Pontiac pontiac 2001 User's Manual
Contents
1. IMPORTANT In any area damaged beyond recognition space plug weld holes every 40 mm 1 1 2 in apart Drill 8 mm 5 16 in plug weld holes as necessary in locations noted from the original Rear Outer Wheelhouse Prepare all attachment surfaces as necessary Apply weld thru primer to all bare metal surfaces Position the Rear Outer Wheelhouse Plug weld accordingly IMPORTANT Prior to refinishing refer to publication GM4901M D 01 GM Approved Refinish Materials for recommended products Do not combine paint systems Refer to paint manufacturer s recommendations Clean and prepare all welded surfaces Apply the following as necessary e Anti corrosion materials e Sound deadeners 1 e Sealers Refinish as necessary Install all related panels and components 2001 Pontiac Aztek 1 45 Aztek Plastic Panel Identification 1 TPO Thermoplastic Olefin 2 Xenoy 3 Polypropylene Energy Foam 1 46 2001 Pontiac Aztek Aztek Metal Panel Identification H u AN IWS 1 TSGS Two Sided Galvanized Steel 2 UHSS Ultra High Strength Steel 3 AL Aluminum 2001 Pontiac Aztek 1 47 Body Dimensions Body Side 1 48 2001 Pontiac Aztek Body Dimensions 355 716 687 747 WIDTH WIDTH 355 716 I te N D pes ye 7 e Cl L Z HE C sa IE AV i 925 1028 HEIGHT 1038 1159 1181 s Ain LENGTH LINE R 206 q 432. 2001 Pontiac Aztek Radiator Support Replacement Upper Removal Procedure 1 Remove all related panels and components including front fascia supports right and left 1 2 Restore as much of the damage as possible to factory specifications 3 Note the location and remove the following as necessary e Sealers e Sound deadeners e Anti corrosion materials IMPORTANT Do not damage any inner panels or reinforcements 4 Locate and drill out all factory welds Note the number and location of welds for installation of the Radiator Support Assembly 5 Remove the damaged Radiator Support Assembly 2001 Pontiac Aztek 1 1 2 N lt 2 S S a N Radiator Support Replacement Upper Installation Procedure IMPORTANT In any area damaged beyond recognition space plug weld holes every 40 mm 1 1 2 in apart 1 Drill 8 mm 5 16 in plug weld holes as necessary in locations noted from the original panel 2 Prepare all attachment surfaces as necessary 3 Apply weld thru primer to all bare metal surfaces 4 Position the Radiator Support Assembly 5 Plug weld accordingly 6 Clean and prepare all welded surfaces IMPORTANT Prior to refinishing refer to publication GM4901M D 01 GM Approved Refinish Materials for recommended products Do not combine paint systems Refer to paint manufacturer s recommendations 7 Apply the following as necessary e Anti
3. paint manufacturer s recommendations Apply the following as necessary e Anti corrosion materials e Sound deadeners e Sealers Refinish as necessary Install all related panels and components 2001 Pontiac Aztek Rail Replacement Upper Removal Procedure 1 Remove all related panels and components 2 Restore as much of the damage as possible to factory specifications 3 Note the location and remove the following as necessary e Anti corrosion materials e Sound deadeners e Sealers IMPORTANT Do not damage any inner panels or reinforcements 4 Locate and drill out all factory welds Note the number and location of welds for installation of the Front Upper Rail 5 Remove the damaged Front Upper Rail 2001 Pontiac Aztek 1 5 Rail Replacement Upper Installation Procedure 1 6 IMPORTANT In any area damaged beyond recognition space plug weld holes every 40 mm 1 1 2 in apart Drill 8 mm 5 16 in plug weld holes as necessary in locations noted from the original front upper rail Prepare all attachment surfaces as necessary Apply weld thru primer to all bare metal surfaces Position the Upper Rail Plug weld accordingly IMPORTANT Prior to refinishing refer to publication GM4901M D 01 GM Approved Refinish Materials for recommended products Do not combine paint systems Refer to paint manufacturer s recommendations Clean and prepare all welded
