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Pontiac 2001 manual

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Table of contents for the manual

  • Page 1

    2001 Pontiac Aztek 1-1 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: • Sealers • Sound deadeners • Anti-co[...]

  • Page 2

    1-2 2001 Pontiac Aztek 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[...]

  • Page 3

    2001 Pontiac Aztek 1-3 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[...]

  • Page 4

    1-4 2001 Pontiac Aztek 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[...]

  • Page 5

    2001 Pontiac Aztek 1-5 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 r[...]

  • Page 6

    1-6 2001 Pontiac Aztek 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-thr[...]

  • Page 7

    2001 Pontiac Aztek 1-7 Wheelhouse Replacement (Fr ont) 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 • [...]

  • Page 8

    1-8 2001 Pontiac Aztek Wheelhouse Replacement (Fr ont) 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[...]

  • Page 9

    2001 Pontiac Aztek 1-9 Rail Sub-Assembly Replacement (Fr ont 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 [...]

  • Page 10

    1-10 2001 Pontiac Aztek Rail Sub-Assembly Replacement (Fr ont 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 damage[...]

  • Page 11

    2001 Pontiac Aztek 1-11 Left Fr ont 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 speci[...]

  • Page 12

    1-12 2001 Pontiac Aztek 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 c[...]

  • Page 13

    2001 Pontiac Aztek 1-13 Left Fr ont 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). 2. Step the top, bottom and side tabs inward (4) to allow the [...]

  • Page 14

    1-14 2001 Pontiac Aztek Right Fr ont 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 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 [...]

  • Page 15

    2001 Pontiac Aztek 1-15 Right Fr ont 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) turned 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 servic[...]

  • Page 16

    1-16 2001 Pontiac Aztek Door Fr ame Sectioning—Outer (Fr ont 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[...]

  • Page 17

    2001 Pontiac Aztek 1-17 Door Fr ame Sectioning—Outer (Fr ont 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[...]

  • Page 18

    1-18 2001 Pontiac Aztek 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 n[...]

  • Page 19

    2001 Pontiac Aztek 1-19 Door Fr ame 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: • Anti-corrosion materials • Sound deadeners (1) • Sealers IMPORTANT: Do not d[...]

  • Page 20

    1-20 2001 Pontiac Aztek Door Fr ame 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, c[...]

  • Page 21

    2001 Pontiac Aztek 1-21 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 necess[...]

  • Page 22

    1-22 2001 Pontiac Aztek Door Fr ame 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 no[...]

  • Page 23

    2001 Pontiac Aztek 1-23 Door Fr ame Sectioning—Outer (Rear Lock Pillar) 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 [...]

  • Page 24

    1-24 2001 Pontiac Aztek 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 nece[...]

  • Page 25

    2001 Pontiac Aztek 1-25 Door Fr ame 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: • Anti-corrosion materials • Sound deadeners (1) • Sealers 4. By measuring[...]

  • Page 26

    1-26 2001 Pontiac Aztek 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.[...]

  • Page 27

    2001 Pontiac Aztek 1-27 Door Fr ame 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. In the Rear Lock Pil[...]

  • Page 28

    1-28 2001 Pontiac Aztek 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 into the sectioning joint (2). Clamp and plug weld to the vehicle. 9. Align the Rocker Panel using th[...]

  • Page 29

    2001 Pontiac Aztek 1-29 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 re[...]

  • Page 30

    1-30 2001 Pontiac Aztek 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 [...]

  • Page 31

    2001 Pontiac Aztek 1-31 Quarter P anel 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 (1) • Anti-corrosion materials IMPORTANT: Do not damage any inner pane[...]

  • Page 32

    1-32 2001 Pontiac Aztek Quarter P anel 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 u[...]

  • Page 33

    2001 Pontiac Aztek 1-33 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 LE[...]

  • Page 34

    1-34 2001 Pontiac Aztek 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 materia[...]

  • Page 35

    2001 Pontiac Aztek 1-35 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 [...]

  • Page 36

    1-36 2001 Pontiac Aztek 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.) apar[...]

  • Page 37

    2001 Pontiac Aztek 1-37 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[...]

  • Page 38

    1-38 2001 Pontiac Aztek Floor P anel 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 [...]

  • Page 39

    2001 Pontiac Aztek 1-39 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.[...]

  • Page 40

    1-40 2001 Pontiac Aztek Floor P anel 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[...]

  • Page 41

    2001 Pontiac Aztek 1-41 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[...]

  • Page 42

    1-42 2001 Pontiac Aztek P anel 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 pan[...]

  • Page 43

    2001 Pontiac Aztek 1-43 P anel 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. [...]

  • Page 44

    1-44 2001 Pontiac Aztek 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[...]

  • Page 45

    2001 Pontiac Aztek 1-45 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[...]

  • Page 46

    1-46 2001 Pontiac Aztek Aztek Plastic P anel Identification 2 3 3 1 1 1 1 1 1 1 1 1. TPO (Thermoplastic Olefin) 2. Xenoy 3. Polypropylene Energy Foam[...]

  • Page 47

    2001 Pontiac Aztek 1-47 Aztek Metal P anel Identification 1 2 2 2 1 1 1 1 1 3 1 1 1. TSGS (T wo Sided Galvanized Steel) 2. UHSS (Ultra High Strength Steel) 3. AL (Aluminum)[...]

  • Page 48

    1-48 2001 Pontiac Aztek 1058 1052 1 163 1456 982 994 944 1081 HEIGHT DA TUM LINE WIDTH LENGTH Ø U V W X Y Z Ø C L T 91 18 1 139 1 122 1 164 2100 744 111 7 1 130 970 768 807 808 801 807 807 789 1 136 Body Dimensions Point-to-Point Body Side[...]

  • Page 49

    2001 Pontiac Aztek 1-49 S N O P Q R Ø C L C L WIDTH DA TUM LINE WIDTH HEIGHT LENGTH Ø 355 716 687 747 740 355 716 687 747 740 925 1038 1019 852 470 433 206 1028 1 159 1181 Body Dimensions Engine Compartment[...]

  • Page 50

    1-50 2001 Pontiac Aztek D C L Ø DA TUM LINE DRIVER SIDE HEIGHT WIDTH WIDTH LENGTH Ø C L A B C E F G H I J K L M 450 542 538 259 470 450 432 432 432 432 432 432 432 432 432 432 432 432 450 474 474 470 259 538 542 450 663 584 580 419 1 105 953 845 41 1 41 1 11 3 175 415 406 1071 1425 1928 2555 2801 3062 462 504 528 567 571 653 Body Measur ements Un[...]

  • Page 51

    2001 Pontiac Aztek 1-51 905 905 Fr ame Dimensions Point-to-Point[...]