01/12/2014 BodyRepairManualCaptivaROOF,BACKPANELANDREARFLOORPANEL
Captiva
ROOF,BACKPANELANDREARFLOORPANEL
ROOF
GENERALDESCRIPTION
Deformationoftheroofpanelishighlynoticeableintermsofthevehicle'souterappearance.Beforereplacingtheroof,makesurethatthebodyis
horizontal.Beforeweldingtheroofpanel,adjusttheframedooropeningflangessothattheycontacttheroofpanel.Payparticularattentiontotwistsand
parallelism.
1. SpotWeldSealer
REPAIRPROCEDURE
1. Removetherelatedparts.
Roomlamp,doorweatherstripandpillartrims.
Headliningandwiringharness.
Wiper,cowlandwindshield.
Tailgateandothers.
2. Pulloutandstraightenthedamagedareatoapproximatelytheoriginalshape.
Note:Useheatresistantprotectivecoverforprotectpaintingareas,seats,carpetsandotherparts.
Attachthecartotheframestraightenerbytighteningtheunderbodyclampsatthehorizontalpinchwelds.
Beforecuttingofftheroofpanel,pullthemoutsothattheyarerestoredtotheoriginalshape.
Donotpulloutmorethannecessary.
Pulloutandstraightentherelateddamagedpartstoapproximatelytheiroriginalshape.
Note:Makesurethattherightandleftpillarsareparallelwiththewindshieldsurface.Checkthedoorforproperopeningandclosing.
3. Keepthebody,level.
Jackupthebody,andplacesafetystandsatthefourdesignatedplacesoftheframedooropening.
4. Cutandpryofftheroofpanel.
Cuttheroofweldflangeswithahandsawandsnipsattheroofpanelandroofframes.
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Usingachisel,pryofftheroofpanelalongtheboldlinesasshown.
Centerpuncharoundthespotweldimprintsoftheroofweldedflange.
Drillholesusingthespotcutter.
Usingachiselandadiscsander,pryofftheweldedflangefromthefront,rearbodypillarandroofpanel.
Levelandfinishtheburrsofweldedflangeswithadiscsander.
Caution:Topreventeyeinjury,weargogglesorsafetyglasseswheneversanding,cutting,orgrinding.
5. Peeloffthesealer.
Peeloffthesealerwithasteelspatulaattheweldingareasoftheframedooropening.
6. Molddamagedrelatedparts.
Useahammeranddollytomolddamagedareasofthefront,rearbodypillarinnerandframedooropening.
Evenouttheweldingflangeswithahammeranddollyforclosefitwiththeroofpanelweldingflange.
Fillanyholesdrilledbywelding.
7. Setthenewpanels.
Grindbothsidesoftheweldingsectionoftherailwindshieldheader,supportroofpanel,framerearroofpanelandroofpanelwithadisc
sandertoremovethepaintandexposethesteelplate.
Caution:Topreventeyeinjury,weargogglesorsafetyglasseswheneversanding,cutting,orgrinding.
Temporarilysettheroofpanelandclampwiththevisegrips.
Note:Checkthattheflangesurfacefitclosely.Becarefulnottotwistordeformtheroofpanel.
Measurethedimensionsdiagonallyatthewindshieldareaandrearglassareawithatrackinggaugeorconvexruleasshowntocheck
itfortwistingorbending.
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8. Performthemainweldingandfinish.
Caution:Topreventeyeinjuryandburnswhenwelding,wearanapprovedweldinghelmet,glovesandsafetyshoes.
Performatrialweldingfirst,andchecktheweldingcondition.
Increasethenumberofspotby20%forareastobespotwelded.
Useahammeranddollytosmooththespotweldareasonthewindshieldandrearglass.
Cutofftheirregularandunusefulflangesandevenouttheflangesforaclosefitwiththesurfaceoftheroofpanel.
9. Applythesealer.RefertoSection9,Sealing,CaulkingandDeadener.
Applythesealertotheweldedareas.
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10. Applythepaint.
11. Caution:Ventilatewhensprayingpaint.Mostpaintcontainssubstancesthatareharmfulifinhaledorswallowed.Readthepaintlabel
beforeopeningpaintcontainer.
