aztek body panel complete manual

2001 Pontiac Aztek 1-1

Radiator SupportReplacement(Upper)Removal Procedure1. Remove all related panels and

components including front fasciasupports, right and left (1).

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

3. Note the location and remove thefollowing as necessary:

• Sealers

• Sound deadeners

• Anti-corrosion materials

IMPORTANT: Do not damage anyinner panels or reinforcements.

4. Locate and drill out all factorywelds. Note the number andlocation of welds for installation ofthe Radiator Support Assembly.

5. Remove the damaged RadiatorSupport Assembly.

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2001

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2001 Pontiac Aztek

1-2 2001 Pontiac Aztek

Radiator SupportReplacement(Upper)Installation Procedure

IMPORTANT: In any area damagedbeyond recognition, space plug weldholes every 40 mm (1-1/2 in) apart.

1. Drill 8 mm (5/16 in) plug weldholes as necessary in locationsnoted from the original panel.

2. Prepare all attachment surfaces asnecessary.

3. Apply weld-thru primer to all bare-metal surfaces.

4. Position the Radiator SupportAssembly.

5. Plug weld accordingly.

6. Clean and prepare all weldedsurfaces.

IMPORTANT: Prior to refinishing,refer to publication GM4901M-D-01GM Approved Refinish Materials forrecommended products. Do notcombine paint systems. Refer topaint manufacturer’srecommendations.

7. Apply the following as necessary:


• Sound deadeners

• Sealers

8. Refinish as necessary.

9. Install all related panels andcomponents.


Radiator SupportReplacement(Lower)Removal Procedure1. Remove all related panels and

components.



• Sealers

• Sound deadeners



4. Locate and drill out all factorywelds. Note the number andlocation of welds for installation ofthe Lower Radiator Support.

5. Remove the damaged LowerRadiator Support.


Radiator SupportReplacement(Lower)Installation Procedure


1. Drill 8 mm (5/16 in) plug weldholes as necessary in locationsnoted from the original panel.



4. Position the Lower RadiatorSupport.






• Sound deadeners

• Sealers




Rail Replacement(Upper)Removal Procedure1. Remove all related panels and

components.




• Sound deadeners

• Sealers


4. Locate and drill out all factorywelds. Note the number andlocation of welds for installation ofthe Front Upper Rail.

5. Remove the damaged Front UpperRail.


Rail Replacement(Upper)Installation Procedure


1. Drill 8 mm (5/16 in. ) plug weldholes as necessary in locationsnoted from the original front upperrail.



4. Position the Upper Rail.






• Sound deadeners

• Sealers




WheelhouseReplacement(Front)Removal Procedure1. Remove all related panels and

components in the area of thedamaged apron extension (1).




• Sound deadeners

• Sealers


4. Locate and drill out all factorywelds. Note the number andlocation of welds for installation ofthe service part.

5. Remove the damaged apronextension.

1


WheelhouseReplacement(Front)Installation Procedure


1. Drill 8 mm (5/16 in.) plug weldholes in the service part asnecessary in the locations notedfrom the original panel.


IMPORTANT: Prior to refinishing,refer to the publication GM4901M-D-01 GM Approved RefinishMaterials for recommendedproducts. Do not combine paintsystems. Refer to paintmanufacturer’s recommendations.

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

4. Position the apron extension.





• Sound deadening materials

• Sealers




Rail Sub-AssemblyReplacement (FrontLower)Removal Procedure1. Remove all related panels and

components.




• Sound deadeners

• Sealers

4. Separate the floor panreinforcement (1) weld flanges fromthe inside of the lower rail. Caremust be taken not to damage theweld flanges.


5. Locate and drill out all factorywelds. Note the number andlocation of welds for installation ofthe Front Lower Rail.

6. Remove the damaged rail.

1


Rail Sub-AssemblyReplacement (FrontLower)Installation Procedure

1. Prepare the mating surfaces of thefloor 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 weldholes as necessary in locationsnoted from removal.

IMPORTANT: In any area damagedbeyond recognition, space plug weldholes every 40 mm (1-1/2 in.) apart.

