Saturn 2003 Ion Service Manual Supplement
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Saturn 2003 Ion Service Manual Supplement

General body construction
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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 3-1

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Summary of Contents for Saturn 2003 Ion

  • Page 1: Description And Operation

    Since the individual underbody components also contribute directly to the overall strength of the body, it is essential that the proper welding techniques be 2003 Saturn Ion 3-1...

  • Page 2: Component Locator

    (2) ABS + PC (9) PET (3) PA + PPE (10) PA + PPE (4) ABS + PC (11) ABS + PC (5) PET (12) PA + PPE (6) Steel (13) TPO (7) ABS + PC (14) PET 3-2 2003 Saturn Ion...
  • Page 3 Instrument Panels, Exterior Acrylonitrite/Butadine-Styrene Babyland, Proloy, ABS + PC Door Panels, Rocker Panel + Polycarbonate Cycoloy, KHA Covers Ethylene/Polypropylene TPO, TPR (Thermoplastic E/P/TPO Bumper Covers (Rubber) Rubber) EPI, EPII Polyamide + PA + PPE Fenders Polyphenylene Ether 2003 Saturn Ion 3-3...
  • Page 4 Tie Bar Replacement - Left on page 3-19 Tie Bar Replacement – Right Tie Bar Replacement - Right on page 3-23 Bracket Replacement Front Bracket Replacement Side Rail – Front Compartment Compartment - Side Rail on page 3-30 3-4 2003 Saturn Ion...
  • Page 5 Rocker Panel Extension Replacement – Inner Inner on page 3-95 Rocker Panel Reinforcement Replacement – Inner Rocker Panel Reinforcement Replacement - Inner on page 3-97 Rocker Panel Reinforcement Sectioning – Inner Rocker Panel Reinforcement Sectioning - Inner on page 3-100 2003 Saturn Ion 3-5...
  • Page 6 Impact Bar Anchor Plate Replacement – Rear Bumper Impact Bar Anchor Plate Replacement - Rear Bumper on page 3-160 Body Rear End Panel Replacement Body Rear End Panel Replacement on page 3-162 Battery Tray Replacement Battery Tray Replacement on page 3-28 3-6 2003 Saturn Ion...
  • Page 7 1326 Roof Attachment Hole Rear Header Panel d (Coupe) 4068 1285 Roof Attachment Hole All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless otherwise specified. 2003 Saturn Ion 3-7...
  • Page 8 Rocker Panel Center Hole 3228 Rocker Panel Front Hole 2432 Front Lower Hinge Rear Hole 2260 Front Lower Hinge 2225 Front Hole Body Side Control Hole 2175 Front Upper Hinge 2225 Front Hole Front Upper Hinge Rear Hole 2260 3-8 2003 Saturn Ion...
  • Page 9 Lower Tie Outer Slot Front Header Panel Roof Attachment Hole 2799 1307 (Sedan and Coupe) All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless otherwise specified. 2003 Saturn Ion 3-9...
  • Page 10 Underbody 876938 3-10 2003 Saturn Ion...
  • Page 11 Rear Rail Rear Hole to Rear l to n — — — Rail Rear Hole All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless otherwise specified. 2003 Saturn Ion 3-11...
  • Page 12 Rail Surface Not Top of Stud Rear Engine Mount Hole Rail 1657 Surface Not Top of Stud All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless otherwise specified. 3-12 2003 Saturn Ion...
  • Page 13 Sedan Side 876943 2003 Saturn Ion 3-13...
  • Page 14 Front Door Opening Point to Point Measurement to Weld — — — 1337 Flange Die Marks All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless otherwise specified. 3-14 2003 Saturn Ion...

  • Page 15: Repair Instructions

    Important: Note the number and location of the factory welds for installation of the impact bar bracket - front bumper 6. Locate and drill out all the factory welds from the outside surface of the rail. 867608 2003 Saturn Ion 3-15...
  • Page 16 2. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 867597 Important: Verify the location of the front rail using 3-dimensional measuring equipment. 3. Position the impact bar bracket on the rail and clamp in place. 867609 3-16 2003 Saturn Ion...
  • Page 17 867423 Important: Do not damage any inner panels or reinforcements. 6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the tie bar. 867488 2003 Saturn Ion 3-17...
