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.
4. Drill 8 mm (5/16 in) along the sectioning cuts on
the remaining original part. Locate these holes
13 mm (
1
⁄
2
in) from the edge of the part and
spaced 40 mm (1
1
⁄
2
in) apart.
5. Drill 8 mm (5/16- in) plug weld holes in the service
part as necessary in the corresponding locations
noted on the original panel.
6. Prepare all mating surfaces for welding as
necessary.
7. Apply 3M Weld-Thru Coating P/N 05916 or
equivalent to all mating surfaces.
8. Fit the backing plates into the sectioning joints for
the following 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 pillar to the vehicle using
3-dimensional measuring equipment. Clamp the
pillar in place.
11. Plug weld accordingly.
12. To create a solid weld with minimum heat
distortion, make a 25 mm (1 in) stitch weld along
the seam with gaps of 25 mm (1 in). Go back
and complete the stitch weld.
13. Clean and prepare all of the welded surfaces.
14. Apply sound deadening materials as necessary.
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
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