Component Locator Panel Identification
873924
Legend (1) (2) (3) (4) (5) (6) (7)
PA + PPE ABS + PC PA + PPE ABS + PC PET Steel ABS + PC
3-2 2003 Saturn Ion
(8) (9) (10) (11) (12) (13) (14)
TPO PET PA + PPE ABS + PC PA + PPE TPO PET
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 Typical Area where Used
Common or Trade Names
Polyethylene
Inner Fender Panels, Valances, Spoilers, Inner Trim Panels, Seatbelt Covers, Gas Tank Shields
Dylan, Fortiflex, Marlex, Alathon, Hi-Fax, Hosalen, Paxon
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
PE
PP
2003 Saturn Ion
Chemical Composition or Plastic “Family� Name
Identifying Symbol
2003 Saturn Ion 3-3
Structure Identification
867419
Structure Identification Number 1 2 3 4 5 6 7
Description
Procedure
Impact Bar Bracket Replacement – Front Bumper
Impact Bar Bracket Replacement Front Bumper on page 3-15
Tie Bar Replacement
Tie Bar Replacement on page 3-17
Tie Bar Replacement – Lower Latch Primary Support Replacement – Hood Tie Bar Replacement – Left Tie Bar Replacement – Right Bracket Replacement Side Rail – Front Compartment
3-4 2003 Saturn Ion
Tie Bar Replacement - Lower on page 3-21 Latch Primary Support Replacement Hood on page 3-26 Tie Bar Replacement - Left on page 3-19 Tie Bar Replacement - Right on page 3-23 Bracket Replacement Front Compartment - Side Rail on page 3-30
Structure Identification (cont’d) 8 9 10 11 12 13 14 15 16 17 18 19 20
Description Wheelhouse Replacement – Front
Procedure
Wheelhouse Replacement - Front on page 3-32
Wheelhouse Extension Replacement – Front
Wheelhouse Extension Replacement Front on page 3-34
Rail Replacement Front Compartment – Side Upper
Rail Replacement Front Compartment Side Upper on page 3-36
Rail Sectioning Front Compartment – Side Upper
Rail Sectioning Front Compartment Side Upper on page 3-39
Plenum Panel Replacement – Upper
Plenum Panel Replacement - Upper on page 3-43
Plenum Panel Replacement – Lower
Plenum Panel Replacement - Lower on page 3-45
Dash Panel Replacement
Dash Panel Replacement on page 3-48
Cross Bar New Replacement – Floor Panel
Cross Bar No.1 Replacement - Floor Panel on page 3-51
Rail Replacement Front Compartment – Front
Rail Replacement Front Compartment Front on page 3-53
Rail Replacement Front Compartment – Front Half
Rail Replacement Front Compartment Front Half on page 3-55
Rail Sectioning Front Compartment – Front Rail Replacement Front Side Underbody – Outer Suspension Support Replacement – Front
Rail Sectioning Front Compartment Front on page 3-59 Rail Replacement Front Side Underbody - Outer on page 3-63 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 24 25 26 27 28 29 30 31 32 33
Hinge Pillar Body Replacement – Front Inner Hinge Pillar Body Reinforcement Replacement – Front Inner Hinge Pillar Body Sectioning – Front Roof Panel Replacement – Outer
Hinge Pillar Body Replacement - Front Inner on page 3-75 Hinge Pillar Body Reinforcement Replacement - Front Inner on page 3-73 Hinge Pillar Body Sectioning - Front on page 3-78 Roof Panel Replacement - Outer on page 3-81
Windshield Frame Header Panel Replacement – Front
Windshield Frame Header Panel Replacement - Front on page 3-85
Rear Window Frame Header Panel Replacement – Rear
Rear Window Frame Header Panel Replacement - Rear on page 3-87
Floor Panel Replacement – Center
Floor Panel Replacement - Center on page 3-89
Rocker Panel Replacement – Inner
Rocker Panel Replacement - Inner on page 3-93
Rocker Panel Extension Replacement – Inner Rocker Panel Reinforcement Replacement – Inner Rocker Panel Reinforcement Sectioning – Inner
Rocker Panel Extension Replacement Inner on page 3-95 Rocker Panel Reinforcement Replacement - Inner on page 3-97 Rocker Panel Reinforcement Sectioning - Inner on page 3-100
2003 Saturn Ion 3-5
2003 Saturn Ion
Number
Structure Identification (cont’d) Number 34 35 36 37 38
Description Pillar Lock Front Door Sectioning – Outer Pillar Lock Front Door Reinforcement Replacement – Outer
Pillar Lock Front Door Reinforcement Replacement - Outer on page 3-107
