Body Repair ManualCaptiva FRONT

FRONT

TIE BAR

GENERAL DESCRIPTION

The tie bar is joined to the front wheelhouse andfront compartment side rail. It forms the base for the headlampsand other parts and maintains the rigidity of the frontsection of the body. Pay particular attention to twistsand parallelism and check mounting of related partswhen welding.

REPAIR PROCEDURE

Remove the related parts.

Hood and front bumper.
Head lamps and fender.
Engine, radiator and related parts.
Aircon condenser and related parts.
Others.

Roughly pull out and straighten the damaged area.

Check the damage to the front wheelhouse andfront compartment side rail before removing the tie bar.Use the frame straightener to roughly pull out andrepair the damaged tie bar before removingthe tie bar.

Note : Check the fit of the door, taking care not topull the damaged area out more than necessary.

Use the horizontal pinch weld clamps and attachthe car to the frame straightener at the clampingpoints securely.

Keep the body, level.

Jack up the body, and place safety stands at thefour designated places of the frame door opening.

Cut and pry off the tie bar.

Center punch around the spot weld imprints.
Use the special spot cutter to drill holes at thespot weld nuggets on the front wheel house andfront compartment side rail.

Note : When drilling holes be careful not to drill downto the front wheelhouse and front compartment side rail themselves.

Cut off the tie bar with an air chisel, leavingthe welding flanges intact.
Level and finish the burrs from the pried off spotwelds with disc sander.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grinding.

Mold damaged related parts.

Use a hammer and dolly to mold damaged areasof the front wheelhouse and longitudinal.
Even out the welding flanges with a hammer anddolly.
Fill any holes drilled by welding.

Set the tie bar.

Grind both sides of the welding section of the tie bar with a sander to remove the paint and expose the steel plate.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grinding.

Clamp both the right and left sides with the visegrips as shown.
Weld the clamped sections for temporary installation.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Note : Make sure that the right and left tie barare in line with each others.

Measure the front compartment diagonally.

Measure the front compartment diagonally with atracking gauge or convex rule to checkit for twisting or bending.
Temporarily assemble the fender, head lampsand hood, then check the clearances and leveldifferences.

Perform the main welding.

Spot weld the tie bar as shown.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Perform a trial welding first, and check the weldng condition.
Increase the number of spot by 20% for areas tobe spot welded.

Finish the welding areas.

Use a hammer and dolly to even out the frontwheelhouse and front compartment side rail flanges for a closefit with the surface of the tie bar.

Apply the undercoat.

Undercoat to the damaged areas of front wheelhouse and front compartment side rail if necessary.

Apply the paint.
Caution : Ventilate when spraying paint. Most paint containssubstances that are harmful if inhaled or swallowed.Rear the paint label before opening paint container.
Caution : Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriateclothing when painting.
Caution : Paint is flammable. Store in a safe place, andkeep it away from sparks, flames or cigarettes.
Install the related parts.

Engine, radiator and related parts.
Aircon condenser and related parts.
Head lamps and fenders.
Hood, radiator grill, and bumper.
Others
Install in the reverse order in which they were removed.

Note : After install the all related parts, rub in greaseto the moving parts and replenish cooling liquid,break oil, aircon gas and others.

Check and adjust

Check clearances and level differences.
Check the hood locking and unlocking condition.
Adjust the head lamp aim.
Check all operation.
Check for gas, oil and liquid leaks.

Note : Use specified check sheet for operationcheck properly.

FRONT WHEELHOUSE

GENERAL DESCRIPTION

The front wheelhouse component is constructed as aunit with the locator shockabsorber. Therefore, replacement of the component affects the front wheel alignment.When assembling it, either use a jig or follow dimensions on the body repair chart for positioning. It mustbe welded carefully.

REPAIR PROCEDURE

Remove the related parts.

Parts on passenger side of dash panel lowerwhich are especially flammable.
Instrument panel, wiring harness, related partsand others.

Roughly pull out and straighten the damaged areato approximately the original shape.

Attach the car to the frame straightener by tightening the underbody clamps at the horizontalpinch weld points.
Before cutting off the damaged sections, pull themout so that they are restored to the original shape.
Do not pull out more than necessary.
Pull out and straighten the damaged areas of therear wheelhouse and dash panel lower, front filar and other parts.

Note : Check the condition of the door and hinges.

Remove the front wheelhouse panel upper rail

Center punch around the spot weld imprints.
Use the special spot cutter to drill holes at thespot weld nuggets on the brace wheelhouse.
Remove the MIG weld areas with a disc sander.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grinding.