  • Page 18 7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. 8. Paint the repair area. 9. Install all related panels and components. 10. Connect the negative battery cable. 11. Enable the SIR system. 867423 3-18 2003 Saturn Ion...
  • Page 19 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 tie bar-left. 6. Locate and drill out all the necessary factory welds. 867500 2003 Saturn Ion 3-19...
  • Page 20 2. Prepare all mating surfaces as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 865272 4. Position the left tie bar to the vehicle using 3-dimensional measuring equipment. Clamp the tie bar in place. 867504 3-20 2003 Saturn Ion...
  • Page 21 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. 2003 Saturn Ion 3-21...
  • Page 22 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. 865257 3-22 2003 Saturn Ion...
  • Page 23 Caution: Refer to SIR Caution on page 1-1 in General Information. Important: The graphic shows the left hand procedure. The right hand procedure is similar. 1. Disable the SIR system. 867423 2003 Saturn Ion 3-23...
  • Page 24 Important: Note the number and location of the factory welds for installation of the right tie bar. 6. Locate and drill out all the necessary factory welds. 867500 7. Remove the right tie bar panel from the vehicle. 867504 3-24 2003 Saturn Ion...
  • Page 25 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. 867423 2003 Saturn Ion 3-25...
  • Page 26 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 latch primary support. 6. Locate and drill out all the necessary factory welds. 867511 3-26 2003 Saturn Ion...
  • Page 27 2. Prepare all mating surfaces as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 865273 4. Position the latch primary support on the vehicle using 3-dimensional measuring equipment. Clamp the support into place. 867514 2003 Saturn Ion 3-27...
  • Page 28 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. 3-28 2003 Saturn Ion...
  • Page 29 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. 872730 2003 Saturn Ion 3-29...
  • Page 30 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 bracket side rail-front compartment. 6. Locate and drill out all the necessary factory welds. 867617 3-30 2003 Saturn Ion...
  • Page 31 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 865267 4. Position the side rail bracket to the front compartment lower rail and tie bar side panel. Clamp the bracket in place. 867618 2003 Saturn Ion 3-31...
  • Page 32 4. Visually inspect the damaged area. Repair as much of the damage as possible. Refer to Dimensions - Body on page 3-7 . 867478 3-32 2003 Saturn Ion...
  • Page 33 2. Prepare the mating surfaces as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 4. Position the front wheelhouse in the vehicle using 3-dimensional measuring equipment. Clamp the wheelhouse in place. 865277 2003 Saturn Ion 3-33...
  • Page 34 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. 3-34 2003 Saturn Ion...
  • Page 35 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. 865281 2003 Saturn Ion 3-35...
  • Page 36 Caution: Refer to SIR Caution on page 1-1 in General Information. 1. Disable the SIR system. 868719 3-36 2003 Saturn Ion...
  • Page 37 Important: Do not damage any inner panels or reinforcements. 6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the front upper rail. 868721 7. Remove the damaged front upper rail. 868722 2003 Saturn Ion 3-37...
  • Page 38 7. Install all related panels and components. 8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. 9. Paint the repair area. 10. Connect the negative battery cable. 11. Enable the SIR system. 868719 3-38 2003 Saturn Ion...
  • Page 39 Important: Note the number and location of the factory welds for installation of the front compartment of the side upper rail. 6. Locate and drill out all the necessary factory welds. 874293 2003 Saturn Ion 3-39...
  • Page 40 11. Drill 2 8 mm (5/16 in) plug weld holes 10 mm (1/2 in) rearward from the edge of the top, bottom, and outer side on the front edge of the remaining portion of the side upper rail on the vehicle. 874299 3-40 2003 Saturn Ion...
  • Page 41 Mark the location on top of the rail. 8. Using the mark made in the previous step as a starting point, use a sliding square to transfer a line on the top, side, and bottom of the rail. 874290 2003 Saturn Ion 3-41...
  • Page 42 14. Install all of the related panels and components. 15. Apply the sealers and anti-corrosion materials to the repair area, as necessary. 16. Paint the repaired area. 17. Connect the negative battery cable. 18. Enable the SIR system. 868719 3-42 2003 Saturn Ion...
  • Page 43 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 upper plenum panel. 6. Locate and drill out all the necessary factory welds. 870852 2003 Saturn Ion 3-43...
