For 1990-2009 cars

### Removal

Important: Sedan shown; wagon similar

Important: Some parts have structural weld-thru adhesive in the joint areas. It is necessary to replace this with additional spot welds at the attachment points. This can be accomplished by adding an additional weld between each factory weld in all areas.

Important: Some 2001 and all 2002, 2003 vehicles are equipped with structural reinforcement inserts located in the front body hinge pillar/rocker area, and upper center pillar roof area. Contact your SATURN Retailer with the vehicles VIN to determine if the 2001 vehicle you are repairing was originally equipped with structural reinforcement inserts. Structural reinforcement inserts are ONLY to be replaced if the vehicle was originally equipped with structural reinforcement inserts. Failure to replace any structural reinforcement inserts as described above will compromise the structural integrity of the vehicle.

Important: Sectioning should be performed only in the recommended areas. Failure to do so will compromise the structural integrity of the vehicle. The side door frame openings feature a unique modular build design to improve manufacturing quality. The side door frame openings are composed of pre-assembled components. Some 2000 model year vehicles were manufactured with weld on hinges. The hinges supplied with the replacement parts must have final welding done when the door is fitted to the body after the new service part is installed!

1. Remove all related panels and components.
2. Restore as much of the damage as possible to factory specifications.
3. Visually inspect upper center pillar roof area if damage is present that will not be repaired by this procedure, the body side ring must be replaced. (Refer to "Body Side Ring" removal and replacement procedure in this section.)
4. Note the location and remove the following as necessary:

4.1. | Sealers

4.2. | Sound Deadeners

4.3. | Anti-Corrosion

Important: Do not damage any inner panels or reinforcements when performing section cuts.

5. The front area of the rocker panel outer may be sectioned anywhere between the rear point of the down turned tab on the upper pinch weld flange and 325 mm (13 in.) when measure rearward of the down turned tab. Refer to the shaded portion of the illustration shown above.
6. The rear area of the rocker panel outer may be sectioned directly behind the down turned tab. Refer to the shaded portion of the illustration shown above.
7. The upper portion of the center pillar may be sectioned 25 mm (1 in.) below the top shoulder belt height adjuster access hole. Refer to illustration shown above.
8. Mark section locations and cut through outer panel only where sectioning is to be performed.
9. Locate and drill out all factory welds. Note the number and location of welds for installation of the service part.
10. Drill out factory welds 100 mm (4 in.) above center pillar sectioning joint so that the inner reinforcements can be removed with the damaged part.
11. Remove damaged center pillar section.

### Installation

Important: Do not damage the inner reinforcement panels behind the center pillar upper sectioning joint when fitting service part.

1. Cut service part to fit remaining original panel. To ensure a secure weld, sectioning joints should have a gap of approximately one and a half times the thickness of the metal.
2. Construct 100 mm (4 in.) backing plate for rocker panel section joint, from unused portion of service part or undamaged sections of original panel. Trim backing plate as necessary to fit behind sectioning joint.
3. Drill 8 mm (5/16 in.) plug weld holes as necessary along sectioning cuts and in locations noted from original panel.
4. Prepare all attachment surfaces as necessary.
5. Apply 3M weld-thru coating P/N 05913 (or equivalent) to all bare metal surfaces.
6. Install backing plates halfway into rocker and windshield pillar section joints, clamp in place. Check for proper fit and MIG plug-weld to vehicle.
7. Position service part on vehicle. The upper portion of the center pillar will be sandwiched between the body side inner and body side outer. Clamp in place and check for proper fit.
8. MIG plug weld flanges accordingly.
9. Stitch weld along both rocker and windshield pillar section joint, make 25 mm (1 in.) stitch welds along the seam with 25 mm (1 in.) gaps between, then go back and complete the stitch weld until entire joint is welded.
10. Clean and prepare all welded surfaces.

Important: It is important that proper corrosion protection processes are used on all repair areas. Apply sealers and corrosion protection materials according to information in the "Body Paint" section of this service manual or paint manufacturer's recommendations.

11. Apply the following as necessary:

• | Anti-Corrosion Materials

• | Sound Deadeners

• | Sealers

12. Refinish as necessary.
13. Install all related panels and components.