4. corrosion materials e Sound deadeners e Sealers Refinish as necessary Install all related panels and components 1 2 2001 Pontiac Aztek IA Q ss Xa E a O Q EY o Radiator Support Replacement Lower Removal Procedure 1 Remove all related panels and components 2 Restore as much of the damage as possible to factory specifications 3 Note the location and remove the following as necessary e Sealers e Sound deadeners e Anti corrosion materials IMPORTANT Do not damage any inner panels or reinforcements 4 Locate and drill out all factory welds Note the number and location of welds for installation of the Lower Radiator Support 5 Remove the damaged Lower Radiator Support 2001 Pontiac Aztek 1 3 Radiator Support Replacement Lower Installation Procedure 1 4 IMPORTANT In any area damaged beyond recognition space plug weld holes every 40 mm 1 1 2 in apart Drill 8 mm 5 16 in plug weld holes as necessary in locations noted from the original panel Prepare all attachment surfaces as necessary Apply weld thru primer to all bare metal surfaces Position the Lower Radiator Support Plug weld accordingly Clean and prepare all welded surfaces IMPORTANT Prior to refinishing refer to publication GM4901M D 01 GM Approved Refinish Materials for recommended products Do not combine paint systems Refer to
5. edge of the second gauge hole rearward 7 Cut the rear rail section 8 Remove the damaged rear rail section 1 34 2001 Pontiac Aztek Rail Sectioning Rear Installation Procedure 1 Mark the cut location on the service rail by measuring 5 mm 1 4 in from the front edge of the second gauge hole forward Cut the rear rail service part Cut and remove 30 mm 1 and 3 16 in from the flanges on either side of the service section rail to create 30 mm 1 and 3 16 in tabs 1 Cut 5 mm 1 4 in wide gaps in the bottom corners 2 Step the tabs inward 1 to allow the service rail section to fit inside of the original rear rail IMPORTANT The metal of the rear rail is of a heavy gauge However the tabs can be created using the appropriate tools Weld the tabs together along the lower edges 2 continued 2001 Pontiac Aztek 1 35 Rail Sectioning Rear Installation Procedure con t IMPORTANT In any area damaged beyond recognition space plug weld holes every 40 mm 1 1 2 in apart 7 Drill 8 mm 5 16 in plug weld holes along the sectioning cut on the original rail Locate these holes 13 mm 1 2 in from the edge and spaced 40 mm 1 2 in apart 8 Prepare all attachment surfaces as necessary 9 Turn the weld flange downward for rewelding 2 10 Apply weld thru primer to all bare metal surfaces 11 Align the service part over the stepped tab using three dim
6. surfaces Apply the following as necessary e Anti corrosion materials e Sound deadeners e Sealers Refinish as necessary Install all related panels and components 2001 Pontiac Aztek Wheelhouse Replacement Front Removal Procedure 1 Remove all related panels and components in the area of the damaged apron extension 1 2 Restore as much of the damage as possible to factory specifications 3 Note the location and remove the following as necessary e Anti corrosion materials e Sound deadeners e Sealers IMPORTANT Do not damage any inner panels or reinforcements 4 Locate and drill out all factory welds Note the number and location of welds for installation of the service part 5 Remove the damaged apron extension 2001 Pontiac Aztek 1 7 Wheelhouse Replacement Front Installation Procedure IMPORTANT In any area damaged beyond recognition space plug weld holes every 40 mm 1 1 2 in apart 1 Drill 8 mm 5 16 in plug weld holes in the service part as necessary in the locations noted from the original panel 2 Prepare all attachment surfaces as necessary IMPORTANT Prior to refinishing refer to the publication GM4901M D 01 GM Approved Refinish Materials for recommended products Do not combine paint systems Refer to paint manufacturer s recommendations 3 Apply weld thru primer to all bare metal surfaces 4 Position the apron extension 5 Plug
7. the seam with 25 mm 1 in gaps between them Then go back and complete the stitch weld IMPORTANT Prior to refinishing refer to publication GM4901M D 01 GM Approved Refinish Materials for recommended products Do not combine paint systems Refer to paint manufacturer s recommendations 12 Clean and prepare all welded surfaces 13 Apply the following as necessary e Anti corrosion materials e Sound deadeners 1 e Sealers 14 Refinish as necessary 15 Install all related panels and components 1 24 2001 Pontiac Aztek Door Frame Sectioning Outer Rocker Sectioning Removal Procedure 1 Remove all related panels and components 2 Restore as much of the damage as possible to factory specifications 3 Note the location and remove the following as necessary e Anti corrosion materials e Sound deadeners 1 e Sealers 4 By measuring from the lower edge of the guide hole 1 downward 30 mm 1 3 16 in locate and mark for sectioning of the Front Hinge Pillar and the Center Pillar 5 With quarter panel removed 2 locate and mark for sectioning of the Rear Lock Pillar 6 Scribe a line horizontally to the rocker IMPORTANT Do not damage any inner panels or reinforcements 7 Cut the panel where sectioning is to be performed continued 2001 Pontiac Aztek 1 25 Door Frame Sectioning Outer Rocker Sectioning Removal Procedure con t 8 Locate and drill out all f
