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2003 Saturn Ion

Description and Operation

General Body Construction (Unibody)
Description

This information pertains to unitized body construction.
The engine and transaxle, front suspension control
arms, and rack and pinion steering are supported by
the engine frame which is bolted to the vehicle at
six locations. Each mounting location is cushioned by
a thick rubber insulator. These insulators are
specifically designed for each location to give the
proper amount of structural strength while providing
maximum road noise isolation. Different insulators are
used at the various frame-to-body attaching points
to change ride and handling characteristics of
the vehicle.

Mounting provisions for the front suspension system
are also shared by the body components through
the suspension strut towers. The towers must
be dimensionally correct in relation to the underbody
to maintain proper suspension geometry.

With unitized body construction, underbody
components must be properly aligned to assure
correct suspension location. In case of collision
damage, it is important that the body dimensions be
checked thoroughly, and if necessary, realigned
in order to accurately establish proper dimensions.

Since the individual underbody components also
contribute directly to the overall strength of the body, it
is essential that the proper welding techniques be

observed during service repair operations. The
underbody components should be properly sealed and
rustproofed whenever body repair operations destroy
or damage the original sealing and rustproofing. When
rustproofing critical underbody components, it is
essential to use a quality air dry primer such as
corrosion-resistant chromate or equivalent material.
Combination type primer-surfacers are not
recommended.

Door Frame Description

The side door frame openings feature a unique
modular build sub-assembly design in order to improve
manufacturing quality. The openings are composed
of numerous individual components that are
pre-assembled and attached to the vehicle as a
single unit.

You may replace the door frame as a complete unit.
Various segments of the door frame may be sectioned,
which is usually much faster and more cost effective.
A front and rear half also are available for complete
or sectioning procedures. There are some key
structural areas where sectioning should not take
place. Service parts for sectioning must be cut from
the service assembly and modified as necessary.

2003 Saturn Ion

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2003

Saturn

Ion

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Содержание 2003 Ion

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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