Saturn 2003 Ion Operating manual

2003 Saturn Ion
Description and Operation
General Body Construction (Unibody)
Description
This information pertains to unitized body construction.
The engine and transaxle, front suspension control
arms, and rack and pinion steering are supported by
the engine frame which is bolted to the vehicle at
six locations. Each mounting location is cushioned by
a thick rubber insulator. These insulators are
specifically designed for each location to give the
proper amount of structural strength while providing
maximum road noise isolation. Different insulators are
used at the various frame-to-body attaching points
to change ride and handling characteristics of
the vehicle.
Mounting provisions for the front suspension system
are also shared by the body components through
the suspension strut towers. The towers must
be dimensionally correct in relation to the underbody
to maintain proper suspension geometry.
With unitized body construction, underbody
components must be properly aligned to assure
correct suspension location. In case of collision
damage, it is important that the body dimensions be
checked thoroughly, and if necessary, realigned
in order to accurately establish proper dimensions.
Since the individual underbody components also
contribute directly to the overall strength of the body, it
is essential that the proper welding techniques be
observed during service repair operations. The
underbody components should be properly sealed and
rustproofed whenever body repair operations destroy
or damage the original sealing and rustproofing. When
rustproofing critical underbody components, it is
essential to use a quality air dry primer such as
corrosion-resistant chromate or equivalent material.
Combination type primer-surfacers are not
recommended.
Door Frame Description
The side door frame openings feature a unique
modular build sub-assembly design in order to improve
manufacturing quality. The openings are composed
of numerous individual components that are
pre-assembled and attached to the vehicle as a
single unit.
You may replace the door frame as a complete unit.
Various segments of the door frame may be sectioned,
which is usually much faster and more cost effective.
A front and rear half also are available for complete
or sectioning procedures. There are some key
structural areas where sectioning should not take
place. Service parts for sectioning must be cut from
the service assembly and modified as necessary.
2003 Saturn Ion 3-1
2003 Saturn Ion

Component Locator
Panel Identification
Legend
(1) PA + PPE
(2) ABS + PC
(3) PA + PPE
(4) ABS + PC
(5) PET
(6) Steel
(7) ABS + PC
(8) TPO
(9) PET
(10) PA + PPE
(11) ABS + PC
(12) PA + PPE
(13) TPO
(14) PET
873924
3-2 2003 Saturn Ion

Exterior body panels are constructed of various
materials, due to the increased dent and corrosion
resistance of modern composites. All vertical panels,
such as fenders, doors, quarters, and rocker
panels, are made from rigid thermoplastic. Front and
rear fascias are constructed of thermoplastic
olefin (TPO). The hood, roof, and deck are steel.
Different materials require different procedures
for preparing and refinishing. Before beginning any
repair, identify the type of material involved.
Panel Identification
Identifying Symbol Chemical Composition or
Plastic “Family” Name Typical Area where Used Common or Trade Names
PE Polyethylene Inner Fender Panels,
Valances, Spoilers, Inner
Trim Panels, Seatbelt
Covers, Gas Tank Shields
Dylan, Fortiflex, Marlex,
Alathon, Hi-Fax,
Hosalen, Paxon
PP Polypropylene
Kick Panels, Deflector
Panels, Cowl Panels, Interior
Moldings, Radiator Shrouds,
Inner Fenders, Bumper
Covers
Profax, Oleflo, Marlex, Azdel,
Novolen, Tenite, Daplen,
Escorene
ABS Acrylonitrite/Butadine/Styrene Instrument Clusters, Trim
Moldings, Consoles, Armrest
Supports, Steering Column
Jackets
ABS, Cycolac, Abson,
Kralastic, Lustran,
Absafil, Dyel
ABS+PC Acrylonitrite/Butadine-Styrene
+ Polycarbonate Instrument Panels, Exterior
Door Panels, Rocker Panel
Covers Babyland, Proloy,
Cycoloy, KHA
E/P/TPO Ethylene/Polypropylene
(Rubber) Bumper Covers TPO, TPR (Thermoplastic
Rubber) EPI, EPII
PA + PPE Polyamide +
Polyphenylene Ether Fenders GTX
2003 Saturn Ion 3-3
2003 Saturn Ion