4. Drill 8 mm (5/16 in.) plug weldholes as necessary in locationsnoted from the original panel.



7. Position the service part




10. Apply the following as necessary :


• Sound deadeners

• Sealers



1

2


Left Front LowerRail SectioningIMPORTANT: If the damage exceeds therecommended area for sectioning and therail cannot be straightened, the completerail must be replaced.

Sectioning procedures have beendeveloped to simplify repair of the lowerrails, providing the majority of thedamage can be returned to factoryspecifications. This allows the damagedfront section to be replaced withoutperforming a full rail replacement. Therails come as a complete assembly. Thefront portion of the rail and bumperbrackets are also serviced separately.IMPORTANT: Failure to follow theinstructions included with the service railmay lead to improper rail sectioning,which may compromise the structuralintegrity of the vehicle.

Removal of DamagedLeft Front Rail1. On top of the rail, locate the cut-out

square (1). From the front edge ofthe square, measure forward 25 mmand scribe a line.

2. Add 10 mm and scribe a second line(1). The second line (35 mm) is thecut location. The additional 10 mmwill be used to create a flange forwelding the new service part to thevehicle.

3. On the outboard side of the rail,locate the brake line pass-thru hole(1). At the larger hole, pull the tapemeasure from the forward edge ofthe hole and mark a line at 392mm. Scribe a line with a straightedge, making sure it is square toinboard and top rail markings.

4. Measure forward 10 mm and scribea second line. The second line (402mm) is cut location.

—continued

35MM1

1

402MM


Removal of DamagedLeft Front Rail con’t5. Locate hole (1), on the inboard side

of the rail. Measure forward 140mm (5-1/2 in.) and mark thelocation. Scribe a straight line onthe rail.

6. Measure forward 10 mm (13/32 in.)and scribe a second line. Thesecond line [150 mm (5-29/32 in.)]is the cut location (2).

7. Make certain all three sides arealigned. Cut through three sides ofthe rail.

8. On the bottom of the damaged rail,scribe a line from the outboard tothe inboard cut locations and cutthe remainder of the rail (1) fromthe vehicle.

9. Remove the damaged section of rail.

150MM

1

2

1

(LEFT OUTBOARD)


Left Front LowerRail SectioningPreparing Service Part forInstallation1. On original rail, cut and remove 10

mm (13/32 in.) of the outboard (1)and downward (2) turned flanges ofthe rail. Cut 10 mm (13/32 in.)gaps along the corners of theoriginal rail (3).

2. Step the top, bottom and side tabsinward (4) to allow the service partto fit over the original rail.

3. Clean and prepare mating surfacesas necessary.

Installation Procedure1. Position the service part over the

original rail. Align and check fitusing three-dimensional measuringequipment.

2. Stitch weld along the entiresectioning joint. Make 25 mm (1in.) welds along the seam with 25mm (1 in.) gaps between them.

3. Go back and complete the stitchweld. This will create a solid weldjoint with minimal heat distortion.



5. Prime with two-part catalyzedprimer.

6. Apply sealers and anti-corrosionmaterials as necessary.


1

2

4

3


Right Front LowerRail SectioningRemoval of DamagedRight Front Rail1. On top of rail, locate the last cut-

out square. From the rear edge ofthe square (1), measure forward 8mm (5/16 in.) and scribe a line.

2. Add 10 mm and scribe a secondline. The second line is the cutlocation. The additional 10 mm(13/32 in.) will be used to create aflange for welding the new servicepart to the vehicle.

3. On the outboard side of the rail,locate the fixturing hole (2).Measure forward 150 mm (5-29/32in.) and mark location. Scribe astraight line on the rail.

4. Measure forward 10 mm (13/32 in.)and scribe a second line. Thesecond line [160 mm (6-5/16 in.)] isthe cut location.

5. On the inboard side of the rail,locate the brake line pass-thru hole(1). At the larger hole, pull the tapemeasure from the forward edge ofthe hole and mark a line at 376mm. Scribe a line with a straightedge, making sure it is square toinboard and top rail markings.

6. Measure forward 10 mm and scribea second line. The second line (386mm) is the cut location.

7. Make certain all three sides arealigned. Cut through three sides ofthe rail.

8. On the bottom of the damaged rail,scribe a line from the outboard tothe inboard cut locations and cutthe remainder of the rail (1) fromthe vehicle. Remove the damagedsection of rail.