Caution:Avoidcontactwithskin.Wearanapprovedrespirator,gloves,eyeprotectionandappropriateclothingwhenpainting.
Caution:Paintisflammable.Storeinasafeplace,andkeepitawayfromsparks,flamesorcigarettes.
12. Installtherelatedparts.
Windshieldandrearglass.
Cowl,wiperandrelatedparts.
Wiringharnessandheadlining.
Pillartrims,doorweatherstripandothers.
Installinthereverseorderinwhichtheywereremoved.
13. Checkandadjust.
Cleanthepassengercompartment.
Checkthewindshieldandrearglassforwaterleaks.
Wiringharnessandheadlining.
READENDPANEL
GENERALDESCRIPTION
Therearendpanelisjoinedtothesidepanel,underbodyrearsiderailandrearfloor.Itformsthebasefortherearcombinationlampsandotherpartsandmaintainsthe
rigidityoftherearbody.Payparticularattentiontotwistsandparallelismandcheckmountingofrelatedpartswhenwelding.
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REPAIRPROCEDURE
1. Removetherelatedparts.
Rearandtailgatetrims
Tailgatelockandrelatedparts.
Rearcombinationlampsandwiringharness.
Rearbumperandrelatedparts.
Otherrelatedparts.
2. Roughlypulloutandstraightenthedamagedarea.
Checkthedamageandroughlypulloutandrepairtherelatedsidepanelinner,sparewheelwellpanel,underbodyrearsiderailand
otherdamagedpartswiththeframestraightenerbeforeremovingthebackpanel.
Attachthecartotheframestraightenerbytighteningtheunderbodyclampslocatedatthejackupdesignatedpointsonthebottomof
theframedooropening.
3. Cutandpryofftherearandpanel.
Centerpuncharoundthespotweldimprintswiththerearsideouterandsaparewheelwellpanel.
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Usethespecialspotcuttertodrillholesatthespotweldnuggetsontherearsideouterandsaparewheelwellpanel.
Note:Whendrillingholesbecarefulnottodrilldowntothesideouterandsparewheelwellpanelthemselves.
Cutofftherearendpanelwithanairchisel,leavingtheweldingflangesintact.
Levelandfinishtheburrsfromthefriedoffspotweldswithdiscsanderandrepairallcracks,holesorotherdefectsbyweldingalso
repairthefloorpanelifnecessary.
Caution:Topreventeyeinjury,weargogglesorsafetyglasseswheneversanding,cutting,orgrinding.
4. Peelofftheundercoatandsealer.
Heattheundercoatandsealerattheweldingareasoftherearsideouterpanelandsaparewheelwellpanelwithagastorchandpeel
offtheundercoatandsealerwithasteelspatula.
5. Molddamagedrelatedparts.
Useahammeranddollytomolddamagedareasoftherearsideouterandsaparewheelwellpanelpanel.
Evenouttheweldingflangeswithahammeranddolly.
Fillanyholesdrilledbywelding.
6. Setthenewrearendpanel.
Grindbothsidesoftheweldingsectionoftherearendpanelwithasandertoremovethepaintandexposethesteelplate.
Caution:Topreventeyeinjury,weargogglesorsafetyglasseswheneversanding,cutting,orgrinding.
Clampboththerightandleftsideswiththevisegrips.
Weldtheclampedsectionsfortemporaryinstallation.
Caution:Topreventeyeinjuryandburnswhenwelding,wearanapprovedweldinghelmet,glovesandsafetyshoes.
7. Measureandcheck.
Measurethetrunkcompartmentdiagonallytocheckitfortwistingorbendinganditscorrectpositionwiththerearbumperinstalled.
Temporarilyassembletherearcombinationlampsandtrunk,thenchecktheclearancesandleveldifferences.
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8. Performthemainwelding.
MakeMIGorgasweldsatthebuttjoints.
Spotweldthebackpanelasshown.
Caution:Topreventeyeinjuryandburnswhenwelding,wearanapprovedweldinghelmet,glovesandsafetyshoes.
Performatrialweldingfirst,andchecktheweldingcondition.
