Frame and Underbody: Adjustments Pontiac Aztek I

Alignment Checking

Insert a 19 mm (0.750 in) diameter guide pin or drill bit into the frame-to-body guide pin hole in order to inspect the frame-to-body alignment. If the guide pins will not fit, the frame is not in correct alignment with the body. To realign the frame refer to FRAME REPLACEMENT - FRONT and CROSSMEMBER REPLACEMENT .

Three-Dimensional Method

The repair equipment for measuring structural repair must be capable of measuring multiple points of length, height and width at the same time. Also you must measure 2/3 of the vehicle body to obtain accurate comparisons to the vehicle structure. Universal measuring system combine the equipment and the techniques used to make the underbody and the upperbody three-dimensional measurement of length, width and height measurements at the same time.

Vehicles involved in an accident of any nature which might result in a bent or sprung frame should always be checked for proper frame alignment.

Frame-To-Body Alignment

Check the frame-to-body alignment by inserting a 19 mm (3/4 in) diameter guide pin or drill bit into the frame-to-body guide pin holes. If the guide pins will not fit the frame the frame is not in correct alignment with the body. To realign the frame refer to FRAME REPLACEMENT - FRONT and CROSSMEMBER REPLACEMENT .

Scheme 1

Scheme 2

1. Install the engine support fixture. Refer to ENGINE SUPPORT FIXTURE in Engine Mechanical - 3.4L.
2. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
3. Remove the front tires and wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
4. Remove the inner fender liner enough to gain access to the front frame bolts. Refer to FRONT FENDER LINER REPLACEMENT in Exterior Trim.
5. Remove both outer tie rod ends from the steering knuckles. Refer to STEERING KNUCKLE REPLACEMENT in Front Suspension.
6. Remove the stabilizer shaft. Refer to STABILIZER SHAFT REPLACEMENT in Front Suspension.
7. For AWD, remove the propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT in Propeller Shaft. IMPORTANT: It is NOT necessary to remove the catalytic converter pipe on FWD models.
8. For AWD, remove the catalytic converter pipe. Refer to CATALYTIC CONVERTER REPLACEMENT in Engine Exhaust.
9. Remove the power steering gear heat shield. Refer to POWER STEERING GEAR HEAT SHIELD REPLACEMENT in Power Steering System.
10. Remove the power steering gear bolts. Refer to POWER STEERING GEAR REPLACEMENT in Power Steering System.
11. Remove the power steering gear from the frame. Refer to POWER STEERING GEAR REPLACEMENT in Power Steering System.
12. Use mechanics wire to secure the power steering gear to the exhaust manifold.
13. Remove the front engine splash shield. Refer to SPLASH SHIELD REPLACEMENT - ENGINE in Body Front End.
14. Remove the power steering cooler pipe from the frame. Refer to POWER STEERING COOLER PIPE/HOSE REPLACEMENT in Power Steering System.
15. Use utility wire in order to secure the power steering cooler line out of the way.
16. Disconnect the front wheel speed sensor connectors.
17. Remove the front wheel speed sensor wiring harnesses from the lower control arms.
18. Remove the lower ball joints from the steering knuckles. Refer to STEERING KNUCKLE REPLACEMENT in Front Suspension.
19. Remove the engine mount nuts. Refer to ENGINE SUPPORT FIXTURE in Engine Mechanical-3.4L
20. Remove the transaxle mount nuts. Refer to AUTOMATIC TRANSMISSION MOUNT REPLACEMENT in Automatic Transaxle-4T65-E.
21. Lower the vehicle until the frame contacts the J 39580.
22. Remove frame front bolts.
23. Remove the frame rear bolts.
24. Raise the vehicle in order to separate the frame from the vehicle.
25. If you are REPLACING the frame, perform the following steps: 25.1. Remove the frame insulators from the frame. Refer to «FRAME CUSHION OR INSULATOR REPLACEMENT - FRONT»(ref-204180-S32476598932005110900000) . 25.2. Remove the lower control arms from the frame. Refer to LOWER CONTROL ARM REPLACEMENT in Front Suspension.

