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Saturn
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2003 Ion
Saturn 2003 Ion User Manual
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6.
Locate
and
drill
out
all
the
necessary
factory
welds.
7.
Locate
and
drill
out
all
of
the
necessary
factory
welds
at
the
following
locations:
•
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
8.
Pull
the
body
side
panel
outward
and
upward.
870828
870842
870838
3-46
2003
Saturn
Ion
45
47
Table of Contents
Description and Operation
1
General Body Construction (Unibody)
1
Door Frame Description
1
Component Locator
2
Panel Identification
2
Structure Identification
4
Specifications
7
Dimensions - Body
7
Coupe Side
8
Front End
9
Underbody
10
Engine Compartment
12
Sedan Side
13
Repair Instructions
15
Impact Bar Bracket Replacement - Front Bumper
15
Installation Procedure
16
Tie Bar Replacement
17
Tie Bar Replacement - Left
19
Tie Bar Replacement - Lower
21
Tie Bar Replacement - Right
23
Latch Primary Support Replacement - Hood
26
Battery Tray Replacement
28
Bracket Replacement Front Compartment - Side Rail
30
Wheelhouse Replacement - Front
32
Wheelhouse Extension Replacement - Front
34
Rail Replacement Front Compartment - Side Upper
36
Installation Procedure
38
Rail Sectioning Front Compartment - Side Upper
39
Plenum Panel Replacement - Upper
43
Plenum Panel Replacement - Lower
45
Dash Panel Replacement
48
Cross Bar No.1 Replacement - Floor Panel
51
Rail Replacement Front Compartment - Front
53
Rail Replacement Front Compartment - Front Half
55
Rail Sectioning Front Compartment - Front
59
Rail Replacement Front Side Underbody - Outer
63
Suspension Support Replacement - Front
66
Extension Replacement Front Compartment Side Rail - Rear
68
Windshield Frame Reinforcement Replacement - Inner Upper
70
Installation Procedure
72
Hinge Pillar Body Reinforcement Replacement - Front Inner
73
Hinge Pillar Body Replacement - Front Inner
75
Hinge Pillar Body Sectioning - Front
78
Roof Panel Replacement - Outer
81
Windshield Frame Header Panel Replacement - Front
85
Rear Window Frame Header Panel Replacement - Rear
87
Floor Panel Replacement - Center
89
Rocker Panel Replacement - Inner
93
Rocker Panel Extension Replacement - Inner
95
Rocker Panel Reinforcement Replacement - Inner
97
Rocker Panel Reinforcement Sectioning - Inner
100
Pillar Lock Front Door Sectioning - Outer
103
Pillar Lock Front Door Reinforcement Replacement - Outer
107
Pillar Lock Front Door Reinforcement Sectioning - Outer
109
Pillar Lock Front Door Replacement - Inner
112
Rear Window Reinforcement Replacement - Lower Front
114
Rear Window Panel Replacement
116
Rear Window Reinforcement Replacement - Rear
119
Pillar Lock Rear Door Replacement - Inner
121
Body Side Panel Replacement - Outer
123
Rear Compartment Floor Panel Sectioning
126
Wheelhouse Replacement - Rear Inner
130
Quarter Panel Sectioning - Outer
133
Quarter Panel Replacement - Inner
136
Cross Bar No.4 Extension Replacement - Floor Panel
138
Cross Bar No.4 Replacement - Floor Panel
140
Cross Bar No.5 Extension Replacement - Floor Panel
143
Cross Bar No.5 Replacement - Floor Panel
145
Rail Replacement Rear Side Underbody
147
Rail Sectioning Rear Side Underbody
150
Rail Underbody Gusset Replacement - Rear
155
Rail Underbody Reinforcement Replacement - Rear
157
Impact Bar Anchor Plate Replacement - Rear Bumper
160
Body Rear End Panel Replacement
162
SIR Zone Identification Views
166
Component Locator
166
SIR Disabling and Enabling Zone 2 (Coupe)
167
SIR Disabling and Enabling Zone 2 (Sedan)
169
SIR Disabling and Enabling Zone 3
171
SIR Disabling and Enabling Zone 5
172
SIR Disabling and Enabling Zone 6 (Coupe)
173
SIR Disabling and Enabling Zone 6 (Sedan)
175
SIR Disabling and Enabling Zone 8 (Coupe)
177
SIR Disabling and Enabling Zone 8 (Sedan)
182
4
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Saturn 2003 Ion Specifications
General
Brand
Saturn
Model
2003 Ion
Category
Automobile
Language
English
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