service repair manual download

1. 2005 ACCESSORIES & EQUIPMENT
Bumpers - Aztek & Rendezvous
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications
DIAGNOSTIC INFORMATION AND PROCEDURES
INSPECTION AFTER COLLISION
The following components may require replacement, if the collision was so severe that the bumper did not
return to the original position:
 The bumper fascia
 The bumper energy absorber
 The bumper impact bar
REPAIR INSTRUCTIONS
FASCIA REPLACEMENT - FRONT BUMPER - UPPER (AZTEK)
Tools Required
J 38778 Door Trim Pad and Garnish Clip Remover
Removal Procedure
Application
Specification
Metric English
Front Bumper Fascia Bolt 10 N.m 89 lb in
Front Bumper Fascia Lower Support Bolt 10 N.m 89 lb in
Front Bumper Fascia Upper Support Bolt 5 N.m 44 lb in
Front Bumper Impact Bar Bolt 50 N.m 37 lb ft
Front Inboard Upper Front Bumper Impact Bar Bolt 50 N.m 37 lb ft
Grille Screws 2 N.m 18 lb in
Lower Outboard Front Bumper Impact Bar Bolt 25 N.m 18 lb ft
Rear Bumper Impact Bar Bolt 50 N.m 37 lb ft
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:35 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
Toshiba
Sunday, June 21, 2009 10:43:43 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.

2. Fig. 1: View Of Front Bumper Fascia Bolts (Aztek)
Courtesy of GENERAL MOTORS CORP.
1. Remove the front fender liners. Refer to Front Fender Liner Replacement in Body Front End.
2. Remove the headlamps. Refer to Headlamp Assembly or Headlamp Bulb Replacement (Aztek) or
Headlamp Assembly or Headlamp Bulb Replacement (Rendezvous) in Lighting Systems.
3. Remove the fog lamps. Refer to Fog Lamp Replacement - Front (Aztek) or Fog Lamp Replacement -
Front (Rendezvous) in Lighting Systems.
4. Remove the bolts from the front bumper fascia at the fender.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:35 AM Page 2 © 2005 Mitchell Repair Information Company, LLC.

3. Fig. 2: Identifying Upper Bumper Fascia Support Push-In Retainers (Aztek)
Courtesy of GENERAL MOTORS CORP.
5. Remove the push-in retainers from the upper bumper fascia support using J 38778 .
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:35 AM Page 3 © 2005 Mitchell Repair Information Company, LLC.

4. Fig. 3: Locating Front Bumper Energy Absorber Push-In Retainers (Aztek)
Courtesy of GENERAL MOTORS CORP.
6. Remove the push-in retainers to the fascia at the front bumper energy absorber using J 38778 .
7. Remove the fascia from the vehicle.
8. Remove the grilles from the fascia. Refer to Fascia Grille Replacement (Aztek) or Fascia Grille
Replacement (Rendezvous) .
9. Remove the fascia outer support from the fascia.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:35 AM Page 4 © 2005 Mitchell Repair Information Company, LLC.

5. Fig. 4: View of Upper & Lower Fascia (Aztek)
Courtesy of GENERAL MOTORS CORP.
10. Remove the upper fascia from the lower fascia.
Installation Procedure
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 5 © 2005 Mitchell Repair Information Company, LLC.

6. Fig. 5: View of Upper & Lower Fascia (Aztek)
Courtesy of GENERAL MOTORS CORP.
1. Install the upper fascia to the lower fascia.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 6 © 2005 Mitchell Repair Information Company, LLC.

7. Fig. 6: Identifying Upper Bumper Fascia Support Push-In Retainers (Aztek)
Courtesy of GENERAL MOTORS CORP.
2. Install the fascia outer support to the fascia.
3. Install the grilles. Refer to Fascia Grille Replacement (Aztek) or Fascia Grille Replacement
(Rendezvous) .
4. Position the fascia to the vehicle.
5. Align the alignment pins of the fascia to the front fenders and moldings.
6. Install the push-in the retainers starting at the center, to the front upper bumper fascia support.
NOTE: Refer to Fastener Notice in Cautions and Notices.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 7 © 2005 Mitchell Repair Information Company, LLC.

