01/12/2014 BodyRepairManualCaptivaFRAMEDOOROPENING,DOORANDSIDEPANELOUTER

Captiva

FRAMEDOOROPENING,DOORANDSIDEPANELOUTER
FRAMEDOOROPENING
GENERALDESCRIPTION
Theframedooropeningconsistofframedoorareaandsideouterarea.Itformsthebaseforthefront,reardoorsandotherpartsandmaintainstherigidityof
thedoorsandroof.Theframedooropeningareashould,dependingonthedegreeofdamage,berepairedasmuchaspossibleratherthanrepalced.(Repairby
pullingout)

1. Spotweldsealer

REPAIRPROCEDURE
1. Removetherelatedparts.
Doors.
Weatherstrips,pillartrimsandrelatedparts.
Carpet.
Seatbeltassembly
Doorswitchandwiringharness.
Fuelpipeandbrakeoilpipe.
Otherrelatedparts.

Note:Removeaccrodingtopartdamaged.
2. Pulloutandstraightenthedamagedareatoapproximatelytheoriginalshape.
Damagemayextendtotheinnerroofframe,theinnerframedooropeningandthefloor.Determinetheextentofthedamagefirst,so
theframecanbepulledoutproperly.

Note:Useheatresistantprotectivecoverforprotectpaintingareas,seats,carpetsandotherparts.
Pulloutandstraightenthedamagedareas.
Donotpulloutmorethannecessary.
3. Cutandpryofftheframedooropening.
Checkthedamageontheframedooropening,thencutthenewframedooropeningsoitwilloverlapby30mm(1.18in.)inthepillar,
frontandrear.
Cutthedamagedareawithahandsawalongtheboldlineasshown.

Note:Becarefulnottocuttheinnerpanel.Thiscouldresultinextensiverepair.

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01/12/2014 BodyRepairManualCaptivaFRAMEDOOROPENING,DOORANDSIDEPANELOUTER

Ifthedamageinvolvespartofthecenterpillar,cutthemasshown.

Centerpuncharoundthespotweldimprintsontheweldedflange.
Usethespecialspotcuttertodrillholesatthespotweldnuggets.

Note:Whendrillingholesbecarefulnottodrilldowntotheinnerpanel..
Pryofftheframedooropeningpanelwithanairchisel,leavingtheweldingflangesintact.

Caution:Topreventeyeinjury,weargogglesorsafetyglasseswheneversanding,cutting,orgrinding.

4. Molddamagedrelatedparts.
Fillanyholesdrilledbywelding.

Caution:Topreventeyeinjuryandburnswhenwelding,wearanapprovedweldinghelmet,glovesandsafetyshoes.

Useahammeranddollytomolddamagedareasoftheremaininginnerpanelandevenouttheweldingflanges.
Levelandfinishtheburrsfromthepriedoffspotweldswithdiscsander.
Sandoffthepaintandundercoatfrombothsidesoftheflangetobewelded.
5. Setthenewframedooropening.
Grindbothsidesoftheweldingsectionofthepreparedframedooropeningpartwithadisksandertoremovethepaintandexposethe
steelplate.
Clampthenewpanelinplacewiththevisegrips.
Tackweldtheclampedsectionfortemporaryinstallation.

Caution:Topreventeyeinjuryandburnswhenwelding,wearanapprovedweldinghelmet,glovesandsafetyshoes.

Removethevisegripsandtemporarilyinstallthefenderanddoors,thenchecktheclearances,leveldifferencesandouterappearance.
6. Performthemainwelding.
Weldthefront,rearframedooropeningandcenterpillaratthebuttjointswithagasorMIGwelder.

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01/12/2014 BodyRepairManualCaptivaFRAMEDOOROPENING,DOORANDSIDEPANELOUTER
Spotweldtheframedooropeningandcenterpillarasshown.

Caution:Topreventeyeinjuryandburnswhenwelding,wearanapprovedweldinghelmet,glovesandsafetyshoes.

Performatrialweldingfirst,andchecktheweldingcondition.
Increasethenumberofspotby20%forareastobespotwelded.

7. Finishtheweldingareas.
LevelthegasorMIGweldedareaswithadiscsander,thenevenouthighareaswithahammerbeingcarefulnottodeformthem.

Caution:Topreventeyeinjury,weargogglesorsafetyglasseswheneversanding,cutting,orgrinding.

Useahammeranddollytoevenoutthespotweldedflangesforaclosefitwiththesurfaceoftheframedooropeningpanel.
Fillindeformationsandleveldifferencesoftheweldedareaswithsolderorputty,thenfinish.
8. Applythesealer.RefertoSection9,Sealing,CaulkingandDeadener.
Applythesealertothematchingsurfacesofthefloorandframedooropening.
9. Applytheundercoat.RefertoSection10,RustPrevention.
Undercoattothefrontfloor.
10. Applythepaint.