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2

160MM

18MM

160MM

1

(RIGHT OUTBOARD)

386MM

1


Right Front LowerRail SectioningPreparing the UndamagedPortion of the Rail forInstallation1. On original rail, cut and remove 10

mm of the outboard (1) anddownward (2) turned flanges of therail. Cut 10 mm gaps along thecorners of the original rail.

2. Step the top, bottom and side tabsinward (3) to allow the service partto fit over the original rail.

3. Clean and prepare mating surfacesas necessary.

Installation Procedure

1. Position the service part over theoriginal rail. Align and check fitusing three-dimensional measuringequipment.

2. Stitch weld along the entiresectioning joint. Make 25 mm(1␣ in.) welds along the seam with 25mm (1 in.) gaps between them.

3. Go back and complete the stitchweld. This will create a solid weldjoint with minimal heat distortion.



5. Prime with two-part catalyzedprimer.

6. Apply sealers and anti-corrosionmaterials as necessary.


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2

4

3


Door FrameSectioning—Outer(Front Hinge Pillar)Removal Procedure1. Remove all related panels and

components.




• Sound deadeners (1)

• Sealers


4. Cut the panel where sectioning is tobe performed.


6. Remove the damaged Front HingePillar.

1

1


Door FrameSectioning—Outer(Front Hinge Pillar)Installation Procedure1. Cut the replacement service part in

corresponding locations to fit theremaining original panel. Thesectioning joint should be trimmedto allow a gap of one-and-one-halftimes the metal (1) thickness at thesectioning joint.

2. In the Front Hinge Pillar, create a50 mm (2 in.) backing plate (1)from the unused portion of theDoor Frame Opening. Trim thebacking plate as necessary to fitbehind the sectioning joint.

3. In the rocker locations, create a 100mm (4 in.) backing plate (2) fromthe unused portion of the doorframe opening. Trim the backingplate as necessary to fit behind thesectioning joint.

4. Drill 8 mm (5/16 in.) plug weldholes along the sectioning cut onthe remaining original part

—continued

1

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2


Door Frame Sectioning—Outer(Front Hinge Pillar)Installation Procedure con't





8. Fit the backing plate (1) halfwayinto the sectioning joint (2). Clampand plug weld to the vehicle.

9. Align the Front Hinge Pillar usingthree-dimensional measuringequipment.


11. To create a solid weld withminimum heat distortion, make 25mm (1 in.) stitch welds along theseam with 25 mm (1 in.) gapsbetween them. Then go back andcomplete the stitch weld.

IMPORTANT: Prior to refinishing,refer to publication GM 4901M-D-01 GM Approved Refinish Materialsfor recommended products. Do notcombine paint systems. Refer topaint manufacturer’srecommendations.





• Sealers



25MM(1/2 IN)

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2

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1


Door FrameSectioning—Outer(Center Pillar)Removal Procedure1. Remove all related panels and

components.





• Sealers




6. Remove the damaged Center Pillar.

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1


Door FrameSectioning—Outer(Center Pillar)Installation Procedure1. Cut the replacement Center Pillar

in corresponding locations to fit theremaining original panel. Thesectioning joint should be trimmedto allow a gap of one-and-one-halftimes the metal (1) thickness at thesectioning joint.

2. In the Center Pillar, create a 50 mm(2 in.) backing plate (1) from theunused portion of the Door FrameOpening. Trim the backing plate asnecessary to fit behind thesectioning joint.

3. In the rocker locations, create a 100mm (4 in.) backing plate (2) fromthe unused portion of the doorframe opening. Trim the backingplate as necessary to fit behind thesectioning joint.

4. Drill 8 mm (5/16 in.) plug weldholes along the sectioning cut onthe remaining original part.

—continued

1

1

2

2


Door Frame Sectioning—Outer(Center Pillar)Installation Procedure con't





8. Fit the backing plate (1) halfwayinto the sectioning joint (2) clampand plug weld to the vehicle.

9. Align the Center Pillar using three-dimensional measuring equipment.


11. To create a solid weld withminimum heat distortion, make 25mm (1 in.) stitch welds along theseam with 25 mm (1 in.) gapsbetween them. Then go back andcomplete the stitch weld

IMPORTANT: Prior to refinishing,refer to publication GM 4901M-D-01 GM Approved Refinish Materialsfor recommended products. Do notcombine paint systems. Refer topaint manufacturer’srecommendations.





