Chevrolet Captiva Manuals

Chevrolet Captiva Service & Repair Manual: Rear 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.

Complete

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 frame rail.
7. Remove damaged rear frame rail.

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 new component to vehicle using three dimensional measuring equipment and clamp into place.
5. Plug weld accordingly.
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.

Section

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 in rear spring seat and No. 5 bar extension. Note number and location of welds for installation of components.
7. Locate and drill out all factory welds in rear rail section. Note number and location of welds for installation of rear rail section, Fig. 1.
8. Remove damaged rear rail section, 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. Position rear spring seat and No. 5 bar extension to vehicle using three dimensional measuring equipment. Clamp components into place.
7. Plug weld accordingly.
8. Clean and prepare all welded surfaces.
9. Apply sealers and corrosion protection materials to repair area, as required.
10. Refinish repaired area.
11. Install all related panels and components.
12. Connect battery ground.
13. Enable SIR system.

Fig. 1 Rear rail section weld locations

Fig. 2 Rear rail section removal

Fig. 3 Rear rail section preparation

Fig. 4 Rear rail section installation

Fig. 5 Rear rail section plug weld locations

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