Structure Identification
Structure Identification
Number Description Procedure
1Impact Bar Bracket Replacement – Front Bumper
Impact Bar Bracket Replacement -
Front Bumper on page 3-15
2 Tie Bar Replacement Tie Bar Replacement on page 3-17
3Tie Bar Replacement – Lower
Tie Bar Replacement - Lower on
page 3-21
4Latch Primary Support Replacement – Hood
Latch Primary Support Replacement -
Hood on page 3-26
5Tie Bar Replacement – Left
Tie Bar Replacement - Left on
page 3-19
6Tie Bar Replacement – Right
Tie Bar Replacement - Right on
page 3-23
7Bracket Replacement Side Rail – Front Compartment
Bracket Replacement Front
Compartment - Side Rail on page 3-30
867419
3-4 2003 Saturn Ion

Structure Identification (cont’d)
Number Description Procedure
8Wheelhouse Replacement – Front
Wheelhouse Replacement - Front on
page 3-32
9Wheelhouse Extension Replacement – Front
Wheelhouse Extension Replacement -
Front on page 3-34
10 Rail Replacement Front Compartment – Side Upper
Rail Replacement Front Compartment -
Side Upper on page 3-36
11 Rail Sectioning Front Compartment – Side Upper
Rail Sectioning Front Compartment -
Side Upper on page 3-39
12 Plenum Panel Replacement – Upper
Plenum Panel Replacement - Upper on
page 3-43
13 Plenum Panel Replacement – Lower
Plenum Panel Replacement - Lower on
page 3-45
14 Dash Panel Replacement Dash Panel Replacement on page 3-48
15 Cross Bar New Replacement – Floor Panel
Cross Bar No.1 Replacement - Floor
Panel on page 3-51
16 Rail Replacement Front Compartment – Front
Rail Replacement Front Compartment -
Front on page 3-53
17 Rail Replacement Front Compartment – Front Half
Rail Replacement Front Compartment -
Front Half on page 3-55
18 Rail Sectioning Front Compartment – Front
Rail Sectioning Front Compartment -
Front on page 3-59
19 Rail Replacement Front Side Underbody – Outer
Rail Replacement Front Side
Underbody - Outer on page 3-63
20 Suspension Support Replacement – Front
Suspension Support Replacement -
Front on page 3-66
21 Extension Replacement Front Compartment Side Rail – Rear
Extension Replacement Front
Compartment Side Rail - Rear on
page 3-68
22 Windshield Frame Reinforcement Replacement – Inner Upper
Windshield Frame Reinforcement
Replacement - Inner Upper on
page 3-70
23 Hinge Pillar Body Replacement – Front Inner
Hinge Pillar Body Replacement - Front
Inner on page 3-75
24 Hinge Pillar Body Reinforcement Replacement – Front Inner
Hinge Pillar Body Reinforcement
Replacement - Front Inner on
page 3-73
25 Hinge Pillar Body Sectioning – Front
Hinge Pillar Body Sectioning - Front on
page 3-78
26 Roof Panel Replacement – Outer
Roof Panel Replacement - Outer on
page 3-81
27 Windshield Frame Header Panel Replacement – Front
Windshield Frame Header Panel
Replacement - Front on page 3-85
28 Rear Window Frame Header Panel Replacement – Rear
Rear Window Frame Header Panel
Replacement - Rear on page 3-87
29 Floor Panel Replacement – Center
Floor Panel Replacement - Center on
page 3-89
30 Rocker Panel Replacement – Inner
Rocker Panel Replacement - Inner on
page 3-93
31 Rocker Panel Extension Replacement – Inner
Rocker Panel Extension Replacement -
Inner on page 3-95
32 Rocker Panel Reinforcement Replacement – Inner
Rocker Panel Reinforcement
Replacement - Inner on page 3-97
33 Rocker Panel Reinforcement Sectioning – Inner
Rocker Panel Reinforcement Sectioning
- Inner on page 3-100
2003 Saturn Ion 3-5
2003 Saturn Ion