• Sealers



25MM(1 IN)

1

2

100mm(4 IN)

1

1


Door FrameSectioning—Outer(Rear Lock Pillar)Removal Procedure1. Remove all related panels and

components.





• Sealers




6. Remove the damaged Rear LockPillar.

1

1


Door FrameSectioning—Outer(Rear Lock Pillar)Installation Procedure1. Cut the replacement Rear Lock

Pillar in corresponding locations tofit the remaining original panel. Thesectioning joint should be trimmedto allow a gap of one-and-one-halftimes the metal (1) thickness at thesectioning joint.

2. In the Rear Lock Pillar, create a 50mm (2 in.) backing plate (1) fromthe unused portion of the DoorFrame Opening. Trim the backingplate as necessary to fit behind thesectioning joint.

3. In the rocker locations, create a 100mm (4 in.) backing plate (2) theunused portion of the door frameopening. Trim the backing plate asnecessary to fit behind thesectioning joint.


—continued

1

1

2


Door Frame Sectioning—Outer(Rear Lock Pillar)Installation Procedure con't

IMPORTANT: In any area damagedbeyond recognition, space plug weldholes every 40 mm (1-1/2in.) apart.




8. Fit the backing plate (1) halfwayinto the sectioning joint (2) clampand plug weld to the vehicle.

9. Align the Center Pillar using three-dimensional measuring equipment.








• Sealers



25MM(1 IN)

1

2

100mm(4 IN)

1

1


Door FrameSectioning—Outer(Rocker Sectioning)Removal Procedure1. Remove all related panels and

components.





• Sealers

4. By measuring from the lower edgeof the guide hole (1) downward 30mm (1-3/16 in.), locate and markfor sectioning of the Front HingePillar and the Center Pillar.

5. With quarter panel removed (2),locate and mark for sectioning ofthe Rear Lock Pillar.

6. Scribe a line horizontally to therocker.



—continued

1

1

1

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2

30mm(1 3/16 IN)

30mm(1 3/16 IN)


Door Frame Sectioning—Outer(Rocker Sectioning)Removal Procedure con't8. Locate and drill out all factory

welds. Note the number andlocation of welds for installation ofthe Rocker Panel.

9. Remove the damaged Rocker Panel.


Door FrameSectioning—Outer(Rocker Sectioning)Installation Procedure1. Cut the replacement service part in

corresponding locations to fit theremaining original panel. Thesectioning joint should be trimmedto allow a gap of one-and-one-halftimes the metal (1) thickness at thesectioning joint.

2. In the Rear Lock Pillar, create a 50mm (2 in.) backing plate (1) fromthe unused portion of the DoorFrame Opening. Trim the backingplate as necessary to fit behind thesectioning joint.

3. Use the lower hinge reinforcement(2) as the backing plate in the frontHinge Pillar and the Center HingePillar.


IMPORTANT: In any area damagedbeyond recognition, space plug weldholes every 40 mm (1 in.) apart.

5. Drill 8 mm (5/16 in.) plug weldholes as necessary in locationsnoted from the original panel andalong the sectioning cut.

—continued

1

1

21


Door Frame Sectioning—Outer(Rocker Sectioning)Installation Procedure con't6. Prepare all attachment surfaces as

necessary.


8. Fit the backing plate (1) halfwayinto the sectioning joint (2). Clampand plug weld to the vehicle.

9. Align the Rocker Panel using three-dimensional measuring equipment.








• Sealers

14. Refinish as necessay.


25MM(1 IN)

1

2

1

1

1


Roof OuterReplacementRemoval Procedure1. Remove all related panels and

components.



• Sealers

• Sound deadeners



4. Locate and drill out all factorywelds. Note the number andlocation of welds for installation ofthe roof panel.

5. Remove the damaged roof panel.


Roof OuterReplacementInstallation Procedure1. Drill 8 mm (5/16 in.) plug weld

holes as necessary in locationsnoted from the original panel.




