GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2005 🢒 ION 🢒 Body 🢒 Doors 🢒 Rear Door Energy Absorber Pad Replacement

Removal Procedure

    Caution: This vehicle has energy-absorbing foam blocks for side impact protection. To help avoid personal injury in a collision, foam blocks that are damaged, or removed during repairs must be replaced. Failure to replace foam blocks that are removed can violate federal law.

  1. Open the door.
  2. Remove the door trim panel. Refer to Rear Side Door Trim Panel Replacement .

    3. Object Number: 869659 Size: SH
  3. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement .
  4. Remove the foam absorber adhesive from the door structure.
  5. Remove the screw from the energy absorber.
  6. Remove the energy absorber from the door.

Installation Procedure

    Object Number: 869659 Size: SH
  1. Remove the adhesive backing from the foam block adhesive.
  2. Position the rear door energy absorber in the door.
  3. Press the foam block into place. Engage the adhesive to the door structure.

    4. Notice: Refer to Fastener Notice in the Preface section.

  4. Install the foam absorber screw.

    5. Tighten
    Tighten the screw to 2 N·m (18 lb in).

  5. Install the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement .
  6. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement .