5. Plug weld accordingly.
6. Clean and prepare all of the welded surfaces.
7. Install all of the related panels and components.
8. Apply the sealers and anti-corrosion materials
to the repair area, as necessary.
9. Paint the repaired area.
10. Connect the negative battery cable.
11. Enable the SIR system.
Wheelhouse Replacement - Front
Removal Procedure
Caution: To avoid personal injury when exposed
to welding flashes or to galvanized (Zinc Oxide)
metal toxic fumes while grinding/cutting on
any type of metal or sheet molded compound, you
must work in a properly ventilated area, wearing
an approved respirator, eye protection, earplugs,
welding gloves, and protective clothing.
Caution: When performing service on or near the
SIR components or the SIR wiring, the SIR
system must be disabled. Refer to SIR Disabling
and Enabling Zones. Failure to observe the correct
procedure could cause deployment of the SIR
components, personal injury, or unnecessary SIR
system repairs.
1. Disable the SIR system.
2. Disconnect the negative battery cable.
Important: The upper strut mounting surface is a
dimensionally critical area, and 3-dimensional
measuring equipment should be used to locate the
front wheelhouse assembly. The front wheelhouse can
be serviced as a complete assembly for both the
left and right wheelhouses. A wheelhouse front panel
is also available to service separately on the left or
the right sides.
3. Remove the sealers and anti-corrosion materials
from the repair area, as necessary.
Important: Be sure to inspect the front of the cowl
and dash panel for damage. If the metal surface
is damaged, the cowl panel must be repaired to restore
the structural integrity of the vehicle.
4. Visually inspect the damaged area. Repair as
much of the damage as possible. Refer to
Dimensions - Body on page 3-7
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2003 Saturn Ion