Saturn 2003 Ion Page 144 Service Manual Supplement Download

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7. Remove the #5 bar extension.

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 #5 bar extension.

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3-144

2003 Saturn Ion

Summary of Contents for 2003 Ion

Page 1: ...ned 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 te...

Page 2: ...Component Locator Panel Identification Legend 1 PA PPE 2 ABS PC 3 PA PPE 4 ABS PC 5 PET 6 Steel 7 ABS PC 8 TPO 9 PET 10 PA PPE 11 ABS PC 12 PA PPE 13 TPO 14 PET 873924 3 2 2003 Saturn Ion...

Page 3: ...olyethylene Inner Fender Panels Valances Spoilers Inner Trim Panels Seatbelt Covers Gas Tank Shields Dylan Fortiflex Marlex Alathon Hi Fax Hosalen Paxon PP Polypropylene Kick Panels Deflector Panels C...

Page 4: ...17 3 Tie Bar Replacement Lower Tie Bar Replacement Lower on page 3 21 4 Latch Primary Support Replacement Hood Latch Primary Support Replacement Hood on page 3 26 5 Tie Bar Replacement Left Tie Bar R...

Page 5: ...on Support Replacement Front on page 3 66 21 Extension Replacement Front Compartment Side Rail Rear Extension Replacement Front Compartment Side Rail Rear on page 3 68 22 Windshield Frame Reinforcemen...

Page 6: ...ng on page 3 126 45 Wheelhouse Replacement Rear Inner Wheelhouse Replacement Rear Inner on page 3 130 46 Quarter Panel Sectioning Outer Quarter Panel Sectioning Outer on page 3 133 47 Quarter Panel Re...

Page 7: ...r Attach Hole 5149 587 447 x c Rear Impact Beam Lower Outer Attach Hole 5176 439 327 x d Sedan Rear Header Panel Roof Attachment Hole 4133 306 1326 x d Coupe Rear Header Panel Roof Attachment Hole 406...

Page 8: ...r Inner Lower Hole 4822 730 445 x g Quarter Panel Dog Leg Outer Attach Hole 3955 762 320 x h Quarter Panel Dog Leg Outer Attach Hole 3961 762 235 x i Rocker Panel Rear Hole 3780 762 250 x j Rocker Pan...

Page 9: ...nt to Point 2 Center Line x a Front Lamp Assembly Inner Attach Hole 1146 327 675 x b Front Lamp Assembly Center Attach Hole 1208 458 682 x c Front Lamp Assembly Outer Attach Hole 1271 589 676 x d Fron...

Page 10: ...Underbody 876938 3 10 2003 Saturn Ion...

Page 11: ...le to Rear Rail Master Gage Hole 1174 o to p Rear Rail Master Gage Hole to Front Rail Rear Hole 419 p to q Front Rail Rear Hole to Front Rail Master Gage Hole 956 q to s Front Rail Master Gage Hole to...

Page 12: ...tach 1425 681 739 x e Strut Tower Center Hole 1811 553 815 x f Front Upper Tie Bar Rear Flange Hole 1226 232 700 x g Point to Point Front Fender Attach Hole to Rear Hinge Attach Hole 1499 h Front Engi...

Page 13: ...Sedan Side 876943 2003 Saturn Ion 3 13 2003 Saturn Ion...

Page 14: ...Attachment Hole 1371 500 280 x n Weld Nut Hole Washer Bottle Attachment 1222 540 409 x o Front Upper Outer Rail Front Hole 1880 743 760 x p Body Side Control Hole 2175 745 640 x q Front Upper Hinge Fr...

Page 15: ...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...

Page 16: ...rfaces as necessary 2 Apply 3M Weld Thru Coating P N 05916 or equivalent to all mating surfaces Important Verify the location of the front rail using 3 dimensional measuring equipment 3 Position the i...

Page 17: ...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 b...