Structure Identification (cont’d)
Number Description Procedure
34 Pillar Lock Front Door Sectioning – Outer
Pillar Lock Front Door Sectioning -
Outer on page 3-103
35 Pillar Lock Front Door Reinforcement Replacement
– Outer
Pillar Lock Front Door Reinforcement
Replacement - Outer on page 3-107
36 Pillar Lock Front Door Reinforcement
Pillar Lock Front Door Reinforcement
Sectioning - Outer on page 3-109
37 Pillar Lock Front Door Replacement – Inner
Pillar Lock Front Door Replacement -
Inner on page 3-112
38 Pillar Lock Front Door Sectioning Replacement – Outer
Pillar Lock Front Door Reinforcement
Sectioning - Outer on page 3-109
39 Rear Window Reinforcement Replacement – Lower Front
Rear Window Reinforcement
Replacement - Lower Front on
page 3-114
40 Rear Window Panel Replacement
Rear Window Panel Replacement on
page 3-116
41 Rear Window Reinforcement – Rear
Rear Window Reinforcement
Replacement - Rear on page 3-119
42 Pillar Lock Rear Door Replacement – Inner
Pillar Lock Rear Door Replacement -
Inner on page 3-121
43 Body Side Panel Replacement – Outer
Body Side Panel Replacement - Outer
on page 3-123
44 Rear Compartment Floor Panel Sectioning
Rear Compartment Floor Panel
Sectioning on page 3-126
45 Wheelhouse Replacement – Rear Inner
Wheelhouse Replacement - Rear Inner
on page 3-130
46 Quarter Panel Sectioning – Outer
Quarter Panel Sectioning - Outer on
page 3-133
47 Quarter Panel Replacement – Inner
Quarter Panel Replacement - Inner on
page 3-136
48 Cross Bar No. 4 Replacement – Floor Panel
Cross Bar No.4 Replacement - Floor
Panel on page 3-140
49 Cross Bar No. 4 Extension Replacement – Floor Panel
Cross Bar No.4 Extension Replacement
- Floor Panel on page 3-138
50 Cross Bar No. 5 Replacement – Floor Panel Center
Cross Bar No.5 Replacement - Floor
Panel on page 3-145
51 Cross Bar No. 5 Extension Replacement – Floor Panel
Cross Bar No.5 Extension Replacement
- Floor Panel on page 3-143
52 Rail Replacement Rear Side Underbody
Rail Replacement Rear Side
Underbody on page 3-147
53 Rail Sectioning Rear Side Underbody
Rail Sectioning Rear Side Underbody
on page 3-150
54 Rail Side Underbody Gusset Replacement – Rear
Rail Underbody Gusset Replacement -
Rear on page 3-155
55 Rail Side Underbody Reinforcement Replacement – Rear
Rail Underbody Reinforcement
Replacement - Rear on page 3-157
56 Impact Bar Anchor Plate Replacement – Rear Bumper
Impact Bar Anchor Plate Replacement -
Rear Bumper on page 3-160
57 Body Rear End Panel Replacement
Body Rear End Panel Replacement on
page 3-162
58 Battery Tray Replacement
Battery Tray Replacement on
page 3-28
3-6 2003 Saturn Ion

