the panel. 7. Cut a 100 mm (4 in) section of reinforcement from the unused section of the service part to be used as a welding backer. Trim as necessary to ensure a snug fit. 870917

2003 Saturn Ion 3-101


8. Place the welding backer into the rocker panel backer reinforcement. Insert the welding backer about 50 mm (2 in), or about half-way. 9. Clamp the welding backer in place and weld at the plug weld locations.

870928

10. Cut the outer center 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. 11. Position the reinforcement to the vehicle. Clamp the reinforcement in place. 12. Stitch weld along the sectioning area at the butt weld location. Make 25 mm (1 in) stitch welds with 25 mm (1 in) between each weld. Complete the stitch weld.

870930

13. 14. 15. 16.

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. 17. Paint the repaired area. 18. Connect the negative battery cable. 19. Enable the SIR system.

870926

3-102 2003 Saturn Ion


Pillar Lock Front Door Sectioning - Outer Removal Procedure

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. 1. The 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 the damage to the vehicle. Sectioning must take place in specified areas only. Remove all related panels and components. 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. 2. 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. 3. Disconnect the negative battery cable. 4. Remove the sealers and anti-corrosion materials from the repair area, as necessary and note their location. 5. Repair as much of the damaged area as possible. Refer to Dimensions - Body on page 3-7.

2003 Saturn Ion 3-103


6. At the top of the center pillar, mark a line (a) through the center of the second outer trim attachment hole.

874225

7. Measure down 50 mm (2 in) from the mark created in the previous step.

875628

Important: Sectioning procedures can only take place in the straight areas of the body side panel. 8. Measure from any key feature in the panel. Lay out the cut line location on the body side panel. 9. Create cut lines on the rocker panel within the approved sectioning locations as needed. 10. Cut the panel at the center pillar where the lay out line was previously formed.

876971

3-104 2003 Saturn Ion


11. Cut the panel at the rocker panel area where sectioning is to be performed, within the straight sections only.

876974

12. Locate and drill out all factory welds. Note the number and location of welds for installation of the service part. 13. Remove the damaged center pillar.

876972

Installation Procedure

2003 Saturn Ion

1. Cut the outer center 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. 2. In all the rocker panel areas, create a 100 mm (4 in) backing plate from the unused portion of the service part. Trim the backing plates as necessary to fit behind the sectioning joint. 3. In the upper center pillar area, cut a 50 mm (4 in) backing plate from the unused portion of the source part trim as necessary.

876973

2003 Saturn Ion 3-105


Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (11⁄2 in) apart. 4. Drill 8 mm (5/16 in) along the sectioning cuts on the remaining original part. Locate these holes 13 mm (1⁄2 in) from the edge of the part and spaced 40 mm (11⁄2 in) apart. 5. Drill 8 mm (5/16- in) plug weld holes in the service part as necessary in the corresponding locations noted on the original panel. 6. Prepare all mating surfaces for welding as necessary. 7. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 8. Fit the backing plates into the sectioning joints for the following distances: • 50 mm (2 in) for the rocker section • 25 mm (1 in) for the center pillar section 9. Clamp the backing plates in place. Plug weld the backing plates to the vehicle. 10. Position the outer center pillar to the vehicle using 3-dimensional measuring equipment. Clamp the pillar in place. 11. Plug weld accordingly. 12. 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. 13. Clean and prepare all of the welded surfaces. 14. Apply sound deadening materials as necessary. 15. Apply the sealers and anti-corrosion materials to the repair area, as necessary. 16. Paint the repaired area. 17. Install all of the related panels and components. 18. Connect the negative battery cable. 19. Enable the SIR system.

876969

3-106 2003 Saturn Ion


Pillar Lock Front Door Reinforcement 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: 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.

870941

Important: Do not damage any inner panels or reinforcements.

2003 Saturn Ion

Important: Note the number and location of the factory welds for installation of the center pillar reinforcement. 6. Locate and drill out all the necessary factory welds.