8. Fig. 7: View Of Front Bumper Fascia Bolts (Aztek)
Courtesy of GENERAL MOTORS CORP.
7. Install the bolts to the front fascia at the front fenders.
Tighten: Tighten the front fascia bolts to 10 N.m (89 lb in).
IMPORTANT: Push the retainer tabs up and against the front bumper energy absorber.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 8 © 2005 Mitchell Repair Information Company, LLC.

9. Fig. 8: Locating Front Bumper Energy Absorber Push-In Retainers (Aztek)
Courtesy of GENERAL MOTORS CORP.
8. Install the push-in retainers to the fascia at the energy absorber.
9. Install the fog lamps. Refer to Fog Lamp Replacement - Front (Aztek) or Fog Lamp Replacement -
Front (Rendezvous) in Lighting Systems.
10. Install the headlamps. Refer to Headlamp Assembly or Headlamp Bulb Replacement (Aztek) or
Headlamp Assembly or Headlamp Bulb Replacement (Rendezvous) in Lighting Systems.
11. Install the front fender liners. Refer to Front Fender Liner Replacement in Body Front End.
FASCIA REPLACEMENT - FRONT BUMPER - UPPER (RENDEZVOUS)
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 9 © 2005 Mitchell Repair Information Company, LLC.

10. Tools Required
J 38778 Door Trim Pad and Garnish Clip Remover
Removal Procedure
Fig. 9: View Of Front Bumper Fascia (Rendezvous)
Courtesy of GENERAL MOTORS CORP.
1. Remove the front fender liners. Refer to Front Fender Liner Replacement in Body Front End.
2. Remove the headlamps. Refer to Headlamp Assembly or Headlamp Bulb Replacement (Aztek) or
Headlamp Assembly or Headlamp Bulb Replacement (Rendezvous) in Lighting Systems.
3. Remove the fog lamps. Refer to Fog Lamp Replacement - Front (Aztek) or Fog Lamp Replacement -
Front (Rendezvous) in Lighting Systems.
4. Remove the bolts from the front bumper fascia at the fender.
5. Remove the push-in retainers from the upper bumper fascia support using J 38778 .
6. Remove the push-in retainers from the fascia at the front bumper energy absorber using J 38778 .
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 10 © 2005 Mitchell Repair Information Company, LLC.

11. Fig. 10: Locating Front Fender Ball Socket Retainer (Rendezvous)
Courtesy of GENERAL MOTORS CORP.
7. Disengage the ball socket retainer from the ball on the front fender.
8. Remove the fascia from the vehicle.
9. Remove the grille from the fascia. Refer to Fascia Grille Replacement (Aztek) or Fascia Grille
Replacement (Rendezvous) .
10. Remove the fascia outer support.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 11 © 2005 Mitchell Repair Information Company, LLC.

12. Fig. 11: View Of Upper & Lower Fascia (Rendezvous)
Courtesy of GENERAL MOTORS CORP.
11. Remove the upper fascia from the lower fascia.
Installation Procedure
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 12 © 2005 Mitchell Repair Information Company, LLC.

13. Fig. 12: View Of Upper & Lower Fascia (Rendezvous)
Courtesy of GENERAL MOTORS CORP.
1. Install the upper fascia to the lower fascia.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 13 © 2005 Mitchell Repair Information Company, LLC.

14. Fig. 13: Locating Front Fender Ball Socket Retainer (Rendezvous)
Courtesy of GENERAL MOTORS CORP.
2. Install the fascia outer support.
3. Install the grille to the fascia. Refer to Fascia Grille Replacement (Aztek) or Fascia Grille
Replacement (Rendezvous) .
4. Position the fascia to the vehicle.
5. Align the alignment pins of the fascia to the front fenders and moldings.
6. Engage the ball socket to the ball on the front fender
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 14 © 2005 Mitchell Repair Information Company, LLC.