8. 3 k 470 5 852 j 1019 Engine Compartment 2001 Pontiac Aztek 1 49 Body Measurements poA T H LI j I lun a S T p q 6 iB Wee oe Tt 653 663 580 aaa ie HEIGHT 7888 aig 411 415 462 504 528 567 DATUM LINE LENGTH aie 2 C FE NF 406 5 953 G 1071 H 1425 1105 A T 1928 J 2555 K 2801 L 3062 M Underbody 1 50 2001 Pontiac Aztek Frame Dimensions Point to Point 2001 Pontiac Aztek 1 51
9. INTERIOR OF THE VEHICLE CAUSING PERSONAL INJURY 8 Install GM P N 12399117 Sealing Strip between outer wheelhouse and quarter panel gas door pocket 9 Install service quarter panel leaving a gap of one and one half times the thickness of the metal 1 at the sectioning joint 10 Plug weld accordingly 11 To create a solid weld with minimum heat distortion make 25 mm 1 in stitch welds along the seam with 25 mm 1 in gaps between them Then go back and complete the stitch weld 12 Clean and prepare all welded surfaces 13 Apply the following as necessary e Anti corrosion materials e Sound deadeners e Sealers 14 Refinish as necessary 15 Install all related panels and components 2001 Pontiac Aztek 1 33 Rail Sectioning Rear Removal Procedure IMPORTANT Rear rail sectioning may require replacement of the rear floor panel 1 Remove all related panels and components 2 Restore as much of the damage as possible to factory specifications 3 Note the location and remove the following as necessary e Anti corrosion materials e Sound deadeners e Sealers IMPORTANT Do not damage any inner panels or reinforcements 4 Perform the necessary procedures to gain access to the rear rail 5 Locate and drill out all factory welds Note the number and location of welds for installation of the rear rail 6 Mark the cut location by measuring 5 mm 1 4 in from the rear
10. actory welds Note the number and location of welds for installation of the Rocker Panel 9 Remove the damaged Rocker Panel 1 26 2001 Pontiac Aztek z H Q Rh SA a 00 Z 4 TSEN 09 lt gt W Door Frame Sectioning Outer Rocker Sectioning Installation Procedure 1 Cut the replacement service part in corresponding locations to fit the remaining original panel The sectioning joint should be trimmed to allow a gap of one and one half times the metal 1 thickness at the sectioning joint 2 Inthe Rear Lock Pillar create a 50 mm 2 in backing plate 1 from the unused portion of the Door Frame Opening Trim the backing plate as necessary to fit behind the sectioning joint 3 Use the lower hinge reinforcement 2 as the backing plate in the front Hinge Pillar and the Center Hinge Pillar 4 Drill 8 mm 5 16 in plug weld holes along the sectioning cut on the remaining original part IMPORTANT In any area damaged beyond recognition space plug weld holes every 40 mm 1 in apart 5 Drill 8 mm 5 16 in plug weld holes as necessary in locations noted from the original panel and along the sectioning cut continued 2001 Pontiac Aztek 1 27 Door Frame Sectioning Outer Rocker Sectioning Installation Procedure con t 6 Prepare all attachment surfaces as necessary 7 Apply weld thru primer to all bare metal surfaces 8 Fit the backing plate 1 halfway int
11. allation of the service part 6 Remove the damaged Center Pillar 2001 Pontiac Aztek 1 19 Door Frame Sectioning Outer Center Pillar Installation Procedure 1 Cut the replacement Center Pillar in corresponding locations to fit the remaining original panel The sectioning joint should be trimmed to allow a gap of one and one half times the metal 1 thickness at the sectioning joint 2 In the Center Pillar create a 50 mm 2 in backing plate 1 from the unused portion of the Door Frame Opening Trim the backing plate as necessary to fit behind the sectioning joint 3 In the rocker locations create a 100 mm 4 in backing plate 2 from the unused portion of the door frame opening Trim the backing plate as necessary to fit behind the sectioning joint 4 Drill 8 mm 5 16 in plug weld holes along the sectioning cut on the remaining original part continued 1 20 2001 Pontiac Aztek Door Frame Sectioning Outer Center Pillar Installation Procedure con t IMPORTANT In any area damaged beyond recognition space plug weld holes every 40 mm 1 1 2 in apart 5 Drill 8 mm 5 16 in plug weld holes as necessary in locations noted from the original panel 6 Prepare all attachment surfaces as necessary 7 Apply weld thru primer to all bare metal surfaces 8 Fit the backing plate 1 halfway into the sectioning joint 2 clamp and plug weld to the vehicle 9 Align the Cen