Page 18: ...surfaces as necessary 3 Apply 3M Weld Thru Coating P N 05916 or equivalent to all mating surfaces 4 Position the tie bar to the vehicle using 3 dimensional measuring equipment Clamp the tie bar into p...

Page 19: ...tion 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 eq...

Page 20: ...rill 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 e...

Page 21: ...nd 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 servic...

Page 22: ...rtant 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 i...

Page 23: ...m 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...

Page 24: ...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...

Page 25: ...ld 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 5 Plug weld accordin...

Page 26: ...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...

Page 27: ...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...

Page 28: ...r 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 C...

Page 29: ...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 batter...

Page 30: ...stem 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 to...

Page 31: ...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 0...

Page 32: ...ing 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 bat...

Page 33: ...ot 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...

Page 34: ...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 re...

Page 35: ...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 necess...

Page 36: ...the negative battery cable 11 Enable the SIR system Rail Replacement Front Compartment Side Upper Removal Procedure Caution To avoid personal injury when exposed to welding flashes or to galvanized Z...

Page 37: ...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 Refe...

Page 38: ...ssary 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 5 Plug...

Page 39: ...cing 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 eas...

Page 40: ...transfer a line on the top side and bottom of the rail 9 Cut the side upper rail at the marked location 10 Remove the front portion of the side upper rail 11 Drill 2 8 mm 5 16 in plug weld holes 10 m...

Page 41: ...holes can not be determined space the plug weld holes every 40 mm 11 2 in 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 sur...

Page 42: ...l 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 12 Stitch and plug weld accordingly 13 Cle...

Page 43: ...tion 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 eq...

Page 44: ...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...

Page 45: ...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 Cau...

Page 46: ...l 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 8 Pull...

Page 47: ...f the location of the original plug weld holes can not be determined space the plug weld holes every 40 mm 11 2 in apart 1 Drill 8 mm 5 16 in plug weld holes in the service part as necessary in the co...

Page 48: ...fer 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...

Page 49: ...at 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 de...

Page 50: ...dash 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 r...

Page 51: ...on 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 equi...

Page 52: ...ry 40 mm 11 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 T...

Page 53: ...fer 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...

Page 54: ...an not be determined space the plug weld holes every 40 mm 11 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...

Page 55: ...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...

Page 56: ...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 9 Pry open the outer layer of the rail at the front rail mid joi...

Page 57: ...ice rail assembly mid joint 12 Remove the forward portion of the front rail assembly at the mid joint 13 Prepare the mating surfaces as necessary 14 Apply 3M Weld Thru Coating P N 05916 or equivalent...

Page 58: ...e 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 5 Pl...

Page 59: ...ly 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 m...

Page 60: ...of the straight line shown on the die marks 7 mm 1 4 in 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...

Page 61: ...the vehicle 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 aroun...

Page 62: ...ing backer 4 Prepare the sectioning weld area as necessary for welding 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 m...

Page 63: ...alers 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 Rail Replacement Front Side Underbody Outer...

Page 64: ...utions 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 pos...

Page 65: ...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 5 Plug weld accordingly...

Page 66: ...stem 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 to...

Page 67: ...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...

Page 68: ...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 co...

Page 69: ...Remove the rear extension Installation Procedure 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 1 Drill 8 mm 5 16 i...

Page 70: ...ve battery cable 11 Enable the SIR system Windshield Frame Reinforcement Replacement Inner Upper Removal Procedure Caution To avoid personal injury when exposed to welding flashes or to galvanized Zin...

Page 71: ...sonal 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 Dimen...

Page 72: ...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 5 Plug weld accordingly 6 Clean and prepa...

Page 73: ...e 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 proced...

Page 74: ...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 5 Plug weld ac...

Page 75: ...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...

Page 76: ...mm 11 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 C...

Page 77: ...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 neg...

Page 78: ...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 an...

Page 79: ...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...

Page 80: ...oning joint should be trimmed to allow a gap of 11 2 times the metal thickness at the sectioning joint 4 Create a 50 mm 2 in backing plate from the unused portion of the service part for the windshiel...

