Chevrolet Captiva Manuals

Chevrolet Captiva Service & Repair Manual: Front Lower Frame Rail

Do not damage any inner panels or reinforcements.
If the location of the original plug weld holes can not be determined, space the plug weld holes every 1 1/2 inches apart. Some panels may have structural weld thru adhesive. It is required to replace the weld thru adhesive with an additional spot weld between each factory spot weld.

Removal

1. Disable SIR system.
2. Disconnect battery ground.
3. Remove all related panels and components.
4. Repair as much damage as possible to factory specifications.
5. Remove sealers and corrosion protection materials from repair area.
6. Locate and drill out all factory welds. Note number and location of welds for installation of front lower rail, Fig. 1.
7. Remove damaged front lower rail, Fig. 2.

Installation

1. Drill 5/16 inch holes for plug weld as required on service component, in locations noted from original assembly.
2. Prepare all mating surfaces as required.
3. Apply 3M® Weld Thru Coating P/N 05916, or equivalent, to all mating surfaces.
4. Position front lower rail to vehicle using three dimensional measuring equipment. Clamp front lower rail into place, Fig. 3.
5. Plug weld accordingly, Fig. 4.
6. Clean and prepare all welded surfaces.
7. Apply sealers and corrosion protection materials to repair area, as required.
8. Refinish repaired area.
9. Install all related panels and components.
10. Connect battery ground.
11. Enable SIR system.

Fig. 1 Front lower frame rail weld locations

Fig. 2 Front lower frame rail removal

Fig. 3 Front lower frame rail installation

Fig. 4 Front lower frame rail plug weld locations

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