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).

2. Restore as much of the damage as
possible to factory specifications.

1

1

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.

2. Restore as much of the damage as
possible to factory specifications.

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.

2. Restore as much of the damage as
possible to factory specifications.

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

1

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:

• 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.

2. Restore as much of the damage as
possible to factory specifications.

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.

1

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.

2

1

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

1

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,

1

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).

1

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

1

(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

3

1

4

2

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

1

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.

1

386MM

1

(RIGHT OUTBOARD)

1-14 2001 Pontiac Aztek

Right Front Lower
Rail Sectioning

1

3

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.

4

2

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.

2. Restore as much of the damage as
possible to factory specifications.

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.

1

1

1-16 2001 Pontiac Aztek

Door Frame
Sectioning—Outer

1

(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

1

2

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

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
necessary.

7. Apply weld-thru primer to all bare­metal 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-D­01 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.

25MM

(1/2 IN)

2

1

13. Apply the following as necessary:

• Anti-corrosion materials

• Sound deadeners (1)

• Sealers

14. Refinish as necessary.

15. Install all related panels and
components.

1-18 2001 Pontiac Aztek

1

1

Door Frame
Sectioning—Outer
(Center Pillar)

Removal Procedure

1. Remove all related panels and
components.

1

1

2. Restore as much of the damage as
possible to factory specifications.

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 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.

1

1

2

2

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

25MM

(1 IN)

2

1

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 bare­metal 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 three­dimensional measuring equipment.

10. Plug weld accordingly.

100mm

(4 IN)

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-D­01 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:

• Anti-corrosion materials

• Sound deadeners (1)

• Sealers

14. Refinish as necessary.

1

15. Install all related panels and
components.

1

2001 Pontiac Aztek 1-21

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:

• 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.

1

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 Rear Lock
Pillar.

1-22 2001 Pontiac Aztek

Door Frame
Sectioning—Outer
(Rear Lock Pillar)

1

1

2

Installation Procedure

1. Cut the 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 bare­metal 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 three­dimensional measuring equipment.

10. Plug weld accordingly.

25MM

(1 IN)

2

1

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:

• Anti-corrosion materials

• Sound deadeners (1)

• Sealers

14. Refinish as necessary.

15. Install all related panels and
components.

100mm

(4 IN)

1

1-24 2001 Pontiac Aztek

1

Door Frame
Sectioning—Outer
(Rocker Sectioning)

Removal Procedure

1. Remove all related panels and
components.

1

1

1

1

30mm

(1 3/16 IN)

2

30mm

(1 3/16 IN)

2. Restore as much of the damage as
possible to factory specifications.

3. Note the location and remove the
following as necessary:

• Anti-corrosion materials

• Sound deadeners (1)

• 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 factory
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

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

1

1

2

1

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. 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 bare­metal surfaces.

8. Fit the backing plate (1) halfway
into the sectioning joint (2). Clamp
and plug weld to the vehicle.

9. Align the Rocker Panel using three­dimensional 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.

2

25MM

(1 IN)

1

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:

• Anti-corrosion materials

• Sound deadeners (1)

• Sealers

14. Refinish as necessay.

15. Install all related panels and
components.

1

1

1

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:

• 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 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 necessary 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.

2. Prepare all attachment surfaces as
necessary.

3. Apply weld-thru primer to all bare­metal surfaces.

4. Position the roof panel.

5. Plug weld accordingly.

6. 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.

7. Apply the following as necessary:

• An anti-corrosion primer

• Sound deadeners

• Sealers

8. Refinish as necessary.

9. 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.

1

1

1

1

3. Note the location and remove the
following as necessary:

• Sealers

• Sound deadeners (1)

• 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

2

Replacement

Installation Procedure

1. Cut the replacement quarter 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.

2. 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.

3. 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.

4. 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.

5. 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.

6. Apply weld-thru primer to all bare­metal surfaces.

—continued

50MM
(2 IN)

1

25MM
(1 IN)

50MM
(2 IN)

1-32 2001 Pontiac Aztek

Quarter Panel Replacement
Installation Procedure con't

7. Fit the backing plate halfway into
the sectioning joint, clamp and plug
weld to the vehicle.

1

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
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:

• Anti-corrosion materials

• Sound deadeners

• 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:

• Anti-corrosion materials

• Sound deadeners

• 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 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

5mm

(0.25 in)

5mm

(0.25 in)

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.

