Front Compartment Front Rail Replacement. Saturn ION 2003

For 1990-2009 cars only

Makes 🢒 Saturn 🢒 2003 🢒 ION 🢒 Body and Accessories 🢒 Collision Repair 🢒 Front Compartment Front Rail Replacement

Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

Important: This assembly is replaced at factory seams.

Remove all related panels and components.
Repair as much of the damage as possible. Refer to Dimensions - Body .
Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.

Important: Note the number and location of the factory welds for installation of the full rail service part.

Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1½ in) apart.

Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
Prepare all mating surfaces as necessary.
Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
Position the full rail service part to the vehicle using 3-dimensional measuring equipment. Clamp the rail in place.

Plug weld accordingly.
Clean and prepare all of the welded surfaces.
Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
Install all of the related panels and components.
Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.