GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 ION 🢒 Body and Accessories 🢒 Collision Repair 🢒 Floor Panel Replacement - Center

Removal Procedure

    Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

  1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

    3. Object Number: 870895 Size: SH
  3. Remove all related panels and components.
  4. Repair as much of the damaged area as possible. Refer to Dimensions - Body .
  5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.

    6. Object Number: 870890 Size: SH

    Important: Note the number and location of the factory welds for installation of the center floor panel.

    Important: Do NOT damage or drill through adjacent panels.

  6. Locate and drill out the #2 and #3 bar attachments to the inner rocker panel.
  7. Bend the upper weld flange up and away from the inner rocker panel.

    8. Object Number: 870892 Size: SH

    Important: The rear portion of the front compartment lower rail is a multi-layered assembly.

  8. Note the layering (1,2,3,4) of the weld flanges.
    9. • The rear portion of the front rail to rail assembly
    • The rear upper reinforcement of the front rail to floor pan
    • The intermediate portion of the front rail to rear upper reinforcement of the front rail
    • The intermediate reinforcement to the floor pan

    Object Number: 870893 Size: SH
  9. Drill out all plug welds in the rear portion of the front rail connected to the center floor panel. If the rail portion is undamaged, keep the portion for reinstallation.
  10. Drill out all plug welds that attach the rear portion of the front rail to the intermediate portion of the front rail.

    11. Object Number: 870891 Size: SH

    Important: Remove the rear section of the rail before you remove the center floor panel.

  11. Using a 90-degree bent pry tool, pry the intermediate portion of the front rail apart from the rear portion of the rail far enough to allow the rear portion to slide free of the intermediate portion. Remove the rear portion of the front compartment rail.

    12. Object Number: 870894 Size: SH
  12. Locate and drill out all of the spot welds that attach the center floor pan to the following components:
    13. • The dash and panel
    • The #1 bar area
    • The lower inner rockers
    • The rear floor pan
  13. Remove the center floor panel by lowering the rear edge first and pulling down and rearwards until the floor pan is free from the vehicle.

Installation Procedure

    Object Number: 870888 Size: SH

    Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1½ in) apart.

  1. Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the corresponding locations noted on the original panel.
  2. Prepare all mating surfaces as necessary.
  3. Apply 3M® Weld-Thru coating P/N 05916 or equivalent to all mating surfaces.

    4. Object Number: 870894 Size: SH
  4. Position the center floor panel to the vehicle using 3-dimensional measuring equipment. Clamp the panel in place.

    5. Object Number: 870895 Size: SH
  5. Plug weld accordingly.
  6. Clean and prepare all of the welded surfaces.
  7. Install all of the related panels and components.
  8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
  9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  11. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.