Chevrolet Captiva Manuals

Chevrolet Captiva Service & Repair Manual: Roof

If the location of the original plug weld holes cannot be determined, or if structural weld thru adhesive is present, space the plug weld holes every 1 1/2 inches apart.

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. Remove windshield.
7. Remove liftgate as outlined in Liftgate.
8. Locate and drill out all factory welds. Note number and location of welds for installation of roof panel, Fig. 1.
9. With aid of an assistant, remove roof panel, Fig. 2.

Installation

1. Drill 5/16 inch holes for plug weld as required on service component, in locations noted from original assembly (1), 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. With aid of an assistant, position roof panel to body, 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 Roof weld locations

Fig. 2 Roof removal

Fig. 3 Roof preparation

Fig. 4 Roof installation

Fig. 5 Roof plug weld locations

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    Upper 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 ap ...

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