Remove all of the related panels and the components. Page 60 8. At the marks made forward of the die marks, align a sliding square or similar tool to the bottom side of the front rail. Page 61 1. At the straight line on the die mark, align a sliding square or similar tool to this line and the bottom side of the front lower rail. Scribe a line completely around the frame rail. Page 62 7. Cut at the marked location. Remove the front portion of the rail. Prepare the cut edge of the front rail section for welding.
Page 64 Important: Note the number and location of the factory welds for installation of the outer rail. Remove the outer rail from the vehicle. Page 65 7. Page 66 5. Important: Note the number and location of the factory welds for installation of the front suspension support. Page 67 2. Position the front suspension support to the vehicle using 3—dimensional measuring equipment.
Page 68 2. Disconnect the negative battery cable. Page 69 1. Page 71 Important: Note the number and location of the factory welds for installation of the windshield frame reinforcement. Remove the windshield frame reinforcement. Page 72 7. Page 73 5. Important: Note the number and location of the factory welds for installation of the hinge pillar.
Locate and drill out all factory welds Saturn Ion Page 74 7. Page 75 5. Important: Note the number and location of the factory welds for installation of the inner hinge pillar. Page 76 2. Install the baffle in the inner portion of the front inner hinge pillar.
Page 77 8. Stay away from the door and window opening radius areas. Section only in straight areas of the openings. Page 79 Important: Note the number and location of the factory welds for installation of the hinge pillar.
Page 82 Important: Do not damage any inner panels or reinforcements. Locate and cut the urethane adhesive holding the roof panel to the vehicle. Note the location of the adhesive for installation of the roof panel. Page 83 Important: Place the urethane adhesive on the outboard side of the roof panel stud hole locations.
Page 84 8. Page 85 5. Important: Note the number and location of the factory welds for installation of the header panel. Page 86 2. Position the header panel to the vehicle using 3-dimensional measuring equipment. Clamp the front header panel in place. Page 87 2. Page 88 1. Page 92 7. Page 93 5. Important: Note the number and location of the factory welds for installation of the inner rocker panel.
Page 94 2. Position the inner rocker panel and clamp the panel in place. Page 95 3. Page 96 2. Prepare all mating surfaces for welding as necessary. Page 98 Important: Note the number and location of the factory welds for installation of the rocker panel reinforcement-inner.
Remove the rocker panel reinforcement-inner. Page 99 7. Page 7. Important: When you multi-layer sectioning areas in 2 or more panels, place the sectioning cut lines at least mm 4 in apart. Cut at the laid out cut line location. Cut a mm 4 in section of reinforcement from the unused section of the service part to be used as a welding backer. Page Page 4. Remove the sealers and anti-corrosion materials from the repair area, as necessary and note their location.
Page 9. Create cut lines on the rocker panel within the approved sectioning locations as needed. Cut the panel at the center pillar where the lay out line was previously formed. In the upper center pillar area, cut a 50 mm 4 in backing plate from the unused portion of the source part trim as necessary. Page Important: Do not damage any inner panels or reinforcements. Important: Note the number and location of the factory welds for installation of the center pillar reinforcement.
Page 6. Important: Do not damage any inner reinforcements. Cut the panel at the mark made previously. Remove the damaged center pillar.
Mark a line through the center of the sixth oval hole from the bottom on the center pillar reinforcement service part. Page Important: Note the number and location of the factory welds for installation of the inner pillar lock front door.
Page 2. Position the inner pillar lock front door on the vehicle. Clamp the part in place. Page 3. Page 1. Page Important: Note the number and location of the factory welds for installation of the rear window panel. Remove the rear window panel. Page Important: Note the number and location of the factory welds for installation of the rear enforcement to the rear window panel. Position the rear enforcement to the rear window panel.
Page 5. Important: Note the number and location of the factory welds for installation of the inner pillar lock rear door. Position the inner pillar lock rear door. Place a piece of masking tape along the top radius within this transition area across the panel Saturn Ion Page Important: Note the number and location of the factory welds for installation of the wheelhouse-rear inner.
Remove the rear inner wheelhouse. Page Important: Do NOT damage any other panels or reinforcements when cutting at the marked locations. Cut the panel at the location laid out in the previous steps. Remove the damaged quarter panel. Weld the plug weld holes on the vehicle half of the backing plates. Position the outer front pillar to the vehicle using 3-dimensional measuring equipment. Clamp the quarter panel in place. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary.
Page Important: Note the number and location of the factory welds for installation of the 4 cross bar. Remove the 4 cross bar. Important: Note the number and location of the factory welds for installation of the 5 bar extension. Position the 5 bar extension.
Remove the rear rail. If an extension panel is required, drill out the spot welds. Remove the extension panel if necessary. Position the rear rail to the vehicle using 3-dimensional measuring equipment. Page Scribe a line across the rail. Page 3 sides of the service rail. Cut at the scribe line at the rear of the arrow. Prepare the sectioning area of the rear rail for welding. Position the rear rail section using 3-dimensional measuring equipment.
Clamp the rail section in place. Page Important: Note the number and location of the factory welds for installation of the underbody reinforcement of the rear rail. Remove the underbody reinforcement of the rear rail. Important: Note the number and location of the factory welds for installation of the anchor plate. Position the anchor plate to the rear rail. Page 8.
Gently pull back on the headliner to access the left pretensioner connector. Disconnect the left pretensioner connector. Use caution while reaching in and turn the ignition switch to the ON position. Remove the garnish molding from the upper lock pillar. Disconnect the left roof rail module yellow connector from the vehicle harness yellow connector. Connect the steering wheel module coil yellow connector 4—way to the vehicle harness yellow connector.
Install the CPA to the steering wheel module coil yellow connector. Turn the ignition switch to the OFF position. Remove the key from the ignition switch. Locate the body control module fuse center, then remove the fuse center cover. Install the garnish molding to the upper lock pillar. Gently pull back on the headliner to access the right pretensioner. Connect the right pretensioner connector and install the connector position assurance CPA.
Connect the right roof rail module yellow connector to the vehicle harness yellow connector. Install the CPA to the right roof rail module connector. Locate the body control module fuse center then remove the fuse center cover. Install the CPA to the left roof rail module yellow connector. Install the left outer trim cover.
Install the CPA to the right roof rail module yellow connector. Disconnect the right roof rail module yellow connector from the vehicle harness yellow connector. Other extras included fog lights, and the option of a sunroof, and or spoiler.
The Saturn Ion Quad Coupe has rear half-sized suicide doors while the sedan has the lack of rear hinged doors. I'd love to be emailed when a new, high quality document is available for my Saturn Ion. My email address is:. By using this website, you automatically accept that we use cookies. What for? Toggle navigation. Home Workshop Manuals Saturn Ion. Get notified for new files? We'll send you a quick email when a new Saturn Ion document is added.
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