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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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01/12/2014 BodyRepairManualCaptivaFRAMEDOOROPENING,DOORANDSIDEPANELOUTER
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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01/12/2014 BodyRepairManualCaptivaFRAMEDOOROPENING,DOORANDSIDEPANELOUTER
12. Coatingtheantirustagents.
Coatingtheantirustagentstotheinsideofframedooropeningareassufficiently.
13. Installtherelatedparts.
Cleanthepassengerscompartment.
Wiringharnessandrelatedparts.
Seatbeltassemblyandcarpet.
Trimsandweatherstrips.
Doorandothers.
Installinthereverseorderinwhichtheywereremoved.
14. Checkandadjust.
Checkclearancesandleveldifferences.
Checkthedoorlockingandunlockingcondition.
Checkforwaterleaksinthepassengercompartment.
CopyrightChevroletEurope.Allrightsreserved
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