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2001
User Manual
51 pgs2.59 Mb0

Pontiac 2001 User Manual

2001 Pontiac Aztek
Radiator Support Replacement (Upper)
Removal Procedure
1. Remove all related panels and components including front fascia supports, right and left (1).
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3. Note the location and remove the following as necessary:
• Sealers
• Sound deadeners
• Anti-corrosion materials
2001 Pontiac Aztek
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
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 bare­metal 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:
• Anti-corrosion materials
• Sound deadeners
• Sealers
8. Refinish as necessary.
9. Install all related panels and components.
1-2 2001 Pontiac Aztek
Radiator Support Replacement (Lower)
Removal Procedure
1. Remove all related panels and components.
3. Note the location and remove the following as necessary:
• Sealers
• Sound deadeners
• 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
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 bare­metal surfaces.
4. Position the Lower Radiator Support.
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:
• Anti-corrosion materials
• Sound deadeners
• Sealers
8. Refinish as necessary.
9. Install all related panels and components.
1-4 2001 Pontiac Aztek
Rail Replacement (Upper)
Removal Procedure
1. Remove all related panels and components.
3. Note the location and remove the following as necessary:
• Anti-corrosion materials
• Sound deadeners
• 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
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 front upper rail.
2. Prepare all attachment surfaces as necessary.
3. Apply weld-thru primer to all bare­metal surfaces.
4. Position the Upper Rail.
5. 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.
6. Clean and prepare all welded surfaces.
7. Apply the following as necessary:
• Anti-corrosion materials
• Sound deadeners
• Sealers
8. Refinish as necessary.
9. Install all related panels and components.
1-6 2001 Pontiac Aztek
Wheelhouse
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Replacement (Front)
Removal Procedure
1. Remove all related panels and components in the area of the damaged apron extension (1).
3. Note the location and remove the following as necessary:
• Anti-corrosion materials
• Sound deadeners
• 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 GM4901M­D-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 weld accordingly.
6. Clean and prepare all welded surfaces.
7. Apply the following as necessary:
• Anti-corrosion materials
• Sound deadening materials
• Sealers
8. Refinish as necessary.
9. Install all related panels and components.
1-8 2001 Pontiac Aztek
Rail Sub-Assembly Replacement (Front Lower)
Removal Procedure
1. Remove all related panels and components.
3. Note the location and remove the following as necessary:
• Anti-corrosion materials
• Sound deadeners
• Sealers
4. 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.
5. Locate and drill out all factory welds. Note the number and location of welds for installation of the Front Lower Rail.
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6. Remove the damaged rail.
2001 Pontiac Aztek 1-9
Rail Sub-Assembly Replacement (Front Lower)
Installation Procedure
1. Prepare the mating surfaces of the floor pan reinforcement (1).
2. Turn the weld flanges outward (2) to be welded to the front lower rail.
3. 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.
4. Drill 8 mm (5/16 in.) plug weld holes as necessary in locations noted from the original panel.
5. Prepare all attachment surfaces as necessary.
6. Apply weld-thru primer to all bare­metal surfaces.
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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 :
• Anti-corrosion materials
• Sound deadeners
• Sealers
11. Refinish as necessary.
12. Install all related panels and components.
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 Front Rail
1. On top of the rail, locate the cut-out
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square (1). From the front edge of the square, measure forward 25 mm and scribe a line.
2. 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.
402MM
3. On the outboard side of the rail,
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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).
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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.
9. Remove the damaged section of rail.
150MM
2
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(LEFT OUTBOARD)
1-12 2001 Pontiac Aztek
Left Front Lower Rail Sectioning
Preparing Service Part for Installation
1. On original rail, cut and remove 10
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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).
2. Step the top, bottom and side tabs inward (4) 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 (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 1-13
Right Front Lower Rail Sectioning
Removal of Damaged Right Front Rail
1. On top of rail, locate the last cut­out square. From the rear edge of the square (1), measure forward 8 mm (5/16 in.) and scribe 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.
18MM
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2
160MM
160MM
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.
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386MM
1
(RIGHT OUTBOARD)
1-14 2001 Pontiac Aztek
Right Front Lower Rail Sectioning
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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) turned flanges of the rail. Cut 10 mm gaps along the corners of the original rail.
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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 (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.
3. Note the location and remove the following as necessary:
• Anti-corrosion materials
• Sound deadeners (1)
• 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 Front Hinge Pillar.
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1-16 2001 Pontiac Aztek
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