Pillar Lock Front Door Reinforcement
Pillar Lock Front Door Reinforcement Sectioning - Outer on page 3-109
Pillar Lock Front Door Replacement – Inner
Pillar Lock Front Door Replacement Inner on page 3-112
Pillar Lock Front Door Sectioning Replacement – Outer
Pillar Lock Front Door Reinforcement Sectioning - Outer on page 3-109
Rear Window Reinforcement Replacement – Lower Front 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
Procedure
Pillar Lock Front Door Sectioning Outer on page 3-103
Rear Window Panel Replacement Rear Window Reinforcement – Rear Pillar Lock Rear Door Replacement – Inner Body Side Panel Replacement – Outer Rear Compartment Floor Panel Sectioning Wheelhouse Replacement – Rear Inner Quarter Panel Sectioning – Outer Quarter Panel Replacement – Inner Cross Bar No. 4 Replacement – Floor Panel Cross Bar No. 4 Extension Replacement – Floor Panel Cross Bar No. 5 Replacement – Floor Panel Center Cross Bar No. 5 Extension Replacement – Floor Panel Rail Replacement Rear Side Underbody
Rear Window Reinforcement Replacement - Lower Front on page 3-114 Rear Window Panel Replacement on page 3-116 Rear Window Reinforcement Replacement - Rear on page 3-119 Pillar Lock Rear Door Replacement Inner on page 3-121 Body Side Panel Replacement - Outer on page 3-123 Rear Compartment Floor Panel Sectioning on page 3-126 Wheelhouse Replacement - Rear Inner on page 3-130 Quarter Panel Sectioning - Outer on page 3-133 Quarter Panel Replacement - Inner on page 3-136 Cross Bar No.4 Replacement - Floor Panel on page 3-140 Cross Bar No.4 Extension Replacement - Floor Panel on page 3-138 Cross Bar No.5 Replacement - Floor Panel on page 3-145 Cross Bar No.5 Extension Replacement - Floor Panel on page 3-143 Rail Replacement Rear Side Underbody on page 3-147
Rail Sectioning Rear Side Underbody
Rail Sectioning Rear Side Underbody on page 3-150
Rail Side Underbody Gusset Replacement – Rear
Rail Underbody Gusset Replacement Rear on page 3-155
Rail Side Underbody Reinforcement Replacement – Rear
Rail Underbody Reinforcement Replacement - Rear on page 3-157
Impact Bar Anchor Plate Replacement – Rear Bumper
Impact Bar Anchor Plate Replacement Rear Bumper on page 3-160
Body Rear End Panel Replacement
Body Rear End Panel Replacement on page 3-162
Battery Tray Replacement
3-6 2003 Saturn Ion
Battery Tray Replacement on page 3-28
Specifications Dimensions - Body Rear End
876934
Description Length = x Width = y Height = z Point Center Line — — — Rear Tail Lamp 5162 532 683 a Pocket Hole Rear Impact Beam b Upper Outer 5149 587 447 Attach Hole Rear Impact Beam c Lower Outer 5176 439 327 Attach Hole Rear Header Panel 4133 306 1326 d (Sedan) Roof Attachment Hole Rear Header Panel 4068 306 1285 d (Coupe) Roof Attachment Hole All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical otherwise specified.
to Point x x x
x x x unless
2003 Saturn Ion 3-7
2003 Saturn Ion
Location 2
Coupe Side
876935
Location a b c d e f g h i j k l m n o p
Description Rear Lower Hinge Lower Hole Rear Lower Hinge Upper Hole Rear Upper Hinge Lower Hole Rear Upper Hinge Upper Hole Fascia Bracket Rear Upper Hole Quarter Panel Rear Inner Lower Hole Quarter Panel Dog Leg Outer Attach Hole Quarter Panel Dog Leg Outer Attach Hole Rocker Panel Rear Hole Rocker Panel Center Hole Rocker Panel Front Hole Front Lower Hinge Rear Hole Front Lower Hinge Front Hole Body Side Control Hole Front Upper Hinge Front Hole Front Upper Hinge Rear Hole
3-8 2003 Saturn Ion
Length = x
Width = y
Height = z
Point to Point
3996
770
555
x
4046
759
649
x
4067
747
758
x
4056
738
863
x
4989
768
798
x
4822
730
445
x
3955
762
320
x
3961
762
235
x
3780 3228 2432 2260
762 756 762 750
250 234 250 396
x x x x
2225
750
396
x
2175
745
640
x
2225
739
754
x
2260
739
754
x
Location
Description Length = x Width = y Height = z Point to Point Door Opening Point to Point q Measurement to Weld x x x 1588 Flange Die Marks Door Opening Point to Point r Measurement to Weld x x x 1868 Flange Die Marks All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless otherwise specified.