Increasethenumberofspotby20%forareastobespotwelded.
9. Finishtheweldingareas.
LevelthegasorMIGweldedareaswithdiscsander,thenevenouthighareaswithahammerbeingcarefulnottodeformthem.
Useahammeranddollytoevenouttherearsideouterandextensionrearfloorpanelflangesforaclosefitwiththesurfaceoftherear
endpanel.
10. Applythesealer.RefertoSection9,Sealing,CaulkingandDeadener.
Applythesealertotherearsideouterjointandaroundtherearlampsareasoftherearendpanel.
Applythesealertothesaparewheelwellpanelpanelandrearendpaneljoint.
11. Applytheundercoat.RefertoSection10,RustPrevention.
Undercoattothejointandoverlappedareasoftherearfloorunderside.
12. Applythepaint.
13. CAUTION
Ventilatewhensprayingpaint.Mostpaintcontainssubstancesthatareharmfulifinhaledorswallowed.Readthepaintlabelbefore
openingpaintcontainer.
Avoidcontactwithskin.Wearanapprovedrespirator,gloves,eyeprotectionandappropriateclothingwhenpainting.
Paintisflammable.Storeinasafeplace,andkeepitawayfromsparks,flamesorcigarettes.
14. Installtherelatedparts.
Cleantheluggagecompartment.
Installinthereverseorderinwhichtheywereremoved.
15. Checkandadjust.
Checkclearancesandleveldifferences.
Checkthetrunklockingandunlockingcondition.
Checkalloperation.
Checkforwaterleaksinthetrunkcompartment.
Note:Usespecifiedchecksheetforoperationcheckproperly.
REARSIDERAIL
GENERALDESCRIPTION
Therearsiderailisjoinedtotherearcompartmentandsparewheelwellpanel,itformsthebasefortherearunderbodyandothers.Therefore,replacementofthe
componentaffectstherearwheelalignmentandmaintainstherigidityoftherearsection.Whenassemblingit,eitheruseajigorfollowdimensionsonthebodyrepairchart
forpositioning.Itmustbeweldedcarefully.
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REPAIRPROCEDURE
1. Removetherelatedparts.
Rearseats,wiringharness,relatedpartsandothers.
Note:Removeaccordingtopartdamaged.
2. Roughlypulloutandstraightenthedamagedareatoapproximatelytheoriginalshape.
Attachthecartotheframestraightenerbytighteningtheunderbodyclampsatthehorizontalpinchweldpoints.
Beforecuttingoffthedamagedsections,pullthemoutsothattheyarerestoredtotheoriginalshape.
Roughlycutofftherearsiderailaccordingtotheextentofdamagebeforeroughlypullingoutthedamagemakesrepairoftherelated
partsdifficult.
Donotpulloutmorethannecessary.
Note:Checktheconditionofthedoorandhinges.
3. Peelofftheundercoatandsealer.
Heattheundercoatandsealerattheweldingareasofthedamagedpartswithagastorchandpeelofftheundercoatandsealerwitha
steelspatula.
Caution:Becarefulnottoburnthefittingsinsidethepassengercompartmentwhenheating.
4. Cutandpryofftherearsiderail.
Centerpuncharoundthespotweldimprintsontherearcompartmentpanelandotherrelatedparts.
Usethespecialspotcuttertodrillholesatthespotweldnuggetsonthecenterpunchedareas.
Cutoffthefrontlongitudinalwithanairchisel,leavingtheweldingflangesintact.
Levelandfinishtheburrsfromthepriedoffspotweldswithadiscsander.
Caution:Topreventeyeinjury,weargogglesorsafetyglasseswheneversanding,cutting,orgrinding.
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5. Molddamagedrelatedparts.
Fillanyholesdrilledbywelding.
Caution:Topreventeyeinjuryandburnswhenwelding,wearanapprovedweldinghelmet,glovesandsafetyshoes.
Reshapethewheelhouseandotherdamagedpartsandevenouttheweldingflangeswithahammeranddolly.
6. Setthenewrearsiderail.
Grindbothsidesoftheweldingsectionoftherearsiderailandrearcompartmentpanelwithadiscsandertoremovethepaintand
exposethesteelplate.