  • Page 44 2. Prepare all mating surfaces as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 870847 4. Position the upper plenum panel to the vehicle using 3-dimensional measuring equipment. Clamp the panel in place. 870855 3-44 2003 Saturn Ion...
  • Page 45 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. 2003 Saturn Ion 3-45...
  • Page 46 • 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 870842 8. Pull the body side panel outward and upward. 870838 3-46 2003 Saturn Ion...
  • Page 47 2. Prepare all mating surfaces as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 870826 4. Position the lower plenum panel to the vehicle. 870828 2003 Saturn Ion 3-47...
  • Page 48 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. 3-48 2003 Saturn Ion...
  • Page 49 40 mm (1 ⁄ 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. 865505 2003 Saturn Ion 3-49...
  • Page 50 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. 868877 3-50 2003 Saturn Ion...
  • Page 51 Important: Note the number and location of the factory welds for installation of the cross bar #1 to the floor panel. 6. Locate and drill out all the necessary factory welds. 870816 2003 Saturn Ion 3-51...
  • Page 52 2. Prepare all mating surfaces as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 870815 4. Position the cross bar. Clamp the cross bar in place. 870819 3-52 2003 Saturn Ion...
  • Page 53 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. 2003 Saturn Ion 3-53...
  • Page 54 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 full rail service part to the vehicle using 3–dimensional measuring equipment. Clamp the rail in place. 865235 3-54 2003 Saturn Ion...
  • Page 55 4. Visually inspect the damaged area. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body on page 3-7 . 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. 867423 2003 Saturn Ion 3-55...
  • Page 56 8. Drill out the factory welds. 867545 9. Pry open the outer layer of the rail at the front rail mid joint to allow the front portion of the rail to be removed from the vehicle. 867551 3-56 2003 Saturn Ion...
  • Page 57 12. Remove the forward portion of the front rail assembly at the mid joint. 872672 13. Prepare the mating surfaces as necessary. 14. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 865237 2003 Saturn Ion 3-57...
  • Page 58 4. Position the rail to the vehicle. 867548 5. Plug weld accordingly. 6. Clean and prepare all of the welded surfaces. 7. Install all related panels and components. 8. Apply sealers and anti-corrosion materials to the repair area, as necessary. 867521 3-58 2003 Saturn Ion...
  • Page 59 3. Remove all of the related panels and the components. 4. Remove the sealers and anti-corrosion materials from the repair area, as necessary. 5. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body on page 3-7 . 2003 Saturn Ion 3-59...
  • Page 60 8. At the marks made forward of the die marks, align a sliding square or similar tool to the bottom side of the front rail. Scribe a line 360 degrees around the frame rail, 7 mm ( ⁄ in) forward of the die marks. 867585 3-60 2003 Saturn Ion...
  • Page 61 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 around the frame rail. 867585 2003 Saturn Ion 3-61...
  • Page 62 7. Cut at the marked location. Remove the front portion of the rail. 8. Prepare the cut edge of the front rail section for welding. 9. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 867583 3-62 2003 Saturn Ion...
  • Page 63 Caution: Refer to SIR Caution on page 1-1 in General Information. 1. Disable the SIR system. 867556 2003 Saturn Ion 3-63...
  • Page 64 Important: Note the number and location of the factory welds for installation of the outer rail. 6. Locate and drill out all the necessary factory welds. 867560 7. Remove the outer rail from the vehicle. 867565 3-64 2003 Saturn Ion...
  • Page 65 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. 867556 2003 Saturn Ion 3-65...
  • Page 66 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Important: Note the number and location of the factory welds for installation of the front suspension support. 6. Locate and drill out all the necessary factory welds. 867626 3-66 2003 Saturn Ion...
  • Page 67 2. Prepare all mating surfaces as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 865265 4. Position the front suspension support to the vehicle using 3–dimensional measuring equipment. Clamp the support into place. 867629 2003 Saturn Ion 3-67...
  • Page 68 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 . 3-68 2003 Saturn Ion...
  • Page 69 1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel. 2. Prepare all mating surfaces as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 865268 2003 Saturn Ion 3-69...
  • Page 70 Caution: Refer to SIR Caution on page 1-1 in General Information. 1. Disable the SIR system. 875595 3-70 2003 Saturn Ion...
  • Page 71 Important: Note the number and location of the factory welds for installation of the windshield frame reinforcement. 6. Locate and drill out all the necessary factory welds. 875601 7. Remove the windshield frame reinforcement. 875604 2003 Saturn Ion 3-71...