Page 81: ...f 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 repaire...

Page 82: ...ake 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...

Page 83: ...N 05916 or equivalent to all mating surfaces 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...

Page 84: ...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 cl...

Page 85: ...ystem 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 t...

Page 86: ...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 equival...

Page 87: ...e 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 perso...

Page 88: ...e rear window frame 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 11 2 in apart 1 Drill 8 mm...

Page 89: ...nnect the negative battery cable 11 Enable the SIR system Floor Panel Replacement Center Removal Procedure Caution To avoid personal injury when exposed to welding flashes or to galvanized Zinc Oxide...

Page 90: ...ve 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 da...

Page 91: ...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 th...

Page 92: ...y 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 5 Plug w...

Page 93: ...n 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 equip...

Page 94: ...ry 40 mm 11 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 T...

Page 95: ...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 S...

Page 96: ...mportant 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 necessar...

Page 97: ...tem 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...

Page 98: ...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...

Page 99: ...essary 3 Apply 3M Weld Thru Coating P N 05916 or equivalent to all mating surfaces 4 Position the rocker panel reinforcement inner on the vehicle Clamp the panel in place 5 Plug weld accordingly 6 Cle...

Page 100: ...e 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 te...

Page 101: ...g 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 3M Weld Thru Coating P N 05916 o...

Page 102: ...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...

Page 103: ...g 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...

Page 104: ...ning 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...

Page 105: ...ding locations to fit the remaining original panel The sectioning joint should be trimmed to allow a gap of 11 2 times the metal thickness at the sectioning joint 2 In all the rocker panel areas creat...

Page 106: ...owing 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...

Page 107: ...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...

Page 108: ...rfaces for welding as necessary 3 Apply 3M Weld Thru Coating P N 05916 or equivalent to all mating surfaces 4 Position the service part on the vehicle using 3 dimensional measuring equipment Clamp the...

Page 109: ...y 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 com...

Page 110: ...of the welds for installation of the service part 9 Remove the damaged center pillar Installation Procedure 1 Mark a line through the center of the sixth oval hole from the bottom on the center pillar...

Page 111: ...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...

Page 112: ...m 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...

Page 113: ...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 Coati...

Page 114: ...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 syst...

Page 115: ...ant 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...

Page 116: ...e 11 Enable the SIR system 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...

Page 117: ...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 possibl...

Page 118: ...re 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 rear window panel 5 Plug weld accordingly 6 Clean and prepare...

Page 119: ...re 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 c...

Page 120: ...every 40 mm 11 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...

Page 121: ...n 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 th...

Page 122: ...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 A...

Page 123: ...mponents 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 inju...

Page 124: ...t 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 1 Drill 8 mm 5 16 in plug weld holes in the service part as necessary in the...

Page 125: ...nd 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 C...

Page 126: ...ure 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 i...

Page 127: ...is will aid in identifying the location from the top side of the floor pan 8 Apply a piece of masking tape to the top surface of the rear compartment panel along the holes drilled in the floor pan Imp...

Page 128: ...grind flush the original panel of the rear compartment panel at the rear edge of the 5 crossbar Installation Procedure 1 On the rear compartment floor panel service part locate the transition area fr...

Page 129: ...e original panel 5 Lay out and drill 2 additional rows of 8 mm 5 16 in plug weld holes on top of the 5 bar weld flanges 6 Prepare all mating surfaces for welding as necessary 7 Apply 3M Weld Thru Coat...

Page 130: ...as necessary 15 Install all related panels and components 16 Connect the negative battery cable 17 Enable the SIR system Wheelhouse Replacement Rear Inner Removal Procedure Caution To avoid personal...

Page 131: ...se 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 Re...

Page 132: ...elding as necessary 3 Apply 3M Weld Thru Coating P N 05916 or equivalent to all mating surfaces 4 Position the rear inner wheelhouse to the vehicle Clamp the part in place 5 Plug weld accordingly 6 Cl...

