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: 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. Note amount and location of spot welds.
2. Remove all related panels and components.
3. Restore as much of the damage as possible to factory specifications.
4. Drill spot welds from:

4.1. | Sealers

4.2. | Sound Deadeners

4.3. | Anti-Corrosion

5. Locate and drill out all factory welds. Note the number and location of welds for installation of the service part.
6. Remove damaged body side ring.
7. If the vehicle that the body side door ring is being replaced on is equipped with structural reinforcement inserts the roof and roof side rail reinforcement must be replaced to allow for replacement of the center pillar structural reinforcement insert. (Refer to "Roof Panel Replacement" removal procedure in this section.)

### Installation

1. Drill 8 mm (5/16 in.) plug weld holes as necessary along locations noted from original panel.
2. Prepare all attachment surfaces as necessary.
3. Apply 3M weld-thru coating P/N 05913 (or equivalent) to all bare metal surfaces.
4. Position service part on vehicle. Clamp in place and check for proper fit.

Important: Structural reinforcement inserts are to be installed only if vehicle was originally equipped with structural reinforcement inserts. If vehicle was not originally equipped with structural reinforcement inserts proceed to step 17.

5. Remove service part.
6. Apply 3M Pinchweld Urethane Primer P/N 08686 (or equivalent) to structural reinforcement insert. Refer to shaded area of illustration for appropriate placement. Allow primer to dry for 5-10 minutes. Apply 3M Fast Cure Autoglass Urethane P/N 08690 (or equivalent) to primed areas of structural reinforcement insert.
7. Attach structural reinforcement inserts to body side inner as shown in illustration.
8. Position roof side rail reinforcement on vehicle. Clamp in place and check for proper fit.

Caution: When using tools that may create smoke when cutting or heating urethane adhesive, work should be done in a well ventilated area and/or with a NIOSH/MSHA approved air supplied respirator to prevent possible harmful exposure. When the urethane adhesive is heated enough to give off smoke, high levels of methylene diisocyanate may be present. Unprotected exposure to methylene diisocyanate may result in severe, chronic, debilitating respirator problems.

9. MIG plug weld flanges accordingly.

Important: Ensure that urethane adhesive does not contact lower hinge adjustment plate, or block sunroof drain hose channel.

10. Apply 3M Pinchweld Urethane Primer P/N 08686 (or equivalent) to structural reinforcement inserts. Refer to shaded area of illustration for appropriate placement.
11. Allow primer to dry for 5-10 minutes. Apply 3M Fast Cure Autoglass Urethane P/N 08690 (or equivalent) to primed areas of structural reinforcement inserts.
12. Attach structural reinforcement inserts to service part outer panel as shown in illustration.
13. Apply 3M Pinchweld Urethane Primer P/N 08686 (or equivalent) to structural reinforcement inserts. Refer to shaded area of illustration for appropriate placement.
14. Allow primer to dry for 5-10 minutes. Apply 3M Fast Cure Autoglass Urethane P/N 08690 (or equivalent) to primed areas of structural reinforcement inserts.
15. Position body side door ring on vehicle. Clamp in place and check for proper fit.
16. Position roof on vehicle. (Refer to "Roof Panel Replacement" installation procedure in this section.)
17. MIG plug weld flanges accordingly.
18. 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.

19. Apply the following as necessary:

• | Anti-Corrosion Materials

• | Sound Deadeners

• | Sealers

20. Refinish as necessary.
21. Install all related panels and components.
22. Clean all weld seams with a wire brush. Prime and seal all repair areas.
23. Apply permanent underbody sealant.

Important: Ensure that proper corrosion protection processes are used on all repair areas.

24. Prime with two-part catalyzed primer.
25. Apply sealers and corrosion protection materials according to information in the "Body Paint" section of this service manual or paint manufacturer's recommendations.
26. Clean surface for welding and grind primer off new part at connecting points. Apply 3M® Weld-Thru Coating P/N 05913 (or equivalent) to all areas to be welded.
27. Measure and align. Clamp in place.
28. Use MIG to plug weld.