Saturn 2003 Ion - User Manual

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
2003 Saturn Ion

Summary

Description and Operation

General Body Construction (Unibody) Description

Details unitized body construction, mounting points, and suspension geometry.

Door Frame Description

Explains the modular door frame design and sectioning procedures.

Component Locator and Identification

Panel Identification

Visual key to exterior body panels and their material composition.

Panel Identification Details

Details material composition, typical use, and trade names for various body panels.

Structural Identification and Dimensions

Structure Identification Diagram

Diagram identifying structural components and their replacement procedures.

Rear End Dimensions

Provides rear end body panel dimensions for measurement.

Key Repair Procedures

Impact Bar Bracket Replacement - Front Bumper

Procedure for removing and installing the front bumper impact bar bracket.

Wheelhouse Replacement - Front

Procedure for removing and installing the front wheelhouse assembly.

Floor Panel Replacement - Center

Procedure for removing and installing the center floor panel.

SIR System Safety Procedures

SIR Zone Identification Views

Illustrates approximate locations of SIR components for disabling/enabling zones.

SIR Disabling and Enabling - Zone 2 (Coupe)

Procedure for disabling SIR system components in the Coupe, focusing on air bag fuse.

Saturn 2003 Ion Specifications

General

Brand	Saturn
Model	2003 Ion
Category	Automobile
Language	English