Pontiac 2001 manual Rail Sectioning- Rear

Page 35

5mm (0.25 in)

1

1

2

1

2

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 (1 and 3/16 in.) tabs (1).

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

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

IMPORTANT: The metal of the rear rail is of a heavy gauge. However, the tabs can be created using the appropriate tools.

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

—continued

2001 Pontiac Aztek 1-35

Image 35
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