Page 133: ...lectrical 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 i...

Page 134: ...on of the factory welds for installation of the quart panel 8 Locate and drill out all factory welds Important Do NOT damage any other panels or reinforcements when cutting at the marked locations 9 C...

Page 135: ...es can not be determined space the plug weld holes every 40 mm 1 1 2 in apart 6 Drill 8 mm 5 16 in plug weld holes along the sectioning areas in the service part and along the sectioning areas on the...

Page 136: ...loves 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 obser...

Page 137: ...ocation of the original plug weld holes can not be determined or if structural weld thru adhesive is present space the plug weld holes every 40 mm 11 2 in apart 1 Drill 8 mm 5 16 in plug weld holes in...

Page 138: ...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 En...

Page 139: ...ation of the original plug weld holes can not be determined space the plug weld holes every 40 mm 11 2 in apart 1 Drill 8 mm 5 16 in plug weld holes in the service part as necessary in the locations n...

Page 140: ...ystem Cross Bar No 4 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...

Page 141: ...ns 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 p...

Page 142: ...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 4 cross bar 5 Plug weld accordingly 6 Clean and prepare all of t...

Page 143: ...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...

Page 144: ...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...

Page 145: ...ystem 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...

Page 146: ...the location of the original plug weld holes can not be determined space the plug weld holes every 40 mm 11 2 in apart 1 Drill 8 mm 5 16 in plug weld holes in the service part as necessary in the loc...

Page 147: ...ail Replacement Rear Side Underbody 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...

Page 148: ...utions 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...

Page 149: ...ces for welding as necessary 3 Apply 3M Weld Thru Coating P N 05916 or equivalent to all mating surfaces Important The service part includes an inner rocker rear extension The rear rail can be install...

Page 150: ...re 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...

Page 151: ...ny area other than the die mark location given 7 Align a sliding square or similar tool to the line at the tip of the arrow in the die mark Scribe a line across the rail 8 Use the same tool to transfe...

Page 152: ...Remove the damaged component from the vehicle 11 Drill 2 8 mm 5 16 in plug weld holes on each of the 3 sides of the rear rail Position the center of the holes 10 mm 3 8 in from the cut edge 872761 872...

Page 153: ...3 Use the same tool to transfer this scribed line onto the sides and the weld flanges of the rail 4 Place a mark forward towards the rear of the arrow 25 mm 1 in from the scribed line on all 3 sides o...

Page 154: ...ve the small corners 10 Bend the bottom side of the service part at the sectioning location inward slightly by aligning a vice grip flanging tool or similar tool at the first scribed line 11 Prepare t...

Page 155: ...arplugs 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...

Page 156: ...Procedure 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 1 Drill 8 mm 5 16 in plug weld holes in the service part...

Page 157: ...ystem Rail Underbody 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 cutt...

Page 158: ...nal 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 Dimensi...

Page 159: ...as necessary 3 Apply 3M Weld Thru coating P N 05916 or equivalent to all mating surfaces 4 Position the underbody reinforcement to the rear rail and clamp in place 5 Plug weld accordingly 6 Clean and...

Page 160: ...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 r...

Page 161: ...11 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 3M We...

Page 162: ...forming 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 deploymen...

Page 163: ...ng 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 1 Drill 8 mm 5 16 in plug weld holes in the service part as neces...

Page 164: ...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 necess...

Page 165: ...uivalent to a thickness of 3 6 mm 1 8 to 1 4 in to both of the mating surfaces 5 Using a small acid brush 3 spread a coat of adhesive to cover all the bare metal surfaces to ensure corrosion protectio...

Page 166: ...ocated behind the center pillar under the headliner 5 Side Impact Sensor SIS Located under the center pillar trim near the bottom 6 Inflator Module for Right Roof Rail Air Bag Located behind the garni...

Page 167: ...he ON position the AIR BAG warning indicator illuminates This is normal operation and does not indicate an SIR system malfunction 5 Locate and remove the AIR BAG fuse from the body control module fuse...