12. and prepare all welded surfaces 11 Apply the following as necessary e Anti corrosion materials e Sound deadeners e Sealers 12 Refinish as necessary 13 Install all related panels and components 2001 Pontiac Aztek 1 4 Panel Replacement Rear End Removal Procedure l Remove all related panels and components Restore as much of the damage as possible to factory specifications Note the location and remove the following as necessary e Anti corrosion materials e Sound deadeners e Sealers IMPORTANT Do not damage any inner panels or reinforcements Locate and drill out all factory welds Note the number and location of welds for installation of the rear body opening right and left lower reinforcements gaining access to the rear floor panel 5 Remove the Rear End Panel 1 42 2001 Pontiac Aztek Panel Replacement Rear End Installation Procedure IMPORTANT In any area damaged beyond recognition space plug weld holes every 40 mm 1 1 2 in apart 1 Drill 8 mm 5 16 in plug weld holes in the service part as necessary in locations noted from the original panel 2 Prepare all attachment surfaces as necessary 3 Apply weld thru primer to all bare metal surfaces 4 Position the Rear End Panel v Se _ x 7 mek 7 ey lt i PEN ORR B S ae A gi I 2 ema Se f RY J 5 Plug w
13. be a line 2 Add 10 mm and scribe a second line The second line is the cut location The additional 10 mm 13 32 in will be used to create a flange for welding the new service part to the vehicle 3 On the outboard side of the rail locate the fixturing hole 2 Measure forward 150 mm 5 29 32 in and mark location Scribe a straight line on the rail 4 Measure forward 10 mm 13 32 in and scribe a second line The second line 160 mm 6 5 16 in is the cut location 5 On the inboard side of the rail locate the brake line pass thru hole 1 At the larger hole pull the tape measure from the forward edge of the hole and mark a line at 376 mm Scribe a line with a straight edge making sure it is square to inboard and top rail markings 6 Measure forward 10 mm and scribe a second line The second line 386 mm is the cut location 7 Make certain all three sides are aligned Cut through three sides of the rail 8 On the bottom of the damaged rail scribe a line from the outboard to the inboard cut locations and cut the remainder of the rail 1 from the vehicle Remove the damaged section of rail 1 14 2001 Pontiac Aztek 160MM O EREZET NEZ N 4 oD ka 8 i o e lt N RIGHT OUTBOARD Right Front Lower Rail Sectioning Preparing the Undamaged Portion of the Rail for Installation 1 On original rail cut and remove 10 mm of the outboard 1 and downward 2 tu
14. e replacement Rear Lock Pillar in corresponding locations to fit the remaining original panel The sectioning joint should be trimmed to allow a gap of one and one half times the metal 1 thickness at the sectioning joint 2 In the Rear Lock Pillar create a 50 mm 2 in backing plate 1 from the unused portion of the Door Frame Opening Trim the backing plate as necessary to fit behind the sectioning joint 3 In the rocker locations create a 100 mm 4 in backing plate 2 the unused portion of the door frame opening Trim the backing plate as necessary to fit behind the sectioning joint 4 Drill 8 mm 5 16 in plug weld holes along the sectioning cut on the remaining original part continued 2001 Pontiac Aztek 1 23 Door Frame Sectioning Outer Rear Lock Pillar Installation Procedure con t IMPORTANT In any area damaged beyond recognition space plug weld holes every 40 mm 1 1 2in apart 5 Drill 8 mm 5 16 in plug weld holes as necessary in locations noted from the original panel 6 Prepare all attachment surfaces as necessary 7 Apply weld thru primer to all bare metal surfaces 8 Fit the backing plate 1 halfway into the sectioning joint 2 clamp and plug weld to the vehicle 9 Align the Center Pillar using three dimensional measuring equipment 10 Plug weld accordingly 11 To create a solid weld with minimum heat distortion make 25 mm 1 in stitch welds along
