Pontiac 2001 manual Preparing the Undamaged Portion of the Rail for Installation

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Right Front 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 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

(1Ê 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