Page 168: ...ector 4 Install garnish molding to the upper lock pillar 5 Gently pull back on the headliner to access the left pretensioner 6 Connect the left pretensioner connector and install the connector positio...

Page 169: ...mal operation and does not indicate an SIR system malfunction 5 Locate and remove the AIR BAG fuse from the body control module fuse center 6 Remove the lower center pillar 7 Remove the connector posi...

Page 170: ...ect the left pretensioner and install the connector position assurance CPA 6 Install the lower center pillar 7 Install the AIR BAG fuse into the body control module fuse center 8 Install the body cont...

Page 171: ...alfunction 5 Locate and remove the AIR BAG fuse from the body control module fuse center 6 Remove the left driver outer trim cover from the I P 7 Remove the connector position assurance CPA from the s...

Page 172: ...switch to the OFF position 3 Remove the key from the ignition switch 4 Locate the body control module fuse center then remove the fuse center cover Important With the AIR BAG fuse removed and the igni...

Page 173: ...n while reaching in and turn the ignition switch to the ON position The AIR BAG indicator will flash then turn OFF 8 Perform the SIR Diagnostic System Check if the AIR BAG warning indicator does not o...

Page 174: ...connect the right passenger connector 11 Remove the garnish molding from the upper lock pillar 12 Remove the connector position assurance CPA from the right passenger roof rail module connector 13 Dis...

Page 175: ...will flash then turn OFF 12 Perform the SIR Diagnostic System Check if the AIR BAG warning indicator does not operate as described SIR Disabling and Enabling Zone 6 Sedan Disabling Procedure 1 Turn t...

Page 176: ...llow connector from the vehicle harness connector 9 Remove the garnish molding from the upper lock pillar 10 Remove the connector position assurance CPA from the right passenger roof rail module conne...

Page 177: ...AIR BAG indicator will flash then turn OFF 10 Perform the SIR Diagnostic System Check if the AIR BAG warning indicator does not operate as described SIR Disabling and Enabling Zone 8 Coupe Disabling...

Page 178: ...rail module yellow connector from the vehicle harness yellow connector 9 Remove the passenger right outer trim cover from the I P 3 10 Remove the CPA from the I P module yellow connector 1 11 Disconne...

Page 179: ...r to access the left driver pretensioner connector 21 Remove the connector position assurance CPA from the left driver pretensioner connector 22 Disconnect the left driver pretensioner connector 23 Re...

Page 180: ...t outer trim cover to the instrument panel I P 5 Gently pull back on the headliner and connect the left driver pretensioner connector 6 Install the connector position assurance CPA to the left driver...

Page 181: ...er connector 14 Install the connector position assurance CPA to the right pretensioner connector 15 Install the trim panel to the high mount stop lamp 16 Install the coat hooks 17 Connect the passenge...

Page 182: ...ch to the OFF position 3 Remove the key from the ignition switch 4 Locate the body control module fuse center then remove the fuse center cover Important With the AIR BAG fuse removed and the ignition...

Page 183: ...surance CPA from pretensioner connector 14 Disconnect the right passenger pretensioner connector from the vehicle harness yellow connector 15 Remove the driver left outer trim cover from the instrumen...

Page 184: ...rail module yellow connector 23 Disconnect the left roof rail module yellow connector from the vehicle harness yellow connector Enabling Procedure 1 Remove the key from the ignition switch 2 Connect...

Page 185: ...nector to the vehicle harness yellow connector 9 Install the CPA to the left roof rail module yellow connector 10 Install the left outer trim cover 11 Connect the passenger I P module yellow connector...

Page 186: ...he right roof rail module yellow connector 19 Install the garnish molding to the upper lock pillar 20 Install the AIR BAG fuse into the body control module fuse center 21 Install the body control modu...

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Summary of Contents for 2003 Ion

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Saturn 2003 Ion, Service Manual Supplement

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Summary of Contents for 2003 Ion

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