15. eld accordingly IMPORTANT Prior to refinishing refer to publication GM4901M D 01 GM Approved Refinish Materials for recommended products Do not combine paint systems Refer to paint manufacturer s recommendations 6 Clean and prepare all welded surfaces 7 Apply the following as necessary e Anti corrosion materials e Sound deadeners e Sealers Refinish as necessary Install all related panels and components 2001 Pontiac Aztek 1 43 Wheelhouse Replacement Rear Outer Removal Procedure 1 Remove all related panels and components 2 Restore as much of the damage as possible to factory specifications Note the location and remove the i following as necessary e Anti corrosion materials e Sound deadeners 1 e Sealers IMPORTANT Do not damage any inner panels or reinforcements 4 Using a suitable tool trim off the damaged rear wheelhouse IMPORTANT The original weld flange can be used as an attachment surface for installation of the new wheelhouse Note the number and location of welds for installation of the Rear Outer Wheelhouse JI 6 Remove the damaged Rear Outer Wheelhouse 1 44 2001 Pontiac Aztek h ea D Sto b Q K YYYYYYY v ZE 3 SSN Q t V e 4 CL Wheelhouse Replacement Rear Outer Installation Procedure JI
16. ements Cut the panel where sectioning is to be performed Locate and drill out all factory welds Note the number and location of welds for installation of the service part Remove the damaged Front Hinge Pillar 1 16 2001 Pontiac Aztek Door Frame Sectioning Outer Front Hinge Pillar Installation Procedure 1 Cut the replacement service part in corresponding locations to fit the remaining original panel The sectioning joint should be trimmed to allow a gap of one and one half times the metal 1 thickness at the sectioning joint 2 In the Front Hinge Pillar create a 50 mm 2 in backing plate 1 from the unused portion of the Door Frame Opening Trim the backing plate as necessary to fit behind the sectioning joint 3 In the rocker locations create a 100 mm 4 in backing plate 2 from the unused portion of the door frame opening Trim the backing plate as necessary to fit behind the sectioning joint Ca GZ ANS 4 Drill 8 mm 5 16 in plug weld holes along the sectioning cut on the remaining original part continued 2001 Pontiac Aztek 1 17 Door Frame Sectioning Outer Front Hinge Pillar Installation Procedure con t IMPORTANT In any area damaged beyond recognition space plug weld holes every 40 mm 1 1 2 in apart 5 Drill 8 mm 5 16 in plug weld holes as necessary in locations noted from the original panel 6 Prepare all attachment surfaces as necessa
17. ensional measuring equipment 12 Plug weld accordingly continued 1 36 2001 Pontiac Aztek Rail Sectioning Rear Installation Procedure con t 13 To create a solid weld with minimum heat distortion make 25 mm 1 in stitch welds along the seam with 25 mm 1 in gaps between them Then go back and complete the stitch weld IMPORTANT Prior to refinishing refer to publication GM4901M D 01 GM Approved Refinish Materials for recommended products Do not combine paint systems Refer to paint manufacturer s recommendations 14 Clean and prepare all welded surfaces Il JI Apply the following as necessary e Anti corrosion materials e Sound deadeners e Sealers 16 Install all related panels and components 2001 Pontiac Aztek 1 37 Floor Panel Replacement Removal Procedure 1 Remove all related panels and components Restore as much of the damage as possible to factory specifications Note the location and remove the following as necessary e Anti corrosion materials e Sound deadeners e Sealers IMPORTANT Do not damage any inner panels or reinforcements Locate and drill out all factory welds Note the number and location of welds for installation of the rear body opening right and left lower reinforcements gaining access to the rear floor panel Locate Rear Floor Panel to mid floor overlay seam 6 Cut rearward of the mid floor Use a straight l
18. from the original panel 5 Prepare all attachment surfaces as necessary 6 Apply weld thru primer to all bare metal surfaces 7 Position the service part 8 Plug weld accordingly IMPORTANT Prior to refinishing refer to publication GM4901M D 01 GM Approved Refinish Materials for recommended products Do not combine paint systems Refer to paint manufacturer s recommendations 9 Clean and prepare all welded surfaces 10 Apply the following as necessary e Anti corrosion materials e Sound deadeners e Sealers 11 Refinish as necessary 12 Install all related panels and LS N at components W DZ 1 10 2001 Pontiac Aztek 35MM Left Front Lower Rail Sectioning IMPORTANT If the damage exceeds the recommended area for sectioning and the rail cannot be straightened the complete rail must be replaced Sectioning procedures have been developed to simplify repair of the lower rails providing the majority of the damage can be returned to factory specifications This allows the damaged front section to be replaced without performing a full rail replacement The rails come as a complete assembly The front portion of the rail and bumper brackets are also serviced separately IMPORTANT Failure to follow the instructions included with the service rail may lead to improper rail sectioning which may compromise the structural integrity of the vehicle Removal of Damaged Left Fr