  • Page 72 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. 875595 3-72 2003 Saturn Ion...
  • Page 73 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 875622 2003 Saturn Ion 3-73...
  • Page 74 7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. 8. Paint the repaired area. 9. Install all of the related panels and components. 10. Connect the negative battery cable. 11. Enable the SIR system. 875620 3-74 2003 Saturn Ion...
  • Page 75 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. 870899 2003 Saturn Ion 3-75...
  • Page 76 2. Prepare all mating surfaces as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 870898 4. Install the baffle in the inner portion of the front inner hinge pillar. 870903 3-76 2003 Saturn Ion...
  • Page 77 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. 870896 2003 Saturn Ion 3-77...
  • Page 78 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. 874304 3-78 2003 Saturn Ion...
  • Page 79 Important: Note the number and location of the factory welds for installation of the hinge pillar. 8. Locate and drill out all factory welds. 876965 2003 Saturn Ion 3-79...
  • Page 80 40 mm (1 1/2 in) apart. 7. Drill 8 mm (5/16 in) plug weld holes along the sectioning area in the service part, and at the locations noted from the original panel. 876967 3-80 2003 Saturn Ion...
  • Page 81 Caution: Refer to SIR Caution on page 1-1 in General Information. 1. Disable the SIR system. 870880 2003 Saturn Ion 3-81...
  • Page 82 Important: Do not damage any inner panels or reinforcements. 8. Locate and cut the urethane adhesive holding the roof panel to the vehicle. Note the location of the adhesive for installation of the roof panel. 874270 3-82 2003 Saturn Ion...
  • Page 83 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 GM P/N 12346392 on the perimeter of the vehicle roof attachment points. 874273 2003 Saturn Ion 3-83...
  • Page 84 8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. 9. Paint the repair area. 10. Install all related panels and components. 11. Connect the negative battery cable. 12. Enable the SIR system. 870875 3-84 2003 Saturn Ion...
  • Page 85 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 header panel. 6. Locate and drill out all the necessary factory welds. 870860 2003 Saturn Ion 3-85...
  • Page 86 2. Prepare all mating surfaces as necessary. ® 3. Apply 3M Weld-Thru coating P/N 05916 or equivalent to all mating surfaces. 870858 4. Position the header panel to the vehicle using 3-dimensional measuring equipment. Clamp the front header panel in place. 870867 3-86 2003 Saturn Ion...
  • Page 87 2. Disconnect the negative battery cable. 3. Remove all related panels and components. 4. Repair as much of the damaged area as possible. Refer to Dimensions - Body on page 3-7 . 2003 Saturn Ion 3-87...
  • Page 88 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. 870869 3-88 2003 Saturn Ion...
  • Page 89 Caution: Refer to SIR Caution on page 1-1 in General Information. 1. Disable the SIR system. 870895 2003 Saturn Ion 3-89...
  • Page 90 • The rear upper reinforcement of the front rail to floor pan • The intermediate portion of the front rail to rear upper reinforcement of the front rail • The intermediate reinforcement to the floor pan 870892 3-90 2003 Saturn Ion...
  • Page 91 • The lower inner rockers • The rear floor pan 13. Remove the center floor panel by lowering the rear edge first and pulling down and rearwards until the floor pan is free from the vehicle. 870894 2003 Saturn Ion 3-91...
  • Page 92 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. 870886 3-92 2003 Saturn Ion...
  • Page 93 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 rocker panel. 6. Locate and drill out all the necessary factory welds. 870908 2003 Saturn Ion 3-93...
  • Page 94 2. Prepare all mating surfaces as necessary. ® 3. Apply 3M Weld-Thru coating P/N 05916 or equivalent to all mating surfaces. 870906 4. Position the inner rocker panel and clamp the panel in place. 870909 3-94 2003 Saturn Ion...
  • Page 95 3. Remove all related panels and components. 4. Repair as much of the damaged area as possible. Refer to Dimensions - Body on page 3-7 . 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. 2003 Saturn Ion 3-95...
  • Page 96 2. Prepare all mating surfaces for welding as necessary. ® 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 870911 3-96 2003 Saturn Ion...
  • Page 97 Caution: Refer to SIR Caution on page 1-1 in General Information. 1. Disable the SIR system. 870916 2003 Saturn Ion 3-97...