Specifications
Dimensions - Body
Rear End
Location Description Length = x Width = y Height = z Point to Point
2 Center Line — — — x
aRear Tail Lamp
Pocket Hole 5162 532 683 x
bRear Impact Beam Upper Outer
Attach Hole 5149 587 447 x
cRear Impact Beam Lower Outer
Attach Hole 5176 439 327 x
d (Sedan) Rear Header Panel
Roof Attachment Hole 4133 306 1326 x
d (Coupe) Rear Header Panel
Roof Attachment Hole 4068 306 1285 x
All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless
otherwise specified.
876934
2003 Saturn Ion 3-7
2003 Saturn Ion

Coupe Side
Location Description Length = x Width = y Height = z Point to Point
aRear Lower Hinge
Lower Hole 3996 770 555 x
bRear Lower Hinge
Upper Hole 4046 759 649 x
cRear Upper Hinge
Lower Hole 4067 747 758 x
dRear Upper Hinge
Upper Hole 4056 738 863 x
eFascia Bracket Rear
Upper Hole 4989 768 798 x
fQuarter Panel Rear Inner
Lower Hole 4822 730 445 x
gQuarter Panel Dog Leg
Outer Attach Hole 3955 762 320 x
hQuarter Panel Dog Leg
Outer Attach Hole 3961 762 235 x
i Rocker Panel Rear Hole 3780 762 250 x
j Rocker Panel Center Hole 3228 756 234 x
k Rocker Panel Front Hole 2432 762 250 x
l Front Lower Hinge Rear Hole 2260 750 396 x
mFront Lower Hinge
Front Hole 2225 750 396 x
n Body Side Control Hole 2175 745 640 x
oFront Upper Hinge
Front Hole 2225 739 754 x
p Front Upper Hinge Rear Hole 2260 739 754 x
876935
3-8 2003 Saturn Ion

Location Description Length = x Width = y Height = z Point to Point
qDoor Opening Point to Point Measurement to Weld
Flange Die Marks x x x 1588
rDoor Opening Point to Point Measurement to Weld
Flange Die Marks x x x 1868
All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless
otherwise specified.
Front End
Location Description Length = x Width = y Height = z Point to Point
2 Center Line — — — x
aFront Lamp Assembly Inner
Attach Hole 1146 327 675 x
bFront Lamp Assembly Center
Attach Hole 1208 458 682 x
cFront Lamp Assembly Outer
Attach Hole 1271 589 676 x
dFront Lamp Assembly Lower
Attach Hole 1307 561 594 x
e Lower Tie Bar Outer Hole 998 314 428 x
f Center Brace Hole 1089 17 568 x
g Lower Tie Outer Slot 998 314 428 x
hFront Header Panel Roof Attachment Hole
(Sedan and Coupe) 2799 297 1307 x
All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless
otherwise specified.
876936
2003 Saturn Ion 3-9
2003 Saturn Ion

Underbody
876938
3-10 2003 Saturn Ion

Location Description Length = x Width = y Height = z Point to Point
2 Center Line — — — x
a Rear Cradle Attachment Hole 2100 332 201 x
bFront Rail Outer Torque Box
Master Gage Hole 2218 600 121 x
cFloor Pan Drain Hole
Front Hole 2420 542 190 x
dFront Rail Hole Front of Rear
Portion 2675 421 134 x
eFloor Pan Sled Rail
Front Hole 2585 162 133 x
fFront Rail Hole Rear of Rear
Portion 3171 601 167 x
gFloor Pan Sled Rail
Rear Hole 3374 170 144 x
h Floor Pan Rear Drain Hole 3378 521 190 x
iRear Rail Torque Box Master
Gage Hole 3593 592 203 x
j Front Rail Hole 3826 600 184 x
k 5 Bar Outer Hole 4235 180 354 x
l Rear Rail Rear Slot 4757 487 372 x
mRear Compartment Floor
Pan Drain Hole 5000 40 221 x
tFront Cradle
Attachment Hole 1371 474 231 x
ntoo Rear Rail Rear Hole to Rear
Rail Master Gage Hole — — — 1174
otop Rear Rail Master Gage Hole
to Front Rail Rear Hole — — — 419
ptoq Front Rail Rear Hole to Front
Rail Master Gage Hole — — — 956
qtos Front Rail Master Gage Hole to Front Cradle
Attachment Hole — — — 847
rtos Rear Cradle Attachment Hole to Front Cradle
Attachment Hole — — — 742
stot Front Cradle Attachment Hole to Front Cradle
Attachment Hole — — — 948
ttor Front Cradle Attachment Hole to Opposite Rear
Cradle Attachment — — — 1087
rtof Rear Cradle Attachment Hole to Opposite Rear Rail
Rear Hole — — — 1756
rtoi Rear Cradle Attachment Hole to Rear Rail Master
Gage Hole — — — 1756
ftoo Front Rail Rear Hole to Opposite Rear Rail Master
Gage Hole — — — 1243
otol Rear Rail Master Gage Hole to Opposite Rear Rail
Rear Hole — — — 1591
lton Rear Rail Rear Hole to Rear
Rail Rear Hole — — — 974
All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless
otherwise specified.
2003 Saturn Ion 3-11
2003 Saturn Ion