Front End
876936
Description Length = x Width = y Height = z Point to Point Center Line — — — x Front Lamp Assembly Inner 1146 327 675 x a Attach Hole Front Lamp Assembly Center 1208 458 682 x b Attach Hole Front Lamp Assembly Outer 1271 589 676 x c Attach Hole Front Lamp Assembly Lower 1307 561 594 x d Attach Hole 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 Front Header Panel Roof h Attachment Hole 2799 297 1307 x (Sedan and Coupe) 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 3-9
2003 Saturn Ion
Location 2
Underbody
876938
3-10 2003 Saturn Ion
Description Length = x Width = y Height = z Point to Point Center Line — — — x Rear Cradle Attachment Hole 2100 332 201 x Front Rail Outer Torque Box 2218 600 121 x b Master Gage Hole Floor Pan Drain Hole 2420 542 190 x c Front Hole Front Rail Hole Front of Rear 2675 421 134 x d Portion Floor Pan Sled Rail 2585 162 133 x e Front Hole Front Rail Hole Rear of Rear 3171 601 167 x f Portion Floor Pan Sled Rail 3374 170 144 x g Rear Hole h Floor Pan Rear Drain Hole 3378 521 190 x Rear Rail Torque Box Master 3593 592 203 x i Gage Hole 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 Rear Compartment Floor 5000 40 221 x m Pan Drain Hole Front Cradle 1371 474 231 x t Attachment Hole Rear Rail Rear Hole to Rear — — — 1174 n to o Rail Master Gage Hole Rear Rail Master Gage Hole — — — 419 o to p to Front Rail Rear Hole Front Rail Rear Hole to Front — — — 956 p to q Rail Master Gage Hole Front Rail Master Gage Hole q to s to Front Cradle — — — 847 Attachment Hole Rear Cradle Attachment Hole r to s to Front Cradle — — — 742 Attachment Hole Front Cradle Attachment s to t Hole to Front Cradle — — — 948 Attachment Hole Front Cradle Attachment t to r Hole to Opposite Rear — — — 1087 Cradle Attachment Rear Cradle Attachment Hole r to f to Opposite Rear Rail — — — 1756 Rear Hole Rear Cradle Attachment Hole r to i to Rear Rail Master — — — 1756 Gage Hole Front Rail Rear Hole to f to o Opposite Rear Rail Master — — — 1243 Gage Hole Rear Rail Master Gage Hole o to l to Opposite Rear Rail — — — 1591 Rear Hole Rear Rail Rear Hole to Rear — — — 974 l to n Rail Rear Hole 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
Location 2 a
Engine Compartment
876940
Location 2
Description Length = x Width = y Height = z Point to Point Center Line — — — x Upper Cowl Panel Rear 2115 590 873 x a Flange Hole Front Upper Rail Rear 1786 698 805 x b Fender Attach Front Upper Rail Center 1594 688 773 x c Fender Attach Front Upper Rail Front 1425 681 739 x d Fender Attach e Strut Tower Center Hole 1811 553 815 x Front Upper Tie Bar Rear 1226 232 700 x f Flange Hole Point to Point Front Fender g Attach Hole to Rear Hinge — — — 1499 Attach Hole Front Engine Mount Hole 1461 470 515 x h Rail Surface Not Top of Stud Rear Engine Mount Hole Rail 1657 465 515 x i Surface Not Top of Stud All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless otherwise specified.
3-12 2003 Saturn Ion
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Sedan Side
2003 Saturn Ion
876943
2003 Saturn Ion 3-13
Location
Description Length = x Width = y Height = z Point to Point Rear Upper Hinge 3301 746 776 x a Upper Hole Quarter Panel Dog Leg 4226 779 768 x b Outer Attachment Hole Fascia Bracket Rear 4974 746 596 x c Upper Hole Quarter Panel Dog Leg 4068 767 617 x d Outer Attach Hole Quarter Panel Dog Leg 3991 767 437 x e Outer Attachment Hole Quarter Panel Dog Leg 3780 762 250 x f Outer Attachment Hole 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 Front Lower Hinge 2225 740 396 x k Front Hole l Front Rail Outer Panel Hole 1840 463 430 x Front Cradle 1371 500 280 x m Attachment Hole Weld Nut Hole Washer Bottle 1222 540 409 x n Attachment Front Upper Outer Rail 1880 743 760 x o Front Hole p Body Side Control Hole 2175 745 640 x Front Upper Hinge 2224 737 754 x q Front Hole r Front Upper Hinge Rear Hole 2260 737 754 x Front Door Latch Striker 3263 748 574 x s Upper Hole Rear Upper Hinge 3299 754 741 x t Lower Hole Rear Latch Striker 4145 739 736 x u Upper Hole Rear Door Opening Point to v Point Measurements to Weld — — — 1015 Flange Die Marks Rear Door Opening Point to w Point Measurement to Weld — — — 1188 Flange Die Marks Front Door Opening Point to x Point Measurement to Weld — — — 970 Flange Die Marks Front Door Opening Point to y Point Measurement to Weld — — — 1337 Flange Die Marks 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