  • Page 98 Important: Note the number and location of the factory welds for installation of the rocker panel reinforcement-inner. 6. Locate and drill out all the necessary factory welds. 870918 7. Remove the rocker panel reinforcement-inner. 870919 3-98 2003 Saturn Ion...
  • Page 99 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. 870916 2003 Saturn Ion 3-99...
  • Page 100 7. Locate and drill out all the necessary factory welds. Important: When you multi-layer sectioning areas in 2 or more panels, place the sectioning cut lines at least 100 mm (4 in) apart. 8. Cut at the laid out cut line location. 870920 3-100 2003 Saturn Ion...
  • Page 101 7. Cut a 100 mm (4 in) section of reinforcement from the unused section of the service part to be used as a welding backer. Trim as necessary to ensure a snug fit. 870917 2003 Saturn Ion 3-101...
  • Page 102 15. Install all of the related panels and components. 16. Apply the sealers and anti-corrosion materials to the repair area, as necessary. 17. Paint the repaired area. 18. Connect the negative battery cable. 19. Enable the SIR system. 870926 3-102 2003 Saturn Ion...
  • Page 103 4. Remove the sealers and anti-corrosion materials from the repair area, as necessary and note their location. 5. Repair as much of the damaged area as possible. Refer to Dimensions - Body on page 3-7 . 2003 Saturn Ion 3-103...
  • Page 104 9. Create cut lines on the rocker panel within the approved sectioning locations as needed. 10. Cut the panel at the center pillar where the lay out line was previously formed. 876971 3-104 2003 Saturn Ion...
  • Page 105 Trim the backing plates as necessary to fit behind the sectioning joint. 3. In the upper center pillar area, cut a 50 mm (4 in) backing plate from the unused portion of the source part trim as necessary. 876973 2003 Saturn Ion 3-105...
  • Page 106 15. Apply the sealers and anti-corrosion materials to the repair area, as necessary. 16. Paint the repaired area. 17. Install all of the related panels and components. 18. Connect the negative battery cable. 19. Enable the SIR system. 876969 3-106 2003 Saturn Ion...
  • Page 107 Important: Do not damage any inner panels or reinforcements. Important: Note the number and location of the factory welds for installation of the center pillar reinforcement. 6. Locate and drill out all the necessary factory welds. 870945 2003 Saturn Ion 3-107...
  • Page 108 7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. 8. Paint the repaired area. 9. Install all of the related panels and components. 10. Connect the negative battery cable. 11. Enable the SIR system. 870941 3-108 2003 Saturn Ion...
  • Page 109 6. On the center pillar reinforcement, locate and mark the top of the fifth oval hole up from the bottom. Important: Do not damage any inner reinforcements. 7. Cut the panel at the mark made previously. 870953 2003 Saturn Ion 3-109...
  • Page 110 872397 9. Remove the damaged center pillar. 872396 Installation Procedure 1. Mark a line through the center of the sixth oval hole from the bottom on the center pillar reinforcement service part. 884760 3-110 2003 Saturn Ion...
  • Page 111 13. Apply the sealers and anti-corrosion materials to the repair area, as necessary. 14. Paint the repaired area. 15. Install all of the related panels and components. 16. Connect the negative battery cable. 17. Enable the SIR system. 2003 Saturn Ion 3-111...
  • Page 112 Important: Note the number and location of the factory welds for installation of the inner pillar lock front door. 6. Locate and drill out all the necessary factory welds. 870938 3-112 2003 Saturn Ion...
  • Page 113 2. Prepare all mating surfaces for welding as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 870937 4. Position the inner pillar lock front door on the vehicle. Clamp the part in place. 870939 2003 Saturn Ion 3-113...
  • Page 114 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. 3-114 2003 Saturn Ion...
  • Page 115 1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel. 2. Prepare all mating surfaces for welding as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 872696 2003 Saturn Ion 3-115...
  • Page 116 Caution: Refer to SIR Caution on page 1-1 in General Information. 1. Disable the SIR system. 872710 3-116 2003 Saturn Ion...
  • Page 117 Important: Note the number and location of the factory welds for installation of the rear window panel. 6. Locate and drill out all the necessary factory welds. 872717 7. Remove the rear window panel. 872718 2003 Saturn Ion 3-117...