11. Caution:Ventilatewhensprayingpaint.Mostpaintcontainssubstancesthatareharmfulifinhaledorswallowed.Readthepaintlabel
beforeopeningpaintcontainer.

Caution:Avoidcontactwithskin.Wearanapprovedrespirator,gloves,eyeprotectionandappropriateclothingwhenpainting.

Caution:Paintisflammable.Storeinasafeplace,andkeepitawayfromsparks,flamesorcigarettes.

12. Coatingtheantirustagents.RefertoSection10,RustPrevention.
Coatingtheantirustagentstotheinsideofframedooropeningareassufficiently.

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01/12/2014 BodyRepairManualCaptivaFRAMEDOOROPENING,DOORANDSIDEPANELOUTER

13. Installtherelatedparts.
Cleanthepassengercompartment.
Wiringharnessandrelatedparts.
Seatbeltassemblyandcarpet.
Trimsandweatherstrips.
Doorandothers.
Installinthereverseorderinwhichtheywereremoved.
14. Checkandadjust.
Checkclearancesandleveldifferences.
Checkthedoorlockingandunlockingcondition.
Checkforwaterleaksinthepassengercompartment.

DOOR
REPAIRPROCEDURE
1. Removetherelatedparts.
Doortrimandrelatedparts.
Wiringharnessandsolenoidvalve.
Glassandwindowlifter.
Linkage,locksetandhandle.
Others.

Note:Inspectionandchoosetheusableparts.
2. Removethedoor.
Removetheboltfromdoorcheckhinge(1)andremovethefourbolts(2)fromdoorassembly.

3. Preparationofthenewdoor.
Preparationofthenewdoorandcheckdamagedareas.
4. Preinstallthedoor.
Fixthefourbolts.
Checkandadjusttheclearancesandleveldifferencesofdoors,fender,pillar,roofandsidepanelouters.

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01/12/2014 BodyRepairManualCaptivaFRAMEDOOROPENING,DOORANDSIDEPANELOUTER

Checkanydeformation.
5. Removethenewdoor.
Removethefourboltsfromdoorassembly.
6. Applythepaint.
7. CAUTION
Ventilatewhensprayingpaint.Mostpaintcontainssubstancesthatareharmfulifinhaledorswallowed.Readthepaintlabelbefore
openingpaintcontainer.
Avoidcontactwithskin.Wearanapprovedrespirator,gloves,eyeprotectionandappropriateclothingwhenpainting.
Paintisflammable.Storeinasafeplace,andkeeptawayfromsparks,flamesorcigarettes.
8. Coatingtheantirustagents.
Coatingtheantirustagentstotheinsideofbottomareas.

9. Installthedoor.
Installthedoorwithfourbolts.
Installthedoorchecklinksetinthedoorandfixthebolt.
Checkclearancesandleveldifferences.
10. Installtherelatedparts.
Handle,linkageandlockset.
Glassandwindowlifter.
Solenoidvalveandwiringharness.
Installdoortrimandothers.

Note:Beforeinstallthedoortrimandrelatedparts,rubingreasetothemovingpartsandcheckalloperation.
11. Checkandadjust.
Checkclearanceandleveldifferences.
Checkthedoorlockingandunlockingcondition.
Checkforwaterleaksinthepassengercompartment.
Installdoortrimandothers.

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01/12/2014 BodyRepairManualCaptivaFRAMEDOOROPENING,DOORANDSIDEPANELOUTER
SIDEPANELOUTER
GENERALDESCRIPTION
Thesidepanelouterconsistsofsideouterareaandframedoorarea.Thesideouterareaisaconspicuouspartoftheouterappearanceofthevehicle.Itisespecially
importantforthebodylinecontinuingfromdoor.Therefore,payparticularattentiontoitwhenconductingwork.Thispartmustbealignedwiththereardoor,tailgate,rear
glassandotherparts.

REPAIRPROCEDURE
1. Removetherelatedparts.
Rearandtailgatetrims.
Rearcombinationlampsandwiringharness.
Rearbumperandrelatedparts.
Rearseatandrearseatbelt.
Chassisandfuelparts.
Otherrelatedparts.

Caution:Donotsmokewhileworkingnearthefuelsystem.Keepopenflameawayfromthefuelsystem.Ifnecessary,removethefuel
tankandofflines.

2. Pulloutandstraightenthedamagedareatoapproximatelytheoriginalshape.
Attachthecartotheframestraightenerbytighteningtheunderbodyclampsatthefourdesignatedsupportpoints.
Beforecuttingoffthedamagedsections,pullthemoutsothattheyarerestoredtotheoriginalshape.
Donotpulloutmorethannecessary.
Pulloutandstraightenthedamagedareasoftherearsideouterpanel,sideinnerpanelandwheelhouseinner.