Scheme 3

Scheme 4

1. If you are REPLACING the frame, perform the following steps: 1.1. Install the lower control arms to the frame. Refer to LOWER CONTROL ARM REPLACEMENT in Front Suspension. 1.2. Install the frame insulators to the frame. Refer to «FRAME CUSHION OR INSULATOR REPLACEMENT - FRONT»(ref-204180-S32476598932005110900000) .
2. Position the transaxle table with the frame under the vehicle. IMPORTANT: Ensure that the power steering cooler line does not become trapped by the engine mount during this step.
3. Lower the vehicle until the frame is close to the vehicle. IMPORTANT: Ensure that the alignment pins remain installed during the frame installation.
4. Insert two 19 mm (0.75 in) diameter X 203 mm (8.0 in) long guide pins or drill bits into the frame right side alignment holes in order to align the frame. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
5. Install the frame front bolts. Tighten Tighten the bolts to 155 N.m (114 lb ft).
6. Install the frame rear bolts. Tighten Tighten the bolts to 240 N.m (177 lb ft).
7. Remove the alignment pins from the frame.
8. Install the transaxle mount nuts. Refer to AUTOMATIC TRANSMISSION MOUNT REPLACEMENT in Automatic Transaxle-4T65-E.
9. Install the engine mount nuts. Refer to ENGINE MOUNT REPLACEMENT in Engine Mechanical-3.4L.
10. Install the wheel speed sensor wiring harnesses to the lower control arms.
11. Connect the wheel speed sensor electrical connectors.
12. Install the lower ball joints to the steering knuckles. Refer to STEERING KNUCKLE REPLACEMENT in Front Suspension.
13. Install the power steering cooler pipe to the frame. Refer to POWER STEERING COOLER PIPE/HOSE REPLACEMENT in Power Steering System.
14. Install the front engine splash shield. Refer to SPLASH SHIELD REPLACEMENT - ENGINE in Body Front End.
15. Remove the mechanics wire and install the power steering gear to the frame. Refer to POWER STEERING GEAR REPLACEMENT in Power Steering System.
16. Install the power steering gear bolts. Refer to POWER STEERING GEAR REPLACEMENT in Power Steering System.
17. Install the power steering gear heat shield. Refer to POWER STEERING GEAR HEAT SHIELD REPLACEMENT in Power Steering System.
18. For AWD, install the propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT in Propeller Shaft.
19. For AWD, install the catalytic converter pipe. Refer to CATALYTIC CONVERTER REPLACEMENT in Engine Exhaust.
20. Install the stabilizer shaft. Refer to STABILIZER SHAFT REPLACEMENT in Front Suspension.
21. Install both tie rod ends to the steering knuckles. Refer to STEERING KNUCKLE REPLACEMENT in Front Suspension.
22. Install front fender liner. Refer to FRONT FENDER LINER REPLACEMENT in Exterior Trim.
23. Install the front tires and wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
24. Lower the vehicle.
25. Remove the engine support fixture. Refer to ENGINE SUPPORT FIXTURE in Engine Mechanical - 3.4L.

Scheme 5

Scheme 6

1. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
2. Remove the tire and the wheel. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
3. Support rear differential carrier using utility stand.
4. Remove the rear differential carrier mounting bolts (5) from the rear crossmember. Refer to DIFFERENTIAL REPLACEMENT in Rear Drive Axle.
5. Remove the rear suspension knuckle. Refer to KNUCKLE REPLACEMENT (ALL WHEEL DRIVE) in Rear Suspension.
6. Disconnect the wheel speed sensor harness from the lower control arm and from the rear cross member.
7. Remove the rivets that attach the park brake cable to the rear crossmember.
8. Remove the ALC height sensor and link. Refer to AUTOMATIC LEVEL CONTROL SENSOR REPLACEMENT in Automatic Level Control.
9. Remove the ALC ball stud.
10. Secure the ALC wiring harness out of the way.
11. Using a utility jack, support the rear crossmember.
12. Scribe the rear crossmember mounting points to the frame.
13. Remove the rear crossmember mounting bolts.
14. Lower the rear crossmember.
15. Remove the rear stabilizer shaft. Refer to STABILIZER SHAFT REPLACEMENT (ALL WHEEL DRIVE) in Rear Suspension.
16. Remove the rear axle upper control arms from the rear crossmember. Refer to REAR AXLE UPPER CONTROL ARM REPLACEMENT (ALL WHEEL DRIVE) in Rear Suspension.
17. Remove the rear axle lower control arms from the rear crossmember. Refer to REAR AXLE LOWER CONTROL ARM REPLACEMENT (ALL WHEEL DRIVE) in Rear Suspension.
18. Remove the tie rods from the rear crossmember. Refer to TIE ROD REPLACEMENT (FRONT WHEEL DRIVE) or TIE ROD REPLACEMENT (ALL WHEEL DRIVE) in Rear Suspension.

Scheme 7

Scheme 8

1. Install the tie rods to the crossmember. Refer to TIE ROD REPLACEMENT (FRONT WHEEL DRIVE) or TIE ROD REPLACEMENT (ALL WHEEL DRIVE) in Rear Suspension.
2. Install the rear axle lower control arms onto the rear crossmember. Refer to REAR AXLE LOWER CONTROL ARM REPLACEMENT (ALL WHEEL DRIVE) in Rear Suspension.
3. Install the rear axle upper control arms onto the rear crossmember. Refer to REAR AXLE UPPER CONTROL ARM REPLACEMENT (ALL WHEEL DRIVE) in Rear Suspension.
4. Install the rear stabilizer shaft onto the rear crossmember. Refer to STABILIZER SHAFT REPLACEMENT (ALL WHEEL DRIVE) in Rear Suspension.
5. Raise the rear crossmember, and align the rear crossmember with the scribe marks on the frame.
6. Install the rear crossmember mounting bolts. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
7. Tighten the mounting bolts. Tighten Tighten the rear crossmember mounting bolts to 130 N.m (96 lb ft).
8. Install the ALC height sensor onto the vehicle. Refer to AUTOMATIC LEVEL CONTROL SENSOR REPLACEMENT in Automatic Level Control.
9. Install the ALC ball stud to the vehicle.
10. Install the rear differential carrier mounting bolts (5). Refer to DIFFERENTIAL REPLACEMENT in Rear Drive Axle.
11. Attach the parking brake cable onto the rear crossmember.
12. Connect the wheel speed sensor harness onto the rear crossmember and the lower control arm.
13. Install the rear suspension knuckle. Refer to KNUCKLE REPLACEMENT (ALL WHEEL DRIVE) in Rear Suspension.
14. Install the tire and the wheel. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
15. Inspect the rear camber and toe angles and adjust as necessary. Refer to REAR CAMBER ADJUSTMENT (AWD) and REAR TOE ADJUSTMENT in Wheel Alignment.
16. Lower the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.