8. Prepare all mating surfaces as necessary.
9. Apply 3M Weld-Thru Coating P/N 05916 or
equivalent to all mating surfaces.
10. Fit the backing plates halfway into the sectioning
joints, 25 mm (1 in) at the windshield pillar and
50 mm (2 in) at the rocker panel areas. Clamp the
plates in place, and plug weld to the section joint
11. Position the outer front pillar to the vehicle using
3-dimensional measuring equipment. Clamp the
pillar in place.
12. Plug weld accordingly.
13. Plug weld accordingly.
14. Stitch weld the butt weld locations.
15. To create a solid weld with minimum heat
distortion, make a 25 mm (1 in) stitch weld along
the seam with gaps of 25 mm (1 in). Go back
and complete the stitch weld.
16. Clean and prepare all of the welded surfaces.
17. Apply the sealers and anti-corrosion materials to
the repair area, as necessary.
18. Paint the repaired area.
19. Install all of the related panels and components.
20. Connect the negative battery cable.
21. Enable the SIR system.
Roof Panel Replacement - Outer
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.
Caution: Refer to SIR Caution on page 1-1 in
General Information.
1. Disable the SIR system.
876968
787665
870880
2003 Saturn Ion
3-81
2003 Saturn Ion
To Next Page
Loading...
Need help?
General
