Frame and Underbody: Overview Saturn ION I

Floor Pan Insulators Description

Floor pan insulators have been designed for the higher floor pan temperatures. Higher temperatures result from the use of the catalytic converter in the exhaust system. If you remove or disturb any insulators when servicing the vehicle in the field, reinstall the insulators in the original sequence and location. Use the material specified for that particular location on the floor pan if you replace an insulator.

1. Floor pan insulator (cerra blanket thermal) Consists of 10 mm (3/8 in) thick aluminum silica (type 1).
2. Floor pan insulator (amberlite) Consists of 10 mm (3/8 in) thick resonated fibers (type 2).
3. Floor pan insulator sheet (phenolic bonded fiberglass) 305 x 457 mm (12 x 18 in) cut to size (type 3)

Types 1 and 2 have the following characteristics

1. Rolled stock
2. Ordered by linear foot
3. Cut to fit

When servicing or replacing interior insulators, observe the following instructions

1. Install the insulators in the original position and sequence. Place the pieces close together in order to avoid gapping or overlapping.
2. Use the original part for the following reasons: In order to determine the amount of replacement material required As a template for cutting and fitting the new piece to the floor pan
3. When installing the insulator, do not enlarge the cutouts or holes. The cutouts or holes are used for the attachment of the interior components such as seats or seat belts.
4. Route the cross body harnesses for the following interior components over the floor pan insulators and into the original location: The power seats The lap belt warning light and alarm The rear speakers Clip the cross body harnesses into place.
5. Do not apply the spray-on deadeners and trim adhesive to the top of the floor pan at the area located directly over the catalytic converter or muffler(s).

The front suspension lower control arms are bolted to a suspension support. The front suspension support attaches to the underbody using four bolts. The engine bolts to the integral front side rails. Ensure that the suspension strut towers are dimensionally correct in relation to the remainder of the underbody. This will allow the vehicle to maintain correct caster and camber angles.

The individual underbody components contribute directly to the overall strength of the body. Ensure that you use the proper welding techniques. Properly seal and rustproof the underbody components under the following conditions

1. Whenever the body repair operations destroy or damage the original sealing
2. Whenever the body repair operations destroy or damage the rust proofing

When rustproofing critical underbody components, use a good quality type of air dry primer such as corrosion resistant chromate, or an equivalent material. Do not use combination type primer surfacers.