service repair manual

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.
7. Remove the outer rail from the vehicle.
867560
867565
3-64 2003 Saturn Ion

2. 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 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 outer rail to the vehicle using 3–
dimensional measuring equipment. Clamp the
outer rail 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 repair area, as necessary.
9. Paint the repaired area.
10. Connect the negative battery cable.
11. Enable the SIR system.
865261
867565
867556
2003 Saturn Ion 3-65
2003SaturnIon

3. Suspension Support 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 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.
867622
867626
3-66 2003 Saturn Ion

4. 7. Remove the front suspension support.
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 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 front suspension support to the
vehicle using 3–dimensional measuring
equipment. Clamp the support into place.
867629
865265
867629
2003 Saturn Ion 3-67
2003SaturnIon

5. 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.
Extension Replacement Front
Compartment Side Rail - 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 damage as possible. Refer
to Dimensions - Body on page 3-7.
867622
867632
3-68 2003 Saturn Ion

6. 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.
7. 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 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.
867635
867636
865268
2003 Saturn Ion 3-69
2003SaturnIon

7. 4. Position the rear extension to the vehicle using 3–
dimensional measuring equipment. Clamp the
support into 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 repair area, as necessary.
9. Paint the repaired area.
10. Connect the negative 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 (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.
867636
867632
875595
3-70 2003 Saturn Ion

8. 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.
7. Remove the windshield frame reinforcement.
875601
875604
2003 Saturn Ion 3-71
2003SaturnIon

9. 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 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 windshield frame reinforcement to the
vehicle.
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.
875599
875604
875595
3-72 2003 Saturn Ion

10. 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.
Important: Note the number and location of the
factory welds for installation of the hinge pillar.
6. Locate and drill out all factory welds
875620
875622
2003 Saturn Ion 3-73
2003SaturnIon

11. 7. Remove the damaged hinge pillar reinforcement.
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.
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.
875623
875621
875620
3-74 2003 Saturn Ion

12. 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.
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.
870896
870899
2003 Saturn Ion 3-75
2003SaturnIon

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14. 7. Remove the inner hinge pillar.
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 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. Install the baffle in the inner portion of the front
inner hinge pillar.
870901
870898
870903
3-76 2003 Saturn Ion

15. 5. Position the hinge pillar body to the vehicle.
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 necessary.
10. Paint the repaired area.
11. Connect the negative battery cable.
12. Enable the SIR system.
870901
870896
2003 Saturn Ion 3-77
2003SaturnIon

16. Hinge Pillar Body Sectioning - 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: 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.
874221
874304
3-78 2003 Saturn Ion

17. 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: 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.
Important: Note the number and location of the
factory welds for installation of the hinge pillar.
8. Locate and drill out all factory welds.
876963
876965
2003 Saturn Ion 3-79
2003SaturnIon