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.


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.


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

Servicing the front lower frame rail of a Chevrolet Captiva model year (from 2006 to 2018) is a critical aspect of maintaining the vehicle's structural integrity and safety standards. The process involves several meticulous steps to ensure proper removal and installation of this vital component.

Firstly, preparation is key. The vehicle must be securely lifted using appropriate equipment and supported on jack stands to provide sufficient clearance for accessing the front lower frame rail. Safety precautions, such as disconnecting the battery and wearing protective gear, are strictly observed to prevent any accidents or injuries during the servicing procedure.

The removal process begins by disconnecting any components attached to the front lower frame rail, such as splash shields, brackets, or electrical connectors. Technicians then proceed to carefully remove the fasteners securing the rail to the chassis, ensuring that no damage is caused to surrounding components. Once detached, the front lower frame rail is inspected thoroughly for signs of damage, corrosion, or wear that may compromise its structural integrity.

After inspection, the installation phase commences. A new or repaired front lower frame rail is aligned precisely with the vehicle's chassis mounting points, taking care to ensure proper fitment and alignment. Technicians use manufacturer specifications and guidelines to securely tighten all fasteners and ensure the rail is correctly positioned. Comprehensive testing and calibration procedures follow, including structural integrity tests and road tests to assess handling and stability. Final checks are conducted to ensure all components are properly reconnected, electrical systems are functioning, and safety measures are in place, providing peace of mind to both technicians and vehicle owners.

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