15. Fig. 14: View Of Front Bumper Fascia (Rendezvous)
Courtesy of GENERAL MOTORS CORP.
7. Install the push-in the retainers starting at the center, to the front upper bumper fascia support.
8. Install the bolts to the front fascia at the front fenders.
Tighten: Tighten the front fascia bolts to 10 N.m (89 lb in).
9. Install the push-in retainers to the fascia at the energy absorber.
10. Install the fog lamps. Refer to Fog Lamp Replacement - Front (Aztek) or Fog Lamp Replacement -
Front (Rendezvous) in Lighting Systems.
11. Install the headlamps. Refer to Headlamp Assembly or Headlamp Bulb Replacement (Aztek) or
Headlamp Assembly or Headlamp Bulb Replacement (Rendezvous) in Lighting Systems.
12. Install the front fender liners. Refer to Front Fender Liner Replacement in Body Front End.
NOTE: Refer to Fastener Notice in Cautions and Notices.
IMPORTANT: Push the retainer tabs up and against the front bumper energy absorber.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 15 © 2005 Mitchell Repair Information Company, LLC.

16. FASCIA REPLACEMENT - FRONT BUMPER - LOWER (AZTEK)
Tools Required
J 38778 Door Trim Pad and Garnish Clip Remover
Removal Procedure
Fig. 15: View Of Front Bumper Fascia Bolts (Aztek)
Courtesy of GENERAL MOTORS CORP.
1. Remove the front fender liners. Refer to Front Fender Liner Replacement in Body Front End.
2. Remove the headlamps. Refer to Headlamp Assembly or Headlamp Bulb Replacement (Aztek) or
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 16 © 2005 Mitchell Repair Information Company, LLC.

17. Headlamp Assembly or Headlamp Bulb Replacement (Rendezvous) in Lighting Systems.
3. Remove the fog lamps. Refer to Fog Lamp Replacement - Front (Aztek) or Fog Lamp Replacement -
Front (Rendezvous) in Lighting Systems.
4. Remove the bolts from the front bumper fascia at the fender.
Fig. 16: Identifying Upper Bumper Fascia Support Push-In Retainers (Aztek)
Courtesy of GENERAL MOTORS CORP.
5. Remove the push-in retainers from the upper bumper fascia support using J 38778 .
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 17 © 2005 Mitchell Repair Information Company, LLC.

18. Fig. 17: Locating Front Bumper Energy Absorber Push-In Retainers (Aztek)
Courtesy of GENERAL MOTORS CORP.
6. Remove the push-in retainers to the fascia at the front bumper energy absorber using J 38778 .
7. Remove the fascia from the vehicle.
8. Remove the grilles from the fascia. Refer to Fascia Grille Replacement (Aztek) or Fascia Grille
Replacement (Rendezvous) .
9. Remove the fascia outer support from the fascia.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 18 © 2005 Mitchell Repair Information Company, LLC.

19. Fig. 18: View of Upper & Lower Fascia (Aztek)
Courtesy of GENERAL MOTORS CORP.
10. Remove the upper fascia from the lower fascia.
Installation Procedure
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 19 © 2005 Mitchell Repair Information Company, LLC.

20. Fig. 19: View of Upper & Lower Fascia (Aztek)
Courtesy of GENERAL MOTORS CORP.
1. Install the upper fascia to the lower fascia.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 20 © 2005 Mitchell Repair Information Company, LLC.