19. ine to cut Rear Floor Panel continued 1 38 2001 Pontiac Aztek Floor Panel Replacement Removal Procedure con t 7 Locate and drill out all factory welds Note the number and location of the welds for installation of the Rear Floor Panel 8 Remove the damaged Rear Floor Panel 2001 Pontiac Aztek 1 39 Floor Panel Replacement Installation Procedure IMPORTANT In any area damaged beyond recognition space plug weld holes every 40 mm 1 1 2 in apart 1 Drill 8 mm 5 16 in plug weld holes as necessary in locations noted from the original rear outer wheelhouse 2 Drill 8 mm 5 16 in plug weld holes at the forward edge of the rear floor panel 3 Prepare all attachment surfaces as necessary 4 Apply weld thru primer to all bare metal surfaces 5 Position the rear floor panel to overlap the mid floor panel Plug weld accordingly Drill 8 mm 5 16 in plug weld holes in the service part as necessary in locations noted from the original panel 8 Position right and left lower reinforcements to the rear body opening 9 Plug weld accordingly 1 40 2001 Pontiac Aztek Floor Panel Replacement Installation Procedure con t IMPORTANT Prior to refinishing refer to publication GM4901M D 01 GM Approved Refinish Materials for recommended products Do not combine paint systems Refer to paint manufacturer s recommendations 10 Clean
20. o the sectioning joint 2 Clamp and plug weld to the vehicle 9 Align the Rocker Panel using three dimensional measuring equipment 10 Plug weld accordingly 11 To create a solid weld with minimum heat distortion make 25 mm 1 in stitch welds along the seam with 25 mm 1 in gaps between them Then go back and complete the stitch weld IMPORTANT Prior to refinishing refer to publication GM4901M D 01 GM Approved Refinish Materials for recommended products Do not combine paint systems Refer to paint manufacturer s recommendations 12 Clean and prepare all welded surfaces 13 Apply the following as necessary e Anti corrosion materials e Sound deadeners 1 e Sealers 14 Refinish as necessay 15 Install all related panels and components 1 28 2001 Pontiac Aztek Roof Outer Replacement Removal Procedure 1 Remove all related panels and components 2 Restore as much of the damage as possible to factory specifications 3 Note the location and remove the following as necessary e Sealers e Sound deadeners e Anti corrosion materials IMPORTANT Do not damage any inner panels or reinforcements 4 Locate and drill out all factory welds Note the number and location of welds for installation of the roof panel 5 Remove the damaged roof panel 2001 Pontiac Aztek 1 29 Roof Outer Replacement Installation Procedure 1 Drill 8 mm 5 16 in plug weld holes as nece
21. ont Rail 1 On top of the rail locate the cut out square 1 From the front edge of the square measure forward 25 mm and scribe a line Add 10 mm and scribe a second line 1 The second line 35 mm is the cut location The additional 10 mm will be used to create a flange for welding the new service part to the vehicle 3 On the outboard side of the rail locate the brake line pass thru hole 1 At the larger hole pull the tape measure from the forward edge of the hole and mark a line at 392 mm Scribe a line with a straight edge making sure it is square to inboard and top rail markings 4 Measure forward 10 mm and scribe a second line The second line 402 mm is cut location continued 2001 Pontiac Aztek 1 11 Removal of Damaged Left Front Rail con t 5 Locate hole 1 on the inboard side of the rail Measure forward 140 mm 5 1 2 in and mark the location Scribe a straight line on the rail 6 Measure forward 10 mm 13 32 in and scribe a second line The second line 150 mm 5 29 32 in is the cut location 2 7 Make certain all three sides are lt aligned Cut through three sides of the rail 7 oC ao 8 On the bottom of the damaged rail Eg F Kiki aa scribe a line from the outboard to O56 the inboard cut locations and cut e the remainder of the rail 1 from L gt lt the vehicle 9 Remove the damaged section of rail L LEFT OUTBOARD 1 12 2001 Pontiac Az