Caution:Topreventeyeinjury,weargogglesorsafetyglasseswheneversanding,cutting,orgrinding.
Tightenthenewrearsiderailagainstremainingpartswiththevisegripsandpliers.
Placeajackundertherearsiderailendandsupportit,andmeasurethepositionsforcorrectsetting.
Note:Useofjigsisrecommendedforcorrectpositionsandcheckthattherearsiderailisparallel.
Tackweldtheclampedsectionfortemporaryinstallation.
7. Performthemainwelding.
Weldasmuchaspossiblewiththejigstillmounted.
Caution:Topreventeyeinjuryandburnswhenwelding,wearanapprovedweldinghelmet,glovesandsafetyshoes.
Performatrialweldingfirst,andchecktheweldingcondition.
Increasethenumberofspotby20%forareastobespotwelded.
8. Applytheundercoat.RefertoSection10,RustPrevention.
Undercoattothejointandoverlappedareasofthefrontfloor,siderailundersideandtheinsideoffront,rearwheelhouse.
9. Applythepaint.
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Caution:Ventilatewhensprayingpaint.Mostpaintcontainssubstancesthatareharmfulifinhaledorswallowed.Readthepaintlabel
beforeopeningpaintcontainer.
Caution:Avoidcontactwithskin.Wearanapprovedrespirator,gloves,eyeprotectionandappropriateclothingwhenpainting.
Caution:Paintisflammable.Storeinasafeplace,andkeepitawayfromsparks,flamesorcigarettes.
10. Coatingtheantirustagents.RefertoSection10,RustPrevention.
Coatingtheantirustagentstotheendoffrontpanelsideandthefrontdoorhingeareas.
11. Installtherelatedparts.
Cleanthepassengercompartment.
Wiringharness,instrumentpanelandrelatedparts.
Partsofthepassengercompartment.
Chassiscomponents.
Engine,radiatorandrelatedparts.
Airconcondenserandrelatedparts.
Headlampsandfenders.
Heed,radiatorgrill,andbumper.
Others.
Installinthereverseorderinwhichtheywereremoved.
Note:Afterinstalltheallrelatedparts,rubingreaseothemovingpartsandreplenishcoolingliquid,breakoil,aircongasandothers.
12. Checkandadjust
Checkclearancesandleveldifferences.
Checkthehoodlockingandunlockingcondition.
Adjusttheheadlampaim.
Checkalloperation.
Checkforgas,oilandliquidleaks.
Checkforwaterleaksinthepassengercompartment.
Note:Usespecifiedchecksheetforoperationcheckproperly.
FLOORPANELANDSPAREWHEELWELLPANEL
GENERALDESCRIPTION
Thefloorpanelisthebaseoftheunderbodyanditiscriticalfortherigidityoftheunderbody.Duringreplacement,refertothebodydimensionchartorbody
repairchartanddeterminethepositiontosetthepanelproperly.
Besurethatthepanelisnotbentordeformed.Weldsecurelytomaintaintherigidityoftheunderbody.
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1. SpotWeldSealer
REPAIRPROCEDURE
1. Removetherelatedparts.
Partstoberemovedwhenremovingthebackpanel.
Rearseatbeltandrearseat.
Muffler,fueltankandrelatedparts.
Chassisparts.
Otherrelatedparts.
Caution:Donotsmokewhileworkingnearthefuelsystem.Keepopenflameawayfromthefuelsystem.Ifnecessary,removethefuel
tankandofflines.
2. Roughlypulloutandstraightenthedamagedarea.
Checkthedamageandroughlypulloutandrepairtherelatedbackpanel,sidepanel,wheelhouseinner,rearlongitudinalandother
damagedpartswiththeframestraightenerbeforeremovingtherearfloorpanel,rearfloorpaneandbackpanel.
Attachthecartotheframestraightenerbytighteningtheunderbodyclampslocatedatthejackupdesignatedpointsonthebottomof
theframedooropening.
Note:Measureinreferencetothedimensionsonthebodyrepairchart.
3. Cutandpryofftherearendpanel.
Therearendpaneltobecutandpriedoffwhenremovingtherearendpanel.