21. Fig. 20: Identifying Upper Bumper Fascia Support Push-In Retainers (Aztek)
Courtesy of GENERAL MOTORS CORP.
2. Install the fascia outer support to the fascia.
3. Install the grilles. Refer to Fascia Grille Replacement (Aztek) or Fascia Grille Replacement
(Rendezvous) .
4. Position the fascia to the vehicle.
5. Align the alignment pins of the fascia to the front fenders and moldings.
6. Install the push-in the retainers starting at the center, to the front upper bumper fascia support.
NOTE: Refer to Fastener Notice in Cautions and Notices.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 21 © 2005 Mitchell Repair Information Company, LLC.

22. Fig. 21: View Of Front Bumper Fascia Bolts (Aztek)
Courtesy of GENERAL MOTORS CORP.
7. Install the bolts to the front fascia at the front fenders.
Tighten: Tighten the front fascia bolts to 10 N.m (89 lb in).
IMPORTANT: Push the retainer tabs up and against the front bumper energy absorber.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 22 © 2005 Mitchell Repair Information Company, LLC.

23. Fig. 22: Locating Front Bumper Energy Absorber Push-In Retainers (Aztek)
Courtesy of GENERAL MOTORS CORP.
8. Install the push-in retainers to the fascia at the energy absorber.
9. Install the fog lamps. Refer to Fog Lamp Replacement - Front (Aztek) or Fog Lamp Replacement -
Front (Rendezvous) in Lighting Systems.
10. Install the headlamps. Refer to Headlamp Assembly or Headlamp Bulb Replacement (Aztek) or
Headlamp Assembly or Headlamp Bulb Replacement (Rendezvous) in Lighting Systems.
11. Install the front fender liners. Refer to Front Fender Liner Replacement in Body Front End.
FASCIA REPLACEMENT - FRONT BUMPER - LOWER (RENDEZVOUS)
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 23 © 2005 Mitchell Repair Information Company, LLC.

24. Tools Required
J 38778 Door Trim Pad and Garnish Clip Remover
Removal Procedure
Fig. 23: View Of Front Bumper Fascia (Rendezvous)
Courtesy of GENERAL MOTORS CORP.
1. Remove the front fender liners. Refer to Front Fender Liner Replacement in Body Front End.
2. Remove the headlamps. Refer to Headlamp Assembly or Headlamp Bulb Replacement (Aztek) or
Headlamp Assembly or Headlamp Bulb Replacement (Rendezvous) in Lighting Systems.
3. Remove the fog lamps. Refer to Fog Lamp Replacement - Front (Aztek) or Fog Lamp Replacement -
Front (Rendezvous) in Lighting Systems.
4. Remove the bolts from the front bumper fascia at the fender.
5. Remove the push-in retainers from the upper bumper fascia support using J 38778 .
6. Remove the push-in retainers from the fascia at the front bumper energy absorber using J 38778 .
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 24 © 2005 Mitchell Repair Information Company, LLC.

25. Fig. 24: Locating Front Fender Ball Socket Retainer (Rendezvous)
Courtesy of GENERAL MOTORS CORP.
7. Disengage the ball socket retainer from the ball on the front fender.
8. Remove the fascia from the vehicle.
9. Remove the grille from the fascia. Refer to Fascia Grille Replacement (Aztek) or Fascia Grille
Replacement (Rendezvous) .
10. Remove the fascia outer support.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 25 © 2005 Mitchell Repair Information Company, LLC.

26. Fig. 25: View Of Upper & Lower Fascia (Rendezvous)
Courtesy of GENERAL MOTORS CORP.
11. Remove the upper fascia from the lower fascia.
Installation Procedure
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 26 © 2005 Mitchell Repair Information Company, LLC.

27. Fig. 26: View Of Upper & Lower Fascia (Rendezvous)
Courtesy of GENERAL MOTORS CORP.
1. Install the upper fascia to the lower fascia.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 27 © 2005 Mitchell Repair Information Company, LLC.

