GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 ION 🢒 Body and Accessories 🢒 Collision Repair 🢒 Front Inner Hinge Pillar Body Reinforcement Replacement

Removal Procedure

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

  1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  3. Remove all related panels and components.
  4. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
  5. Repair as much of the damaged area as possible. Refer to Dimensions - Body .

    6. Object Number: 875622 Size: SH

    Important: Note the number and location of the factory welds for installation of the hinge pillar.

  6. Locate and drill out all factory welds

    7. Object Number: 875623 Size: SH
  7. Remove the damaged hinge pillar reinforcement.

Installation Procedure

    Object Number: 875621 Size: SH

    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. Object Number: 875622 Size: SH
  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. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
  8. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
  9. Install all of the related panels and components.
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  11. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.