  • Page 118 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. 872710 3-118 2003 Saturn Ion...
  • Page 119 Important: Note the number and location of the factory welds for installation of the rear enforcement to the rear window panel. 6. Locate and drill out all the necessary factory welds. 872707 2003 Saturn Ion 3-119...
  • Page 120 2. Prepare all mating surfaces for welding as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 872703 4. Position the rear enforcement to the rear window panel. 872715 3-120 2003 Saturn Ion...
  • Page 121 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Important: Note the number and location of the factory welds for installation of the inner pillar lock rear door. 6. Locate and drill out all the necessary factory welds. 2003 Saturn Ion 3-121...
  • Page 122 2. Prepare all mating surfaces for welding as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 872401 4. Position the inner pillar lock rear door. Clamp the part in place. 872403 3-122 2003 Saturn Ion...
  • Page 123 3. Remove all related panels and components. 4. Repair as much of the damaged area as possible. Refer to Dimensions - Body on page 3-7 . 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. 2003 Saturn Ion 3-123...
  • Page 124 1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the corresponding locations noted on the original panel. 2. Prepare all mating surfaces for welding as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 875641 3-124 2003 Saturn Ion...
  • Page 125 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. 875640 2003 Saturn Ion 3-125...
  • Page 126 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 . 3-126 2003 Saturn Ion...
  • Page 127 Important: Do not damage any inner panels or reinforcements. 9. Cut slightly rearward of the tape along the holes drilled in the floor pan. Later, the floor panel will be ground flush to the rear edge of the weld flange. 872728 2003 Saturn Ion 3-127...
  • Page 128 floor pan to the drop-down area which supports the rear seat bottom half. 877233 2. Place a piece of masking tape along the top radius within this transition area across the panel 872726 3-128 2003 Saturn Ion...
  • Page 129 7. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 8. Position the rear floor pan to the vehicle using 3-dimensional measuring equipment. Clamp the part in place. 811139 9. Plug weld accordingly. 811142 2003 Saturn Ion 3-129...
  • Page 130 Caution: Refer to SIR Caution on page 1-1 in General Information. 1. Disable the SIR system. 872413 3-130 2003 Saturn Ion...
  • Page 131 Important: Note the number and location of the factory welds for installation of the wheelhouse-rear inner. 6. Locate and drill out all the necessary factory welds. 872416 7. Remove the rear inner wheelhouse. 874287 2003 Saturn Ion 3-131...
  • Page 132 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. 872413 3-132 2003 Saturn Ion...
  • Page 133 • (b) – 10 mm (3/8 in) rearward of the last upper trim attachment slot. • (c) – 75 mm (3 in) down from the quarter panel exterior panel attachment square hole. 2003 Saturn Ion 3-133...
  • Page 134 Important: Do NOT damage any other panels or reinforcements when cutting at the marked locations. 9. Cut the panel at the location laid out in the previous steps. 884763 10. Remove the damaged quarter panel. 875636 3-134 2003 Saturn Ion...
  • Page 135 11. Weld the plug weld holes on the vehicle half of the backing plates. 12. Position the outer front pillar to the vehicle using 3-dimensional measuring equipment. Clamp the quarter panel in place. 875639 2003 Saturn Ion 3-135...
  • Page 136 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. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. 3-136 2003 Saturn Ion...
  • Page 137 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 Weld-Thru coating P/N 05916 or equivalent to all mating surfaces. 872408 2003 Saturn Ion 3-137...
  • Page 138 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. 3-138 2003 Saturn Ion...
  • Page 139 1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel. 2. Prepare all mating surfaces for welding as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 874179 2003 Saturn Ion 3-139...
  • Page 140 Caution: Refer to SIR Caution on page 1-1 in General Information. 1. Disable the SIR system. 874167 3-140 2003 Saturn Ion...
  • Page 141 Important: Note the number and location of the factory welds for installation of the #4 cross bar. 6. Locate and drill out all the necessary factory welds. 874173 7. Remove the #4 cross bar. 874174 2003 Saturn Ion 3-141...
  • Page 142 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. 874167 3-142 2003 Saturn Ion...
  • Page 143 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 #5 bar extension. 6. Locate and drill out all the necessary factory welds. 874202 2003 Saturn Ion 3-143...