22. r panel in corresponding locations to fit the remaining original panel The sectioning joint should be trimmed to allow a gap of one and one half times the metal thickness at the sectioning joint Create a 50 mm 2 in backing plate from the unused portion of the service part Trim the backing plate as necessary to fit behind the sectioning joint Drill 8 mm 5 16 in plug weld holes 1 along the sectioning cut on the remaining original part 2 IMPORTANT In any area damaged beyond recognition space plug weld holes every 40 mm 1 1 2 in apart Drill 8 mm 5 16 in plug weld holes in the service part as necessary in the locations noted from the original panel and along the sectioning cut Prepare all attachment surfaces as necessary IMPORTANT Prior to refinishing refer to publication GM4901M D 01 GM Approved Refinish Materials for recommended products Do not combine paint systems Refer to paint manufacturer s recommendations Apply weld thru primer to all bare metal surfaces continued 1 32 2001 Pontiac Aztek 1 1 1 esa i Z lt Quarter Panel Replacement Installation Procedure con t 7 Fit the backing plate halfway into the sectioning joint clamp and plug weld to the vehicle CAUTION THE FUEL FILLER OPENING MUST BE PROPERLY SEALED PRIOR TO POSITIONING THE QUARTER PANEL FAILURE TO PROPERLY SEAL THE QUARTER PANEL COULD RESULT IN EXHAUST GAS LEAKAGE INTO THE
23. rned flanges of the rail Cut 10 mm gaps along the corners of the original rail 2 Step the top bottom and side tabs inward 3 to allow the service part to fit over the original rail 3 Clean and prepare mating surfaces as necessary Installation Procedure 1 Position the service part over the original rail Align and check fit using three dimensional measuring equipment 2 Stitch weld along the entire sectioning joint Make 25 mm ay 1 in welds along the seam with 25 mm 1 in gaps between them 3 Go back and complete the stitch weld This will create a solid weld joint with minimal heat distortion 4 Clean and prepare all welded surfaces IMPORTANT Prior to refinishing refer to publication GM4901M D 01 GM Approved Refinish Materials for recommended products Do not combine paint systems Refer to paint manufacturer s recommendations 5 Prime with two part catalyzed primer 6 Apply sealers and anti corrosion materials as necessary 7 Install all related panels and components 2001 Pontiac Aztek 1 15 Door Frame Sectioning Outer Front Hinge Pillar Removal Procedure 1 Remove all related panels and components Restore as much of the damage as possible to factory specifications Note the location and remove the following as necessary e Anti corrosion materials e Sound deadeners 1 e Sealers IMPORTANT Do not damage any inner panels or reinforc
24. ry 7 Apply weld thru primer to all bare metal surfaces 8 Fit the backing plate 1 halfway into the sectioning joint 2 Clamp and plug weld to the vehicle 9 Align the Front Hinge Pillar using three dimensional measuring equipment 10 Plug weld accordingly 11 To create a solid weld with minimum heat distortion make 25 mm 1 in stitch welds along the seam with 25 mm 1 in gaps between them Then go back and complete the stitch weld IMPORTANT Prior to refinishing refer to publication GM 4901M D 01 GM Approved Refinish Materials for recommended products Do not combine paint systems Refer to paint manufacturer s recommendations 12 Clean and prepare all welded surfaces 13 Apply the following as necessary e Anti corrosion materials e Sound deadeners 1 e Sealers 14 Refinish as necessary 15 Install all related panels and components 1 18 2001 Pontiac Aztek Door Frame Sectioning Outer Center Pillar Removal Procedure 1 Remove all related panels and components 2 Restore as much of the damage as possible to factory specifications 3 Note the location and remove the following as necessary e Anti corrosion materials e Sound deadeners 1 e Sealers IMPORTANT Do not damage any inner panels or reinforcements 4 Cut the panel where sectioning is to be performed 5 Locate and drill out all factory welds Note the number and location of welds for inst
25. ssary in locations noted from the original panel IMPORTANT In any area damaged beyond recognition space plug weld holes every 40 mm 1 1 2 in apart Prepare all attachment surfaces as necessary Apply weld thru primer to all bare metal surfaces Position the roof panel Plug weld accordingly Clean and prepare all welded surfaces IMPORTANT Prior to refinishing refer to publication GM4901M D 00 GM Approved Refinish Materials for recommended products Do not combine paint systems Refer to paint manufacturer s recommendations Apply the following as necessary e An anti corrosion primer e Sound deadeners e Sealers Refinish as necessary Install all related panels and components 1 30 2001 Pontiac Aztek Quarter Panel Replacement Removal Procedure 1 Remove all related panels and components 2 Restore as much of the damage as possible to factory specifications 3 Note the location and remove the following as necessary e Sealers e Sound deadeners 1 e Anti corrosion materials IMPORTANT Do not damage any inner panels or reinforcements 4 Cut the quarter panel where sectioning is to be performed 1 5 Locate and drill out all factory welds Note the number and location of welds for installation of the service part 6 Remove the damaged quarter 2001 Pontiac Aztek 1 31 Quarter Panel Replacement Installation Procedure l Cut the replacement quarte