2. Cut the rear rail service part.

3. 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).

1

1

2

1

2

4. Cut 5 mm (1/4 in.) wide gaps in the
bottom corners (2).

5. 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.

6. 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 bare­metal surfaces.

11. Align the service part over the
stepped tab using three-dimensional
measuring equipment.

2

1

12. Plug weld accordingly.

1-36 2001 Pontiac Aztek

—continued

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.

15. Apply the following as necessary:

• Anti-corrosion materials

• Sound deadeners

• 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.

2. Restore as much of the damage as
possible to factory specifications.

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 rear body opening right and left
lower reinforcements, gaining access
to the rear floor panel.

5. Locate Rear Floor Panel to mid­floor overlay seam.

6. Cut rearward of the mid-floor. Use a
straight line 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 bare­metal surfaces.

5. Position the rear floor panel to
overlap the mid-floor panel.

6. Plug weld accordingly.

7. 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 and prepare all welded
surfaces

11. Apply the following as necessary:

• Anti-corrosion materials

• Sound deadeners

• Sealers

12. Refinish as necessary.

13. Install all related panels and
components.

2001 Pontiac Aztek 1-41

Panel Replacement
– Rear End

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:

• 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 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 bare­metal surfaces.

4. Position the Rear End Panel.

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.

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.

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. 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.

5. Note the number and location of
welds for installation of the Rear
Outer Wheelhouse.

1

6. Remove the damaged Rear Outer
Wheelhouse.

1-44 2001 Pontiac Aztek

Wheelhouse
Replacement –
Rear Outer

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. Prepare all attachment surfaces as
necessary.

3. Apply weld-thru primer to all bare­metal surfaces.

4. Position the Rear Outer
Wheelhouse.

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:

1

1

• Anti-corrosion materials

• Sound deadeners (1)

• Sealers

8. Refinish as necessary.

9. Install all related panels and
components.

2001 Pontiac Aztek 1-45

Aztek Plastic Panel Identification

1

1

3

2

1

3

1

1

1

1

1

1. TPO (Thermoplastic Olefin)

2. Xenoy

3. Polypropylene Energy Foam

1-46 2001 Pontiac Aztek

Aztek Metal Panel Identification

1

1

1

1

3

2

2

1

1

2

1

1. TSGS (Two Sided Galvanized Steel)

2. UHSS (Ultra High Strength Steel)

3. AL (Aluminum)

1

2001 Pontiac Aztek 1-47

Body Dimensions

WIDTH

1058

1052

1163

1456

1081

982

Point-to-Point

Ø

789

807

807
801

808

994

944

807

HEIGHT

C

L

LENGTH

1-48 2001 Pontiac Aztek

970

1117

744

1130

91

U

18

1139
1122

T

Ø

V

W

X

1164

2100

Body Side

768

1136

Y

Z

DATUM

LINE

Body Dimensions

C

L

WIDTH

WIDTH

355 716 687 747 740

355 716 687 747 740

Ø

C

L

HEIGHT

LENGTH

925

N

1038

O

852

1019

1028

1159 1181

P

R

433

Q

470

Engine Compartment

206

DATUM

LINE

S

Ø

2001 Pontiac Aztek 1-49

Body Measurements

DRIVER SIDE

Ø

WIDTH

C

L

WIDTH

HEIGHT

LENGTH

450

450

663

A

542 538

584

B

1105

538542

580

C

953

845

259

259

419

470

470

411

113

E

175

474
474

411

406

450

450

415

432 432 432

432432432

462 504 528 567

432 432 432

432 432 432

653

571

C

L

DATUM

LINE

F

G

1071

1425

H

1928

I

2555

J

K

2801

3062

L

M

1-50 2001 Pontiac Aztek

D

Ø

Underbody

Frame Dimensions

905

905

Point-to-Point

2001 Pontiac Aztek 1-51