  • Page 144 2. Prepare all mating surfaces as necessary. ® 3. Apply 3M Weld-Thru coating P/N 05916 or equivalent to all mating surfaces. 874199 4. Position the #5 bar extension. 874205 3-144 2003 Saturn Ion...
  • Page 145 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. 2003 Saturn Ion 3-145...
  • Page 146 1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel. 2. Prepare all mating surfaces for welding as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. 874189 3-146 2003 Saturn Ion...
  • Page 147 Caution: Refer to SIR Caution on page 1-1 in General Information. 1. Disable the SIR system. 872724 2003 Saturn Ion 3-147...
  • Page 148 Important: Note the number and location of the factory welds for installation of the wheelhouse-rear inner. 6. Locate and drill out all the necessary factory welds. 872746 7. Remove the rear rail. 872751 3-148 2003 Saturn Ion...
  • Page 149 4. If an extension panel is required, drill out the spot welds. 872744 5. Remove the extension panel if necessary. 874177 6. Position the rear rail to the vehicle using 3-dimensional measuring equipment. Clamp the rail in place. 872751 2003 Saturn Ion 3-149...
  • Page 150 3. Remove all of the related panels and the components. 4. Remove the sealers and anti-corrosion materials from the repair area, as necessary. 5. Repair as much of the damage as possible. Refer to Dimensions - Body on page 3-7 . 3-150 2003 Saturn Ion...
  • Page 151 Scribe a line across the rail. 872755 8. Use the same tool to transfer this scribed line onto the sides and the weld flanges of the rail. 872758 2003 Saturn Ion 3-151...
  • Page 152 872770 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. 882100 3-152 2003 Saturn Ion...
  • Page 153 3 sides of the service rail. 5. Use the tool to scribe a line on all 3 sides and weld flanges of the rail. 6. Cut at the scribe line at the rear of the arrow. 872758 2003 Saturn Ion 3-153...
  • Page 154 11. Prepare the sectioning area of the rear rail for welding. ® 12. Apply 3M Weld-Thru coating P/N 05916 or equivalent to all mating surfaces. 872763 13. Position the rear rail section using 3-dimensional measuring equipment. Clamp the rail section in place. 872770 3-154 2003 Saturn Ion...
  • Page 155 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. 2003 Saturn Ion 3-155...
  • Page 156 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 Weld-Thru coating P/N 05916 or equivalent to all mating surfaces. 874149 3-156 2003 Saturn Ion...
  • Page 157 Caution: Refer to SIR Caution on page 1-1 in General Information. 1. Disable the SIR system. 874158 2003 Saturn Ion 3-157...
  • Page 158 Important: Note the number and location of the factory welds for installation of the underbody reinforcement of the rear rail. 6. Locate and drill out all the necessary factory welds. 874161 7. Remove the underbody reinforcement of the rear rail. 874164 3-158 2003 Saturn Ion...
  • Page 159 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. 874158 2003 Saturn Ion 3-159...
  • Page 160 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 anchor plate. 6. Locate and drill out all the necessary factory welds. 874140 3-160 2003 Saturn Ion...
  • Page 161 2. Prepare all mating surfaces as necessary. ® 3. Apply 3M Weld-Thru coating P/N 05916 or equivalent to all mating surfaces. 874127 4. Position the anchor plate to the rear rail. 874142 2003 Saturn Ion 3-161...
  • Page 162 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. 3-162 2003 Saturn Ion...
  • Page 163 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. 789114 2003 Saturn Ion 3-163...
  • Page 164 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. 789116 3-164 2003 Saturn Ion...
  • Page 165 9. Apply the sealers and anti-corrosion materials to the repair area, as necessary. 10. Paint the repair area. 11. Install all related panels and components. 12. Connect the negative battery cable. 13. Enable the SIR system. 2003 Saturn Ion 3-165...
  • Page 166 (6) Inflator Module for Right Roof Rail Air Bag– Located behind the garnish molding (12) Steering Wheel Air Bag–Located on the under the upper lock pillar steering wheel 3-166 2003 Saturn Ion...
  • Page 167 8. Gently pull back on the headliner to access the left pretensioner connector. 9. Remove the connector position assurance (CPA) from the left/driver pretensioner. 10. Disconnect the left pretensioner connector. 899819 2003 Saturn Ion 3-167...
  • Page 168 11. Use caution while reaching in and turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 12. Perform the SIR Diagnostic System Check if the AIR BAG warning indicator does not operate as described. 893538 3-168 2003 Saturn Ion...