4. Position the roof panel.





• An anti-corrosion primer

• Sound deadeners

• Sealers




Quarter PanelReplacementRemoval Procedure1. Remove all related panels and

components.



• Sealers




4. Cut the quarter panel wheresectioning is to be performed (1).


6. Remove the damaged quarter.

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1

1 1


Quarter PanelReplacementInstallation Procedure1. Cut the replacement quarter panel

in corresponding locations to fit theremaining original panel. Thesectioning joint should be trimmedto allow a gap of one-and-one-halftimes the metal thickness at thesectioning joint.

2. Create a 50 mm (2 in.) backingplate from the unused portion of theservice part Trim the backing plateas necessary to fit behind thesectioning joint.

3. Drill 8 mm (5/16 in.) plug weldholes (1) along the sectioning cuton the remaining original part (2).


4. Drill 8 mm (5/16 in.) plug weldholes in the service part asnecessary in the locations notedfrom the original panel and alongthe sectioning cut.




—continued

50MM(2 IN)

50MM(2 IN)

25MM(1 IN)

1

2


Quarter Panel ReplacementInstallation Procedure con't7. Fit the backing plate halfway into

the sectioning joint, clamp and plugweld to the vehicle.

CAUTION: THE FUEL FILLEROPENING MUST BE PROPERLYSEALED PRIOR TOPOSITIONING THE QUARTERPANEL. FAILURE TO PROPERLYSEAL THE QUARTER PANELCOULD RESULT IN EXHAUSTGAS LEAKAGE INTO THEINTERIOR OF THE VEHICLE,CAUSING PERSONAL INJURY.

8. Install GM P/N 12399117 SealingStrip between outer wheelhouse andquarter panel gas door pocket.

9. Install service quarter panel leavinga gap of one and one half times thethickness of the metal (1) at thesectioning joint.






• Sound deadeners

• Sealers



1


Rail Sectioning—RearRemoval Procedure

IMPORTANT: Rear rail sectioning mayrequire replacement of the rear floor panel.

1. Remove all related panels andcomponents.




• Sound deadeners

• Sealers


4. Perform the necessary procedures togain access to the rear rail.

5. Locate and drill out all factory welds.Note the number and location ofwelds for installation of the rear rail.

6. Mark the cut location by measuring 5mm (1/4 in.) from the rear edge of thesecond gauge hole rearward

7. Cut the rear rail section.

8. Remove the damaged rear rail section.

5mm(0.25 in)


Rail Sectioning—RearInstallation Procedure1. Mark the cut location on the service

rail by measuring 5 mm (1/4 in.)from the front edge of the secondgauge hole forward.

2. Cut the rear rail service part.

3. Cut and remove 30 mm (1 and 3/16in.) from the flanges on either sideof the service section rail to create30 mm (1 and 3/16 in.) tabs (1).

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

5. Step the tabs inward (1) to allow theservice rail section to fit inside ofthe original rear rail.

IMPORTANT: The metal of the rearrail is of a heavy gauge. However, thetabs can be created using theappropriate tools.

6. Weld the tabs together along thelower edges (2).

—continued

5mm(0.25 in)

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1

2


Rail Sectioning—RearInstallation Procedure con’t


7. Drill 8 mm (5/16 in.) plug weldholes along the sectioning cut onthe original rail. Locate these holes13 mm (1/2 in.) from the edge andspaced 40 mm (1/2 in.) apart.


9. Turn the weld flange downward forrewelding (2).


11. Align the service part over thestepped tab using three-dimensionalmeasuring equipment.


—continued

12


Rail Sectioning—RearInstallation Procedure con’t13. To create a solid weld with

minimum heat distortion, make 25mm (1 in.) stitch welds along theseam with 25 mm (1 in.) gapsbetween them. Then go back andcomplete the stitch weld.





• Sound deadeners

• Sealers



Floor PanelReplacementRemoval Procedure1. Remove all related panels and

components.




• Sound deadeners

• Sealers


4. Locate and drill out all factorywelds. Note the number andlocation of welds for installation ofthe rear body opening right and leftlower reinforcements, gaining accessto the rear floor panel.