Engine Compartment
Location Description Length = x Width = y Height = z Point to Point
2 Center Line — — — x
aUpper Cowl Panel Rear
Flange Hole 2115 590 873 x
bFront Upper Rail Rear
Fender Attach 1786 698 805 x
cFront Upper Rail Center
Fender Attach 1594 688 773 x
dFront Upper Rail Front
Fender Attach 1425 681 739 x
e Strut Tower Center Hole 1811 553 815 x
fFront Upper Tie Bar Rear
Flange Hole 1226 232 700 x
gPoint to Point Front Fender Attach Hole to Rear Hinge
Attach Hole — — — 1499
hFront Engine Mount Hole
Rail Surface Not Top of Stud 1461 470 515 x
iRear Engine Mount Hole Rail
Surface Not Top of Stud 1657 465 515 x
All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless
otherwise specified.
876940
3-12 2003 Saturn Ion

Sedan Side
876943
2003 Saturn Ion 3-13
2003 Saturn Ion

Location Description Length = x Width = y Height = z Point to Point
aRear Upper Hinge
Upper Hole 3301 746 776 x
bQuarter Panel Dog Leg
Outer Attachment Hole 4226 779 768 x
cFascia Bracket Rear
Upper Hole 4974 746 596 x
dQuarter Panel Dog Leg
Outer Attach Hole 4068 767 617 x
eQuarter Panel Dog Leg
Outer Attachment Hole 3991 767 437 x
fQuarter Panel Dog Leg
Outer Attachment Hole 3780 762 250 x
g Rear Lower Hinge Rear Hole 3289 746 430 x
h Rear Lower Hinge Front Hole 3254 747 430 x
i Front Lower Hinge Rear Hole 2259 748 396 x
j Rear Cradle Attachment Hole 2100 332 201 x
kFront Lower Hinge
Front Hole 2225 740 396 x
l Front Rail Outer Panel Hole 1840 463 430 x
mFront Cradle
Attachment Hole 1371 500 280 x
nWeld Nut Hole Washer Bottle
Attachment 1222 540 409 x
oFront Upper Outer Rail
Front Hole 1880 743 760 x
p Body Side Control Hole 2175 745 640 x
qFront Upper Hinge
Front Hole 2224 737 754 x
r Front Upper Hinge Rear Hole 2260 737 754 x
sFront Door Latch Striker
Upper Hole 3263 748 574 x
tRear Upper Hinge
Lower Hole 3299 754 741 x
uRear Latch Striker
Upper Hole 4145 739 736 x
vRear Door Opening Point to Point Measurements to Weld
Flange Die Marks — — — 1015
wRear Door Opening Point to Point Measurement to Weld
Flange Die Marks — — — 1188
xFront Door Opening Point to Point Measurement to Weld
Flange Die Marks — — — 970
yFront Door Opening Point to Point Measurement to Weld
Flange Die Marks — — — 1337
All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless
otherwise specified.
3-14 2003 Saturn Ion

