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 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 rear inner wheelhouse to the vehicle.
Clamp the part 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.
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3-132 2003 Saturn Ion
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