5. Locate Rear Floor Panel to mid-floor overlay seam.

6. Cut rearward of the mid-floor. Use astraight line to cut Rear FloorPanel.

—continued


Floor Panel ReplacementRemoval Procedure con’t7. Locate and drill out all factory

welds. Note the number andlocation of the welds for installationof the Rear Floor Panel.

8. Remove the damaged Rear FloorPanel.


Floor PanelReplacementInstallation Procedure


1. Drill 8 mm (5/16 in.) plug weldholes as necessary in locationsnoted from the original rear outerwheelhouse.

2. Drill 8 mm (5/16 in.) plug weldholes at the forward edge of the rearfloor panel.



5. Position the rear floor panel tooverlap the mid-floor panel.


7. Drill 8 mm (5/16 in.) plug weldholes in the service part asnecessary in locations noted fromthe original panel.

8. Position right and left lowerreinforcements to the rear bodyopening.



Floor Panel ReplacementInstallation Procedure con’t


10. Clean and prepare all weldedsurfaces



• Sound deadeners

• Sealers




Panel Replacement– Rear EndRemoval Procedure1. Remove all related panels and

components.




• Sound deadeners

• Sealers


4. Locate and drill out all factorywelds. Note the number andlocation of welds for installation ofthe rear body opening right and leftlower reinforcements, gaining accessto the rear floor panel.

5. Remove the Rear End Panel.


Panel Replacement– Rear EndInstallation Procedure


1. Drill 8 mm (5/16 in.) plug weldholes in the service part asnecessary in locations noted fromthe original panel.



4. Position the Rear End Panel.






• Sound deadeners

• Sealers




WheelhouseReplacement –Rear OuterRemoval Procedure1. Remove all related panels and

components.





• Sealers


4. Using a suitable tool, trim off thedamaged rear wheelhouse.

IMPORTANT: The original weldflange can be used as an attachmentsurface for installation of the newwheelhouse.

5. Note the number and location ofwelds for installation of the RearOuter Wheelhouse.

6. Remove the damaged Rear OuterWheelhouse.

1


WheelhouseReplacement –Rear OuterInstallation Procedure


1. Drill 8 mm (5/16 in.) plug weldholes as necessary in locationsnoted from the original Rear OuterWheelhouse.



4. Position the Rear OuterWheelhouse.



6. Clean and prepare all weldedsurfaces




• Sealers



11


Aztek Plastic Panel Identification

2

3

3

11

1

1

1

1

1

1

1. TPO (Thermoplastic Olefin)

2. Xenoy

3. Polypropylene Energy Foam


Aztek Metal Panel Identification

1

2

22

1

1

1

1

1

3

1

1

1. TSGS (Two Sided Galvanized Steel)

2. UHSS (Ultra High Strength Steel)

3. AL (Aluminum)


1058

1052

1163

1456

982

994

944

1081

HEIGHT DATUMLINE

WIDTH

LENGTH

Ø

U

V

W

X

Y

Z

Ø

CL

T

91

18

1139

1122

1164

2100

7441117

1130

970768

807

808

801

807

807

789

1136

Body Dimensions

Point-to-Point

Body Side


S

N

O

P

Q

R

Ø

CL CL

WIDTH

DATUMLINE

WIDTH

HEIGHT

LENGTH

Ø

355 716 687 747 740

355 716 687 747 740

925

1038

1019

852

470

433

206

1028

1159 1181

Body Dimensions

Engine Compartment


D

CL

Ø

DATUMLINE

DRIVER SIDE

HEIGHT

WIDTH

WIDTH

LENGTH

Ø

CL

A

B

C E

F

G

H

I

J

K

L

M

450 542 538259

470

450432 432 432

432 432 432

432 432 432432432432

450

474

474

470

259

538542450

663

584

580

419

1105

953

845

411

411

113

175

415

406

1071

1425

1928

2555

2801

3062

462 504 528 567571

653

Body Measurements

Underbody


905

905

Frame Dimensions

Point-to-Point

aztek body panel complete manual

Documents

related panels andcomponents

anyinner panels

damage aspossible

space plug weldholes

number andlocation of

radiator supportassembly

factory specifications

baremetal surfaces