Repair Instructions
Impact Bar Bracket Replacement - Front
Bumper
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.
1. Disable the SIR system.
2. Disconnect the negative battery cable.
3. Remove all related panels and components.
4. Repair as much of the damage as possible. Refer
to
Dimensions - Body on page 3-7 .
5. Remove the sealers and anti-corrosion materials
from the repair area, as necessary.
Important: Note the number and location of the
factory welds for installation of the impact bar bracket
- front bumper
6. Locate and drill out all the factory welds from the
outside surface of the rail.
868868
867608
2003 Saturn Ion 3-15
2003 Saturn Ion

7. Remove the front bumper impact bar bracket.
Installation Procedure
1. Prepare all mating surfaces as necessary.
2. Apply 3M Weld-Thru Coating P/N 05916 or
equivalent to all mating surfaces.
Important: Verify the location of the front rail using
3-dimensional measuring equipment.
3. Position the impact bar bracket on the rail and
clamp in place.
867609
867597
867609
3-16 2003 Saturn Ion

4. Plug weld accordingly.
5. Clean and prepare all of the welded surfaces.
6. Install all of the related panels and components.
7. Apply the sealers and anti-corrosion materials
to the repair area, as necessary.
8. Paint the repaired area.
9. Connect the negative battery cable.
10. Enable the SIR system.
Tie Bar Replacement
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.
1. Disable the SIR system.
2. Disconnect the negative battery cable.
3. Remove all related panels and components.
4. Repair as much of the damage as possible to
factory specifications. Refer to
Dimensions -
Body on page 3-7
.
5. Note the location and remove the sealers and
anti-corrosion materials from the repair area, as
necessary.
Important: Do not damage any inner panels or
reinforcements.
6. Locate and drill out all factory welds. Note the
number and location of the welds for installation
of the tie bar.
868868
867423
867488
2003 Saturn Ion 3-17
2003 Saturn Ion

7. Remove the damaged tie bar.
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 in the locations 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. Position the tie bar to the vehicle using
3-dimensional measuring equipment. Clamp the
tie bar into place.
5. Plug weld accordingly.
6. Clean and prepare all welded surfaces.
7. Apply the sealers and anti-corrosion materials to
the repair area, as necessary.
8. Paint the repair area.
9. Install all related panels and components.
10. Connect the negative battery cable.
11. Enable the SIR system.
867491
865271
867423
3-18 2003 Saturn Ion

Tie Bar Replacement - Left
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: When performing service on or near the
SIR components or the SIR wiring, the SIR
system must be disabled. Refer to SIR Disabling
and Enabling Zones. Failure to observe the correct
procedure could cause deployment of the SIR
components, personal injury, or unnecessary SIR
system repairs.
1. Disable the SIR system.
Caution: Before servicing any electrical
component, the ignition key must be in the OFF or
LOCK position and all electrical loads must be
OFF, unless instructed otherwise in these
procedures. If a tool or equipment could easily
come in contact with a live exposed electrical
terminal, also disconnect the negative battery
cable. Failure to follow these precautions
may cause personal injury and/or damage to the
vehicle or its components.
2. Disconnect the negative battery cable.
3. Remove all related panels and components.
4. Repair as much of the damage as possible. Refer
to
Dimensions - Body on page 3-7 .
5. Remove the sealers and anti-corrosion materials
from the repair area, as necessary.
Important: Note the number and location of the
factory welds for installation of the tie bar-left.
6. Locate and drill out all the necessary
factory welds.
867423
867500
2003 Saturn Ion 3-19
2003 Saturn Ion

7. Remove the left tie bar.
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 in the locations 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. Position the left tie bar to the vehicle using
3-dimensional measuring equipment. Clamp the
tie bar in place.
867504
865272
867504
3-20 2003 Saturn Ion