7. Remove the damaged hinge pillar reinforcement.
Installation Procedure
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 as noted from 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. Align the service part using 3-dimensional
measuring equipment. Clamp in place.
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.
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3-74 2003 Saturn Ion
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