28. Fig. 27: Locating Front Fender Ball Socket Retainer (Rendezvous)
Courtesy of GENERAL MOTORS CORP.
2. Install the fascia outer support.
3. Install the grille to the fascia. Refer to Fascia Grille Replacement (Aztek) or Fascia Grille
Replacement (Rendezvous) .
4. Position the fascia to the vehicle.
5. Align the alignment pins of the fascia to the front fenders and moldings.
6. Engage the ball socket to the ball on the front fender
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 28 © 2005 Mitchell Repair Information Company, LLC.

29. Fig. 28: View Of Front Bumper Fascia (Rendezvous)
Courtesy of GENERAL MOTORS CORP.
7. Install the push-in the retainers starting at the center, to the front upper bumper fascia support.
8. Install the bolts to the front fascia at the front fenders.
Tighten: Tighten the front fascia bolts to 10 N.m (89 lb in).
9. Install the push-in retainers to the fascia at the energy absorber.
10. Install the fog lamps. Refer to Fog Lamp Replacement - Front (Aztek) or Fog Lamp Replacement -
Front (Rendezvous) in Lighting Systems.
11. Install the headlamps. Refer to Headlamp Assembly or Headlamp Bulb Replacement (Aztek) or
Headlamp Assembly or Headlamp Bulb Replacement (Rendezvous) in Lighting Systems.
12. Install the front fender liners. Refer to Front Fender Liner Replacement in Body Front End.
NOTE: Refer to Fastener Notice in Cautions and Notices.
IMPORTANT: Push the retainer tabs up and against the front bumper energy absorber.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 29 © 2005 Mitchell Repair Information Company, LLC.

30. FASCIA GRILLE REPLACEMENT (AZTEK)
Removal Procedure
Fig. 29: View Of Fascia Grille Retaining Tabs (Aztek)
Courtesy of GENERAL MOTORS CORP.
1. Remove the headlamp assembly. Refer to Headlamp Assembly or Headlamp Bulb Replacement
(Aztek) or Headlamp Assembly or Headlamp Bulb Replacement (Rendezvous) in Lighting Systems.
2. Using a small flat-bladed tool, reach into the opening behind the front fascia and depress the retaining
tabs (1, 2, 3, 4, 5) that lock the front fascia grille to the front fascia.
3. Remove the grille from the front fascia.
Installation Procedure
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 30 © 2005 Mitchell Repair Information Company, LLC.

31. Fig. 30: View Of Fascia Grille Retaining Tabs (Aztek)
Courtesy of GENERAL MOTORS CORP.
1. Position the grille retaining tabs to the slots in the front fascia.
2. Install the grille by pressing into place until the retaining tabs (1, 2, 3, 4, 5) are fully seated.
3. Install the headlamp assembly. Refer to Headlamp Assembly or Headlamp Bulb Replacement (Aztek)
or Headlamp Assembly or Headlamp Bulb Replacement (Rendezvous) in Lighting Systems.
FASCIA GRILLE REPLACEMENT (RENDEZVOUS)
Removal Procedure
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 31 © 2005 Mitchell Repair Information Company, LLC.

32. Fig. 31: Locating Fascia Grille Retaining Screws (Rendezvous)
Courtesy of GENERAL MOTORS CORP.
1. Remove the headlamp assembly refer to Headlamp Assembly or Headlamp Bulb Replacement
(Aztek) or Headlamp Assembly or Headlamp Bulb Replacement (Rendezvous) in Lighting Systems.
2. Remove the grille screws.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 32 © 2005 Mitchell Repair Information Company, LLC.

33. Fig. 32: View Of Upper Grille Retainers (Rendezvous)
Courtesy of GENERAL MOTORS CORP.
3. Remove the retainers from the top of the grille.
4. Using a flat bladed tool, reach into the opening behind front fascia and depress the tabs that lock the front
fascia grille to the front fascia.
5. Remove the grille from the front fascia.
Installation Procedure
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 33 © 2005 Mitchell Repair Information Company, LLC.

