Instruction/ maintenance manual of the product 2001 Pontiac
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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).
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 Com.
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 47.
2001 Pontiac Aztek 1-51 905 905 Fr ame Dimensions Point-to-Point.
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If you have not bought Pontiac 2001 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Pontiac 2001 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Pontiac 2001 you will learn all the available features of the product, as well as information on its operation. The information that you get Pontiac 2001 will certainly help you make a decision on the purchase.
If you already are a holder of Pontiac 2001, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Pontiac 2001.
However, one of the most important roles played by the user manual is to help in solving problems with Pontiac 2001. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Pontiac 2001 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
