Pontiac 2001 manual Left Front Lower Rail Sectioning, Preparing Service Part for Installation

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Left Front 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 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

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Contents Pontiac Aztek Removal ProcedureInstallation Procedure Radiator Support Replacement Lower Radiator Support Replacement Lower Rail Replacement Upper Rail Replacement Upper Wheelhouse Replacement Front Wheelhouse Replacement Front Rail Sub-Assembly Replacement Front Lower Rail Sub-Assembly Replacement Front Lower Removal of Damaged Left Front Rail Left Front Lower Rail SectioningRemoval of Damaged Left Front Rail con’t Left Front Lower Rail Sectioning Preparing Service Part for InstallationRemoval of Damaged Right Front Rail Right Front Lower Rail SectioningPreparing the Undamaged Portion of the Rail for Installation Door Frame Sectioning-Outer Front Hinge Pillar Door Frame Sectioning-Outer Front Hinge Pillar 25MM 1/2 Inner panels or reinforcements Door Frame Sectioning-Outer Center PillarInstallation Procedure Door Frame Sectioning-Outer Center Pillar Door Frame Sectioning-Outer Rear Lock Pillar Door Frame Sectioning-Outer Rear Lock Pillar Door Frame Sectioning-Outer Rear Lock Pillar Door Frame Sectioning-Outer Rocker Sectioning Door Frame Sectioning-Outer Rocker Sectioning Cut the replacement service part 25MM 1 Roof Outer Replacement Installation Procedure Quarter Panel Replacement 50MM 2 Quarter Panel Replacement Installation Procedure Rail Sectioning Rear Rail Sectioning- Rear Rail Sectioning-Rear Installation Procedure con’t Rail Sectioning-Rear Installation Procedure con’t Floor Panel Replacement Floor Panel Replacement Removal Procedure con’t Installation Procedure Floor Panel Replacement Installation Procedure con’t Panel Replacement Rear End Installation Procedure Wheelhouse Replacement Rear Outer Important Prior to refinishing Aztek Plastic Panel Identification Aztek Metal Panel Identification Body Dimensions Engine Compartment Underbody Body MeasurementsFrame Dimensions