Chevrolet Captiva Manuals

Chevrolet Captiva Service & Repair Manual: 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 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 upper outer rail, Fig. 1.
7. Remove damaged front upper outer rail, 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 front upper outer rail to vehicle using three dimensional measuring equipment. Clamp front upper outer rail 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 Upper frame rail weld locations

Fig. 2 Upper frame rail removal

Fig. 3 Upper frame rail preparation

Fig. 4 Upper frame rail installation

Fig. 5 Upper frame rail plug weld locations

    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 ...

    Upper Tie Bar
    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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