For 1990-2009 cars

One of the first steps in repairing damage to Saturn's uniframe construction is to determine the extent of the damage to the vehicle's structure. Body dimension charts are provided in this section to assist you in identifying and repairing the damaged areas.

### High Strength Steel

This section contains illustrations that identify the location of high strength low alloy steel (HSLA) in the Saturn Uniframe construction. Saturn recommends that the following procedures be followed when working with HSLA steel.

### Heating High Strength Steels

Cold working is best when straightening damaged HSLA steel components. The application of heat may anneal (soften) high strength low alloy steels and should be avoided whenever possible. If the use of heat is required in the repair of structural components, the "hot working" temperatures should not exceed 654°C (1,200°F). Saturn recommends the use of temperature indicating crayons to assure this temperature limit is not exceeded. Three minutes is the maximum allowable exposure time for heating HSLA steel to 654°C (1200°F). Rust proofing materials must be applied to both sides of any surface that has had a sufficient amount of heat applied to damage the factory coatings.

### Welding

The repair procedures in this section require the use of a metal-inert gas (MIG) welder. Gas (oxyacetylene) welding must not be used.

### Test Welds

Caution: When welding galvanized sheet metal, welding must be done in a properly ventilated area. Zinc oxide, when welded, can give off toxic fumes.

Caution: Protect yourself by wearing safety glasses, earplugs, a respirator, gloves, and safety shoes while performing work on the vehicle.

Caution: Exposure to welding is extremely harmful to the eyes and skin. Prolonged exposure can cause blindness and burns. Never begin welding unless you are wearing eye protection and protective clothing.

Caution: When welding parts near the fuel tank, be sure to remove the fuel tank. Plug the filler port of the tank.

Notice: Disconnect the negative (-) battery cable before MIG welding or electrical wiring shorts could cause damage to the electrical components.

Important: No specific number of spot welds will be given for a welding procedure. Make note of the number of welds when cutting out the damaged panels, and always duplicate the same number of factory welds.

Prior to, and during the welding, test the welds for strength and quality. For setting the welder, use a scrap of similar metal and cut and clamp in a similar position to what you are welding. Then, weld to achieve the desired penetration and strength.

### Corrosion Protection and Sealing

An important part of any damage repair is proper corrosion protection and sealing. Quality corrosion resistant primers should be applied to all seams and weld joints prior to the application of seam sealers. The proper application of seam sealers is important for waterproofing and preventing vehicle exhaust gases from entering the passenger compartment.