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2003 Ion
Saturn 2003 Ion User Manual
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10.
Remove
the
damaged
front
lower
rail.
11.
Drill
out
the
factory
welds
at
the
service
rail
assembly
mid
joint.
12.
Remove
the
forward
portion
of
the
front
rail
assembly
at
the
mid
joint.
13.
Prepare
the
mating
surfaces
as
necessary.
14.
Apply
3M
Weld-Thru
Coating
P/N
05916
or
equivalent
to
all
mating
surfaces.
867552
872672
865237
2003
Saturn
Ion
3-57
2003
Saturn
Ion
56
58
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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