Using a chisel, pry off the welded flange from thefront body puller and wheelhouse.

Peel off the undercoat and sealer.

Heat the undercoat and sealer at the weldingareas of the wheelhouse and front compartment side rail with agas torch and peel off the undercoat and sealerwith a steel spatula.

Cut and pry off the front wheelhouse.

Center punch around the spot weld imprints onthe front compartment side rail and rear wheelhouse.
Use the special spot cutter to drill holes at thespot weld nuggets on the center punched areas.
Cut off the front wheelhouse with an air chisel,leaving the welding flanges intact.
Level and finish the burrs from the pried off spotwelds with disc sander.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grindng.

NOTE :

If damage has occurred only front side, cut thedamaged section of the front wheelhouse, trimthe new panel to fit the remaining section, thenbutt weld both parts at the inner ends.

Mold damaged related parts.

Fill any holes drilled by welding.
Use a hammer and dolly to mold damaged areasof the front compartment side rail, rear wheelhouse andother panels.
Even out the welding flanges with a hammer anddolly.

Set the new front wheelhouse panel.

Grind both sides of the welding section of thefront, rear wheelhouse and front compartment side rail witha disc sander to remove the paint and exposethe steel plate.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grinding.

Clamp to the front compartment side rail with vise grips andsquill vises.
Clamp the tie bar with vise grips.

Note : Use of jigs is recommended.

Weld the clamped sections for temporary installation.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Measure the front compartment diagonally.

Measure the front compartment diagonally with atracking gauge or convex rule to check it for twisting or bending.
Temporarily assemble the fender and hood, thencheck the clearances and level differences.

Perform the main welding.

Weld as much as possible with the jig stillmounted.
Perform a trial welding first, and check the welding condition.
Perform the welding.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Increase the number of spot by 20% for areas tobe spot welded.

Apply the sealer tape.

Apply the sealer tape. Refer to Section 9, Sealing, Caulking and Deadener.

Weld the front wheelhouse panel upper rail.

Spot weld the front wheelhouse panel upper rail as shown.
Make MIG or gas welds at the door hinge areas.

Finish the welding areas.

Use a hammer and dolly to even out the rearwheelhouse and front compartment side rail flanges for aclose fit with the surface of the front wheelhouse.

Apply the sealer

Apply the sealer to the matching and overlappedsurface.

Apply the undercoat.

Undercoat to the inside of the front, rear wheelhouse and front compartment side rail.

Apply the paint.
Caution : Ventilate when spraying paint. Most paint containssubstances that are harmful if inhaled or swallowed. Read the paint label before opening paint container.
Caution : Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriateclothing when panting.
Caution : Paint is flammable. Store in a safe place, andkeep it away from sparks, flames or cigarettes.
Install the related parts.

Wiring harness, instrument panel and relatedparts.
Parts of the passenger compartment.
Parts to be installed when install the tie bar.
Others.
Install in the reverse order in which they were removed..

Note : After install the all related parts, rub in greaseto the moving parts and replenish cooling liquid,break oil, aircon gas and others.

Check and adjust

Measure the front wheel alignment.
Check clearances and level differences.
Check the hood locking and unlocking condition.
Adjust the head lamp aim.
Check all operation.
Check for gas, oil and liquid leaks.

Note : Use specified check sheet for operationcheck properly.

SHROUD UPPER PANEL

GENERAL DESCRIPTION

The shroud upper panel is joined to dash panel. When assembling it, either use a jig or follow dimensions onthe body repair chart for positioning. It must be weldedcarefully.

Spot Weld Sealer

REPAIR PROCEDURE

Remove the related parts.

Parts to be removed when removing the shroud upper panel.
Wiper, windshield glass, wiring harness, related parts andothers.

Note : Remove according to part damaged.

Roughly pull out and straighten the damaged areato approximately the original shape.

Attach the car to the frame straightener by tightening the underbody clamps at the horizontalpinch weld points.
Before cutting off the damaged sections, pull themout so that they are restored to the original shape.
Do not pull out more than necessary.

Peel off the undercoat and sealer.

Heat the undercoat and sealer at the weldingareas of the damaged parts with a gas torch andpeel off the undercoat and sealer with a steelspatula.

Caution : Be careful not to burn the fittings insidethe passenger compartment when heating.

Cut and pry off the shroud upper panel.

Note : It's not necessary to separate the wheelhousefrom the front longitudinal if the wheelhouse is to bereplaced also.

