Chevrolet Captiva Manuals

Chevrolet Captiva Service & Repair Manual: Rear Body Panel

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 rear body panel, Fig. 1.
7. Remove damaged rear body panel, Fig. 2.

Installation

1. Drill 5/16 inch holes for plug weld as required on service component, in locations noted from original assembly, Fig. 3.
2. Prepare all mating surfaces as required.
3. Apply 3M® Weld Thru Coating P/N 05916, or equivalent, to all mating surfaces.
4. Position new component to vehicle using three dimensional measuring equipment and clamp into place, Fig. 4.
5. Plug weld accordingly, Fig. 5.
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 Rear body panel weld locations

Fig. 2 Rear body panel removal

Fig. 3 Rear body panel preparation

Fig. 4 Rear body panel installation

Fig. 5 Rear body panel plug weld locations

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