5. Plug weld accordingly.
6. Clean and prepare all of the welded surfaces.
7. Apply the sealers and anti-corrosion materials to
the repair area, as necessary.
8. Paint the repaired area.
9. Install all of the related panels and components.
10. Connect the negative battery cable.
11. Enable the SIR system.
Rail Replacement Front Compartment -
Front Half
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.
Important: The service part is developed from a
complete assembly and will require the spot weld
removal at the rail mid joint. The lower rail service part
comes as a complete front rail assembly, including
all the brackets and the reinforcements.
Important: Loosen and protect the fuel and brake
lines during rail replacement.
1. Support the engine and the transmission with
suitable equipment.
2. Remove the fasteners to the engine and the
transmission.
3. Remove all the other related panels and
components as necessary, including the
suspension and the crossmember,.
4. Visually inspect the damaged area. Repair as
much of the damage as possible to factory
specifications. Refer to
Dimensions - Body on
page 3-7
.
5. Remove the sealers and anti-corrosion materials
from the repair area, as necessary.
867423
867423
2003 Saturn Ion
3-55
2003 Saturn Ion
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