26. tek Left Front Lower Rail Sectioning Preparing Service Part for Installation 1 On original rail cut and remove 10 mm 13 32 in of the outboard 1 and downward 2 turned flanges of the rail Cut 10 mm 13 32 in gaps along the corners of the original rail 3 Step the top bottom and side tabs inward 4 to allow the service part to fit over the original rail Clean and prepare mating surfaces as necessary Installation Procedure l Position the service part over the original rail Align and check fit using three dimensional measuring equipment Stitch weld along the entire sectioning joint Make 25 mm 1 in welds along the seam with 25 mm 1 in gaps between them Go back and complete the stitch weld This will create a solid weld joint with minimal heat distortion Clean and prepare all welded surfaces IMPORTANT Prior to refinishing refer to publication GM4901M D 01 GM Approved Refinish Materials for recommended products Do not combine paint systems Refer to paint manufacturer s recommendations Prime with two part catalyzed primer Apply sealers and anti corrosion materials as necessary Install all related panels and components 2001 Pontiac Aztek 1 13 Right Front Lower Rail Sectioning Removal of Damaged Right Front Rail 1 On top of rail locate the last cut out square From the rear edge of the square 1 measure forward 8 mm 5 16 in and scri
27. ter Pillar using three dimensional measuring equipment 10 Plug weld accordingly 11 To create a solid weld with minimum heat distortion make 25 mm 1 in stitch welds along the seam with 25 mm 1 in gaps between them Then go back and complete the stitch weld IMPORTANT Prior to refinishing refer to publication GM 4901M D 01 GM Approved Refinish Materials for recommended products Do not combine paint systems Refer to paint manufacturer s recommendations 12 Clean and prepare all welded surfaces 13 Apply the following as necessary e Anti corrosion materials e Sound deadeners 1 e Sealers 14 Refinish as necessary 15 Install all related panels and components 2001 Pontiac Aztek 1 2 Door Frame Sectioning Outer Rear Lock Pillar Removal Procedure 1 Remove all related panels and components 2 Restore as much of the damage as possible to factory specifications 3 Note the location and remove the following as necessary e Anti corrosion materials e Sound deadeners 1 e Sealers IMPORTANT Do not damage any inner panels or reinforcements 4 Cut the panel where sectioning is to be performed 5 Locate and drill out all factory welds Note the number and location of welds for installation of the service part 6 Remove the damaged Rear Lock Pillar 1 22 2001 Pontiac Aztek Door Frame Sectioning Outer Rear Lock Pillar Installation Procedure 1 Cut th
28. weld accordingly 6 Clean and prepare all welded surfaces 7 Apply the following as necessary e Anti corrosion materials e Sound deadening materials e Sealers Refinish as necessary Install all related panels and components 1 8 2001 Pontiac Aztek Rail Sub Assembly Replacement Front Lower Removal Procedure l Remove all related panels and components Restore as much of the damage as possible to factory specifications Note the location and remove the following as necessary e Anti corrosion materials e Sound deadeners e Sealers Separate the floor pan reinforcement 1 weld flanges from the inside of the lower rail Care must be taken not to damage the weld flanges IMPORTANT Do not damage any inner panels or reinforcements Locate and drill out all factory welds Note the number and location of welds for installation of the Front Lower Rail 6 Remove the damaged rail 2001 Pontiac Aztek 1 9 Rail Sub Assembly Replacement Front Lower Installation Procedure l Prepare the mating surfaces of the floor pan reinforcement 1 a Turn the weld flanges outward 2 to be welded to the front lower rail Wo Drill 8 mm 5 16 in plug weld holes as necessary in locations noted from removal IMPORTANT In any area damaged beyond recognition space plug weld holes every 40 mm 1 1 2 in apart Drill 8 mm 5 16 in plug weld holes as necessary in locations noted
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