Quarter Panel Sectioning - Outer
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 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.
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.
1. Disconnect the negative battery cable.
2. Remove all related panels and components.
3. Repair as much of the damaged area as possible.
Refer to
Dimensions - Body on page 3-7
.
4. Remove the sound deadeners as necessary. Note
their location.
5. Remove the sealers and anti-corrosion materials
from the repair area, as necessary.
Important: Sectioning can only be done in the
recommended areas of the rocker panel, dog leg, sail
panel, and upper roof rail area of the body side
panel as necessary.
6. Locate the area on the panel where sectioning will
be performed.
• (a) – Any straight area along the rocker panel
away from the door opening lower front and
rear radius on the body side panel.
• (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.
874226
874220
2003 Saturn Ion
3-133
2003 Saturn Ion
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