  • Page 169 9. Remove the garnish molding from the upper lock pillar. 899818 10. Remove the connector position assurance (CPA) from the left/driver roof rail module connector. 11. Disconnect the left roof rail module yellow connector from the vehicle harness yellow connector. 899820 2003 Saturn Ion 3-169...
  • Page 170 9. Use caution while reaching in and turn the ignition switch to the ON position. The 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. 893538 3-170 2003 Saturn Ion...
  • Page 171 2. Connect the steering wheel module coil yellow connector (4–way) to the vehicle harness yellow connector. 3. Install the CPA to the steering wheel module coil yellow connector. 4. Install the left outer trim cover to the I/P. 877766 2003 Saturn Ion 3-171...
  • Page 172 6. Remove the right/passenger outer trim cover from the I/P (3). 7. Remove the connector position assurance (CPA) from the I/P module yellow connector (2). 8. Disconnect the I/P module yellow connector (1) (4-way) from the vehicle harness yellow connector (2). 816857 3-172 2003 Saturn Ion...
  • Page 173 2. Turn the ignition 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. 893538 2003 Saturn Ion 3-173...
  • Page 174 4. Install the garnish molding to the upper lock pillar. 5. Gently pull back on the headliner to access the right pretensioner. 6. Connect the right pretensioner connector and install the connector position assurance (CPA). 899820 3-174 2003 Saturn Ion...
  • Page 175 2. Turn the ignition 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. 893538 2003 Saturn Ion 3-175...
  • Page 176 2. Connect the right roof rail module yellow connector to the vehicle harness yellow connector. 3. Install the CPA to the right roof rail module connector. 4. Install the garnish molding to the upper lock pillar. 899820 3-176 2003 Saturn Ion...
  • Page 177 2. Turn the ignition 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. 893538 2003 Saturn Ion 3-177...
  • Page 178 14. Gently pull back on the headliner to access the right/passenger pretensioner connector. 816857 15. Remove the connector position assurance (CPA) from the right/passenger connector. 16. Disconnect the right/passenger pretensioner connector 899819 3-178 2003 Saturn Ion...
  • Page 179 23. Remove the garnish molding from the upper lock pillar. 24. Remove the CPA from the left/driver roof rail module yellow connector. 25. Disconnect the left roof rail module yellow connector from the vehicle harness yellow connector. 899820 2003 Saturn Ion 3-179...
  • Page 180 899819 7. Connect the left/driver roof rail module yellow connector to the vehicle harness yellow connector. 8. Install the CPA to the left roof rail module yellow connector. 9. Install the left outer trim cover. 899820 3-180 2003 Saturn Ion...
  • Page 181 17. Connect the passenger/right roof rail module yellow connector to the vehicle harness yellow connector. 18. Install the CPA to the right roof rail module yellow connector. 19. Install the garnish molding to the upper lock pillar. 899820 2003 Saturn Ion 3-181...
  • Page 182 6. Remove the garnish molding from the upper lock pillar. 7. Remove the connector position assurance (CPA) from the right/passenger roof rail module yellow connector. 8. Disconnect the right roof rail module yellow connector from the vehicle harness yellow connector. 899820 3-182 2003 Saturn Ion...
  • Page 183 (I/P). 16. Remove the CPA from the steering wheel module coil yellow connector. 17. Disconnect the steering wheel module coil yellow connector from the vehicle harness yellow connector. 18. Remove the lower left center pillar. 877766 2003 Saturn Ion 3-183...
  • Page 184 2. Connect the steering wheel module coil yellow connector to the vehicle harness yellow connector. 3. Install the CPA to the steering wheel module coil yellow connector. 4. Install the driver/left outer trim cover to the instrument panel (I/P). 877766 3-184 2003 Saturn Ion...
  • Page 185 11. Connect the passenger/I/P module yellow connector (1) to the vehicle harness yellow connector (2). 12. Install the CPA to the I/P module yellow connector (1). 13. Install the passenger/right outer trim cover to the instrument panel (I/P) (3). 816857 2003 Saturn Ion 3-185...
  • Page 186 22. Use caution while reaching in and turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 23. Perform the SIR Diagnostic System Check if the AIR BAG warning indicator does not operate as described. 893538 3-186 2003 Saturn Ion...

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