34. Fig. 33: View Of Upper Grille Retainers (Rendezvous)
Courtesy of GENERAL MOTORS CORP.
1. Align the grille pin and locking tabs to the front fascia.
2. Press inward on the grille until all tabs are locked in place.
3. Install the retainers to the top of the grille.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 34 © 2005 Mitchell Repair Information Company, LLC.

35. Fig. 34: Locating Fascia Grille Retaining Screws (Rendezvous)
Courtesy of GENERAL MOTORS CORP.
4. Install the grille screws.
Tighten: Tighten the grille screws to 2 N.m (18 lb in).
NOTE: Refer to Fastener Notice in Cautions and Notices.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 35 © 2005 Mitchell Repair Information Company, LLC.

36. 5. Install the headlamp assembly refer to Headlamp Assembly or Headlamp Bulb Replacement (Aztek)
or Headlamp Assembly or Headlamp Bulb Replacement (Rendezvous) in Lighting Systems.
FASCIA SUPPORT REPLACEMENT - FRONT BUMPER UPPER
Removal Procedure
Fig. 35: View Of Headlamp Wiring Harness
Courtesy of GENERAL MOTORS CORP.
1. Remove the fascia. Refer to Fascia Replacement - Front Bumper - Upper (Aztek) or Fascia
Replacement - Front Bumper - Upper (Rendezvous) .
2. Remove the hood latch and cable. Refer to Hood Latch Release Cable Replacement .
3. Disconnect the headlamp wiring harness from the fascia upper support.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 36 © 2005 Mitchell Repair Information Company, LLC.

37. 4. Remove the bolts from the fascia upper support.
Fig. 36: Identifying Fascia Upper Support
Courtesy of GENERAL MOTORS CORP.
5. Remove the fascia upper support from the upper radiator support.
Installation Procedure
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 37 © 2005 Mitchell Repair Information Company, LLC.

38. Fig. 37: Identifying Fascia Upper Support
Courtesy of GENERAL MOTORS CORP.
1. Position the fascia upper support to the upper radiator support.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 38 © 2005 Mitchell Repair Information Company, LLC.

39. Fig. 38: View Of Headlamp Wiring Harness
Courtesy of GENERAL MOTORS CORP.
2. Install the bolts to the fascia upper support.
Tighten: Tighten the bolts to 5 N.m (44 lb in).
3. Install the bolts to the fascia lower support.
Tighten: Tighten the bolts to 10 N.m (89 lb in).
4. Connect the headlamp wiring harness to the fascia upper support.
NOTE: Refer to Fastener Notice in Cautions and Notices.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 39 © 2005 Mitchell Repair Information Company, LLC.

40. 5. Install the hood latch and cable. Refer to Hood Latch Release Cable Replacement .
6. Install the front bumper fascia. Refer to Fascia Replacement - Front Bumper - Upper (Aztek) or
Fascia Replacement - Front Bumper - Upper (Rendezvous) .
IMPACT BAR REPLACEMENT - FRONT BUMPER
Removal Procedure
Fig. 39: Cross Sectional View Of Upper Inboard Impact Bolt
Courtesy of GENERAL MOTORS CORP.
1. Remove the front bumper fascia. Refer to Fascia Replacement - Front Bumper - Upper (Aztek) or
Fascia Replacement - Front Bumper - Upper (Rendezvous) .
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 40 © 2005 Mitchell Repair Information Company, LLC.

41. 2. Remove the energy absorber. Refer to Energy Absorber Replacement - Front (Aztek) or Energy
Absorber Replacement - Front (Rendezvous) .
3. Remove the bolt from the upper inboard impact bar through the access hole in the radiator support.
Fig. 40: Locating Horns Mounting Bolts
Courtesy of GENERAL MOTORS CORP.
4. Disconnect the electrical connector from the horn.
5. Remove the horns from the impact bar.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 41 © 2005 Mitchell Repair Information Company, LLC.

