9. Remove the lower plenum panel from the vehicle.
Installation Procedure
Important: The service part comes as an assembly
that includes the lower dash panel. If the repair
does not require the dash panel, remove the dash
panel before you install the lower plenum panel.
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 corresponding locations
noted on the original panel.
2. Prepare all mating surfaces as necessary.
3. Apply 3M Weld-Thru Coating P/N 05916 or
equivalent to all mating surfaces.
4. Position the lower plenum panel to the vehicle.
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870826
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2003 Saturn Ion
3-47
2003 Saturn Ion