870945

2003 Saturn Ion 3-107


7. Remove the damaged front pillar.

870947

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 reinforcement as necessary in the corresponding locations noted on the original panel. 2. Prepare all mating surfaces for welding as necessary. 3. Apply 3MÂŽ Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

870943

4. Position the service part on the vehicle using 3-dimensional measuring equipment. Clamp the part in place. 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.

870941

3-108 2003 Saturn Ion


Pillar Lock Front Door Reinforcement Sectioning - 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: 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 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. 6. On the center pillar reinforcement, locate and mark the top of the fifth oval hole up from the bottom.

872390

2003 Saturn Ion

Important: Do not damage any inner reinforcements. 7. Cut the panel at the mark made previously.

870953

2003 Saturn Ion 3-109


8. Locate and drill out all factory welds. Note the number and location of the welds for installation of the service part.

872397

9. Remove the damaged center pillar.

872396

Installation Procedure 1. Mark a line through the center of the sixth oval hole from the bottom on the center pillar reinforcement service part.

884760

3-110 2003 Saturn Ion


2. Cut the replacement service part at the marked line.

870949

872393

2003 Saturn Ion

3. At the cut area of the service part, notch the weld flange areas down to the top of the fifth hole from the bottom. 4. Drill 8 mm (5/16 in) plug weld holes, 2 holes on each side, along the sectioning cut on the original reinforcement. Locate these holes 10 mm (1â „2 in) from the edge. 5. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the corresponding locations noted on the original panel. 6. Prepare all mating surfaces for welding as necessary. 7. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 8. Slide the top sectioning joint together by sliding the service part under the original part at the sectioning area. 9. Position the service part on the vehicle using 3-dimensional measuring equipment. Clamp the part in place. 10. Plug weld accordingly. 11. To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the sectioning joint seam with gaps of 25 mm (1 in). Go back and complete the stitch weld. 12. Clean and prepare all of the welded surfaces. 13. Apply the sealers and anti-corrosion materials to the repair area, as necessary. 14. Paint the repaired area. 15. Install all of the related panels and components. 16. Connect the negative battery cable. 17. Enable the SIR system.

2003 Saturn Ion 3-111


Pillar Lock Front Door Replacement - Inner Removal Procedure

870934

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. Important: Note the number and location of the factory welds for installation of the inner pillar lock front door. 6. Locate and drill out all the necessary factory welds.

870938

3-112 2003 Saturn Ion


7. Remove the inner pillar.

870939

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 corresponding locations noted on 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.

870937

2003 Saturn Ion

4. Position the inner pillar lock front door on the vehicle. Clamp the part in place.

870939

2003 Saturn Ion 3-113


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.

870934

Rear Window Reinforcement Replacement - Lower Front Removal Procedure

872688

3-114 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 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 rear window reinforcement. 6. Locate and drill out all the necessary factory welds.

872697

7. Remove the rear window reinforcement.

872699

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 (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.

872696

2003 Saturn Ion 3-115


4. Position the rear window reinforcement and clamp in place.

872699

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.

872688

Rear Window 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: Refer to SIR Caution on page 1-1 in General Information. 1. Disable the SIR system.

872710

3-116 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 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 rear window panel. 6. Locate and drill out all the necessary factory welds.

872717

2003 Saturn Ion

7. Remove the rear window panel.

872718

2003 Saturn Ion 3-117


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 corresponding locations noted on 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.

872716

4. Position the rear window panel.

872718

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.

872710

3-118 2003 Saturn Ion


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

872701

2003 Saturn Ion

Important: Note the number and location of the factory welds for installation of the rear enforcement to the rear window panel. 6. Locate and drill out all the necessary factory welds.

872707

2003 Saturn Ion 3-119


7. Remove the rear reinforcement to the rear window panel.

872715

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 corresponding locations noted on 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.

872703

4. Position the rear enforcement to the rear window panel.

872715

3-120 2003 Saturn Ion


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.

872710

Pillar Lock Rear Door Replacement - Inner Removal Procedure

872403

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: 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 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 inner pillar lock rear door. 6. Locate and drill out all the necessary factory welds.

2003 Saturn Ion 3-121


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