42. Fig. 41: View Of Impact Bar Bolts
Courtesy of GENERAL MOTORS CORP.
6. Remove the remainder of the impact bar bolts.
7. Remove the impact bar.
Installation Procedure
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 42 © 2005 Mitchell Repair Information Company, LLC.

43. Fig. 42: View Of Impact Bar Bolts
Courtesy of GENERAL MOTORS CORP.
1. Position the impact bar to the body using the alignment pin for location.
2. Install the bolts to secure the impact bar to the front bumper.
Tighten: Tighten the bolts to 25 N.m (18 lb ft).
IMPORTANT: Position the left side first, then the right side.
NOTE: Refer to Fastener Notice in Cautions and Notices.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 43 © 2005 Mitchell Repair Information Company, LLC.

44. Fig. 43: Cross Sectional View Of Upper Inboard Impact Bolt
Courtesy of GENERAL MOTORS CORP.
3. Through the access hole in the radiator support, install the bolt to secure the impact bar to the front
bumper.
Tighten: Tighten the bolt to 50 N.m (37 lb ft).
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 44 © 2005 Mitchell Repair Information Company, LLC.

45. Fig. 44: Locating Horns Mounting Bolts
Courtesy of GENERAL MOTORS CORP.
4. Install the horn to the impact bar.
5. Install the impact bar bolt to the horn.
Tighten: Tighten the bolt to 50 N.m (37 lb ft).
6. Connect the electrical connector to the horn.
7. Install the energy absorber. Refer to Energy Absorber Replacement - Front (Aztek) or Energy
Absorber Replacement - Front (Rendezvous) .
8. Install the front bumper fascia. Refer to Fascia Replacement - Front Bumper - Upper (Aztek) or
Fascia Replacement - Front Bumper - Upper (Rendezvous) .
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 45 © 2005 Mitchell Repair Information Company, LLC.

46. ENERGY ABSORBER REPLACEMENT - FRONT (AZTEK)
Tools Required
J 38778 Door Trim Pad and Garnish Clip Remover
Removal Procedure
Fig. 45: View Of Front Bumper Energy Absorber Push-In Retainers (Aztek)
Courtesy of GENERAL MOTORS CORP.
1. Remove the front bumper fascia. Refer to Fascia Replacement - Front Bumper - Upper (Aztek) or
Fascia Replacement - Front Bumper - Upper (Rendezvous) .
2. Use J 38778 to remove the push-in retainers from the front bumper energy absorber.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 46 © 2005 Mitchell Repair Information Company, LLC.

47. Fig. 46: Identifying Front Bumper Energy Absorber (Aztek)
Courtesy of GENERAL MOTORS CORP.
3. Remove the energy absorber from the front bumper impact bar.
Installation Procedure
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 47 © 2005 Mitchell Repair Information Company, LLC.

48. Fig. 47: Identifying Front Bumper Energy Absorber (Aztek)
Courtesy of GENERAL MOTORS CORP.
1. Position the energy absorber to the front bumper impact bar.
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 48 © 2005 Mitchell Repair Information Company, LLC.

49. Fig. 48: View Of Front Bumper Energy Absorber Push-In Retainers (Aztek)
Courtesy of GENERAL MOTORS CORP.
2. Starting with the center hole, install the push-in retainers to the front bumper energy absorber.
3. Install the front bumper fascia. Refer to Fascia Replacement - Front Bumper - Upper (Aztek) or
Fascia Replacement - Front Bumper - Upper (Rendezvous) .
ENERGY ABSORBER REPLACEMENT - FRONT (RENDEZVOUS)
Tools Required
J 38778 Door Trim Pad and Garnish Clip Remover
Removal Procedure
2005 Pontiac Aztek
2005 ACCESSORIES & EQUIPMENT Bumpers - Aztek & Rendezvous
Toshiba
Sunday, June 21, 2009 10:43:36 AM Page 49 © 2005 Mitchell Repair Information Company, LLC.

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