Note:Checkthereardoorlockingandunlockingcondition.
3. Cutandpryoffthesidepanelouter.
Cutattherearpillarandsideouter(rearsideofframedooropening)alongtheboldlinesasshownwithahandsawandsnipscarefully.

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Centerpuncharoundthespotweldimprintswiththerearpanel,sidepanelinnerandarcharea.
Usethespecialspotcuttertodrillholesatthespotweldnuggetsontherearsideouterpanel.

Note:Whendrillingholesbecarefulnottodrilldowntothesidepanelinnerandrearpanelthemselves.
Cutthepanelfromthebodywithanairchisel,leavingtheweldingflangesatthesideinnerpanel,wheelhouseinnerandbackpanel
intact.
Levelandfinishtheburrsfromthepriedoffspotweldswithahammer,dollyanddiscsander.

Caution:Topreventeyeinjury,weargogglesorsafetyglasseswheneversanding,cutting,orgrinding.

4. Molddamagedrelatedparts.
Fillanyholesdrilledbywelding.

Caution:Topreventeyeinjuryandburnswhenwelding,wearanapprovedweldinghelmet,glovesandsafetyshoes.

Useahammeranddollytomolddamagedareasoftheremaininginnerpanelandevenouttheweldingflanges.
Sandoffthepaintandundercoatfrombothsidesoftheflangetobewelded.
5. Setthenewsidepanelouter.
Cutthenewsidepaneloutersoitwilloverlapby30mm(1.18in.)intheframedooropeningareawithahandsaw.

Grindbothsidesoftheweldingsectionofthepreparedsidepanelouterwithadisksandertoremovethepaintandexposethesteel
plate.
Clampthenewpanelinplacewiththevisegrips.
Tackweldtheclampedsectionfortemporaryinstallation.

Caution:Topreventeyeinjuryandburnswhenwelding,wearanapprovedweldinghelmet,glovesandsafetyshoes.

Removethevisegripsandtemporarilyinstallthetailgateanddoors,thenchecktheclearances,leveldifferencesandouterappearance.
6. Performthemainwelding.

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01/12/2014 BodyRepairManualCaptivaFRAMEDOOROPENING,DOORANDSIDEPANELOUTER
WeldtheframedooropeningareaandpillaratthebuttjointswithagasorMIGwelder.
Spotweldtheflangesandwheelarchofthesidepanelouterasshown.

Caution:Topreventeyeinjuryandburnswhenwelding,wearanapprovedweldinghelmet,glovesandsafetyshoes.

Performatrialweldingfirst,andchecktheweldingcondition.
Increasethenumberofspotby20%forareastobespotwelded.

7. Finishtheweldingareas.
LevelthegasorMIGweldedareaswithadiscsander,thenevenouthighareaswithahammerbeingcarefulnottodeformthem.

Caution:Topreventeyeinjury,weargogglesorsafetyglasseswheneversanding,cutting,orgrinding.

Useahammeranddollytoevenoutthespotweldedflangesforaclosefitwiththesurfaceofthesidepanelouter.
Fillindeformationsandleveldifferencesoftheweldedareaswithsolderorputty,thenfinish.
8. Applythesealer.RefertoSection9,Sealing,CaulkingandDeadener.
Applythesealertothematchingsurfacesofthewebplate,backpanellower,rearcombinationlampareaandsidepanelouter.
9. Applytheundercoat.RefertoSection10,RustPrevention.
Undercoattotherearwheelhouseanddesignatedrearfloor.
10. Applythepaint.

11. Caution:Ventilatewhensprayingpaint.Mostpaintcontainssubstancesthatareharmfulifinhaledorswallowed.

Caution:Readthepaintlabelbeforeopeningpaintcontainer.

Caution:Avoidcontactwithskin.Wearanapprovedrespirator,gloves,eyeprotectionandappropriateclothingwhenpainting.

Caution:Paintisflammable.Storeinasafeplace,andkeepitawayfromsparks,flamesorcigarettes.

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12. Coatingtheantirustagents.
Coatingtheantirustagentstotheinsideofframedooropeningareassufficiently.
13. Installtherelatedparts.
Cleanthepassengerscompartment.
Wiringharnessandrelatedparts.
Seatbeltassemblyandcarpet.
Trimsandweatherstrips.
Doorandothers.
Installinthereverseorderinwhichtheywereremoved.
14. Checkandadjust.
Checkclearancesandleveldifferences.
Checkthedoorlockingandunlockingcondition.
Checkforwaterleaksinthepassengercompartment.

CopyrightChevroletEurope.Allrightsreserved

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