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

Removing the upper frame rail typically involves several steps to ensure safe and effective disassembly. This includes securing the vehicle on jack stands or a lift to provide adequate clearance and stability. Technicians will disconnect any electrical connectors, hoses, or components attached to the upper frame rail before removing fasteners or bolts that secure it to the vehicle's structure. Careful handling and lifting equipment may be necessary to safely extract the old upper frame rail from the vehicle without causing damage.

When installing a new upper frame rail, precision and attention to detail are crucial. Technicians must ensure the replacement part aligns perfectly with the mounting points on the vehicle's structure before securely fastening it in place with bolts or fasteners. Reconnecting electrical connectors, hoses, and components correctly is essential to restore functionality and integrity. A final inspection is performed to verify that the upper frame rail is properly aligned and secured, and the vehicle is lowered back to the ground if it was lifted during the process.

It's important to note that these procedures may vary depending on the specific model year and trim of the Chevrolet Captiva, and professional guidance from a certified mechanic or consulting the vehicle's service manual is recommended for accurate and safe repairs.

    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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    Chevrolet Captiva Owners Manual

    Chevrolet Captiva Service & Repair Manual

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