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4. Cutandpryoffthefloorandsparewheelwellpanel.
Centerpuncharoundthespotweldimprintswiththerearlongitudinalandwebplate.
Usethespecialspotcuttertodrillholesatthespotweldnuggetsonthecenterpunchedareas.
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Note:Whendrillingholesbecarefulnottodrilldowntotherearlongitudinal,extensionrearlongitudinalandwebplatethemselves.
Cutandpryofftheremainingfloorpanelwithanairchisel,leavingtheweldingflangesintact.
Levelandfinishtheburrsfromthepriedoffspotweldswithdiscsanderandrepairallcracks,holesorotherdefectsbyweldingalso
repairtherearlongitudinalifnecessary.
Caution:Topreventeyeinjury,weargogglesorsafetyglasseswheneversanding,cutting,orgrinding.
5. Peelofftheundercoatandsealer.
Heattheundercoatandsealerattheweldingareaswithagastorchandpeelofftheundercoatandsealerwithasteelspatula.
6. Molddamagedrelatedparts.
Useahammeranddollytomolddamagedareasoftheunderbodyrearsiderail.
Evenouttheweldingflangeswithahammeranddolly.
Fillanyholesdrilledbywelding.
Caution:Topreventeyeinjuryandburnswhenwelding,wearanapprovedweldinghelmet,glovesandsafetyshoes.
Levelandfinishtheburrsfromthepriedoffspotweldswithdiscsander.
Sandoffthepaintandundercoatfrombothsidesoftheflangetobewelded.
7. Cutthenewfloorandsparewheelwellpanel.
Grindbothsidesoftheweldingsectionwithadisksandertoremovethepaintandexposethesteelplate.
Caution:Topreventeyeinjury,weargogglesorsafetyglasseswheneversanding,cutting,orgrinding.
Setandclampthenewpanelinplacewiththevisegrips.
Note:Useofjigsisrecommendedforcorrectpositionsandcheckthatthebothrearlogitudinalisparallel.
Tackweldtheclampedsectionfortemporaryinstallation.
Caution:Topreventeyeinjuryandburnswhenwelding,wearanapprovedweldinghelmet,glovesandsafetyshoes.
Removethevisegripsandtemporarilyinstalltherearendpanel,thencheckthealignment,leveldifferencesandouterappearance.
8. Performthemainwelding.
WeldtherearfloorandrearseatcrossmemberwithaMIGwelderfilletweldingsasshown.
Caution:Topreventeyeinjuryandburnswhenwelding,wearanapprovedweldinghelmet,glovesandsafetyshoes.
Performatrialweldingfirst,andchecktheweldingcondition.
Increasethenumberofspotby20%forareastobespotwelded.
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9. Weldtherearendpanel.
Thebackpaneltobeweldedwhenreplacementthebackpanel.
Useahammeranddollytoevenoutthespotweldedareasforaclosefilltheflangesurfacetogether.
10. Applythesealeranddeadener.RefertoSection9,Sealing,CaulkingandDeadener.
Applythesealerattheoverlappedareasoftherearfloorandweldedsurfacesofthematchingpanelandallsealinggapscompletely.
11. Applytheundercoat.RefertoSection10,RustPrevention.
Undercoattotherearwheelhouseanddesignatedfloor.
12. Applythepaint
Caution:Ventilatewhensprayingpaint.Mostpaintcontainssubstancesthatareharmfulifinhaledorswallowed.Readthepaintlabel
beforeopeningpaintcontainer.
Caution:Avoidcontactwithskin.Wearanapprovedrespirator,gloves,eyeprotectionandappropriateclothingwhenpainting.
Caution:Paintisflammable.Storeinasafeplace,andkeepitawayfromsparks,flamesorcigarettes.
13. Installtherelatedparts.
Installinthereverseorderinwhichtheywereremoved.
14. Checkandadjust
Checkclearancesandleveldifferences.
Checkthetailgatelockingandunlockingcondition.
Checkalloperation.
Checkforwaterleaksintheluggagecompartment.
Note:Usespecifiedchecksheetforoperationcheckproperly.
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