Center punch around the spot weld imprints on thewheelhouse and other related parts.
Use the special spot cutter to drill holes at thespot weld nuggets on the center punched areas.
Cut off the front longitudinal with an air chisel, leaving the welding flanges intact.
Level and finish the burrs from the pried off spotwelds with a disc sander.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grinding.

Mold damaged related parts.

Fill any holes drilled by welding.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Set the new shroud upper panel.

Grind both sides of the welding section of the shroud upper panel with a disc sander to remove the paint and expose the steel plate.

Caution : To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting, or grinding.

Set and clamp the shroud upper panel in place with thevise grips.

Weld the clamped sections for temporary installation.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Perform the main welding.

Weld as much as possible with the jig stillmounted.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Perform a trial welding first, and check the welding condition.
Increase the number of spot by 20% for areas tobe spot welded.

Apply the sealer and deadener. Refer to Section 9, Sealing, Caulking and Deadener.

Undercoat to the joint and overlapped areas ofthe front floor, longitudinal under side and theinside of front, rear wheelhouse.

Apply the paint.

Caution : Ventilate when spraying paint. Most paint containssubstances that are harmful if inhaled or swallowed. Read the paint label before opening paint container.

Caution : Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriateclothing when painting.

Caution : Paint is flammable. Store in a safe place, andkeep it away from sparks, flames or cigarettes.

Install the related parts.

Clean the passenger compartment.
Wiper, windshield glass, wiring harness, instrument panel and related parts.
Others.
Install in the reverse order in which they were removed.

Note : After install the all related parts, rub in greaseto the moving parts and replenish cooling liquid,break oil, aircon gas and others.

Check and adjust

Check clearances and level differences.
Check all operation.
Check for gas, oil and liquid leaks.
Check for water leaks in the passenger compartment.

Note : Use specified check sheet for operationcheck properly.

FRONT COMPARTMENT SIDE RAIL

GENERAL DESCRIPTION

The front compartment side rail is joined to the wheelhouse andtie bar, it forms the base for the front suspension,engine, transmission and others. Therefore, replacement of the component affects the front wheel alignmentand maintains the rigidity of the front section. Whenassembling it, either use a jig or follow dimensions onthe body repair chart for positioning. It must be weldedcarefully.

REPAIR PROCEDURE

Remove the related parts.

Parts to be removed when removing the tie bar and front wheelhouse.
Parts on passenger side of dash panel lower whichare especially flammable.
Instrument panel, wiring harness, related parts andothers.

Note : Remove according to part damaged.

Roughly pull out and straighten the damaged areato approximately the original shape.

Attach the car to the frame straightener by tightening the underbody clamps at the horizontalpinch weld points.
Before cutting off the damaged sections, pull themout so that they are restored to the original shape.
Roughly cut off the front compartment side rail accordingto the extent of damage before roughly pulling outthe damage makes repair of the related partsdifficult.
Do not pull out more than necessary.

Note : Check the condition of the door and hinges.

Peel off the undercoat and sealer.

Heat the undercoat and sealer at the weldingareas of the damaged parts with a gas torch andpeel off the undercoat and sealer with a steelspatula.

Caution : Be careful not to burn the fittings insidethe passenger compartment when heating.

Cut and pry off the front compartment side rail.

Note : It's not necessary to separate the wheelhousefrom the front compartment side rail if the wheelhouse is to bereplaced also.

Center punch around the spot weld imprints on thewheelhouse and other related parts.
Use the special spot cutter to drill holes at thespot weld nuggets on the center punched areas.
Cut off the front compartment side rail with an air chisel, leaving the welding flanges intact.
Level and finish the burrs from the pried off spotwelds with a disc sander.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grinding.

Mold damaged related parts.

Fill any holes drilled by welding.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Reshape the wheelhouse and other damagedparts and even out the welding flanges with ahammer and dolly.

Cut the new front compartment side rail to align it with body,then set the wheelhouse and tie bar.

Cut the new front compartment side rail with a hand sawand it will be butt welded.
Grind both sides of the welding section of the frontcompartment side rail and wheelhouse with a disc sanderto remove the paint and expose the steel plate.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grinding.

Tighten the new front compartment side rail against remaining parts with the vise grips and pliers.
Place a jack under the front compartment side rail end andsupport it, and measure the positions for correctsetting.
Set and clamp the tie bar in place with thevise grips.

Note : Use of jigs is recommended for correct positions and check that the both front compartment side rail andwheelhouse are parallel.

Tack weld the clamped section for temporary installation.

Perform the main welding.

Weld as much as possible with the jig stillmounted.

Spot weld the wheelhouse with the front compartment side rail flange areas and front panel.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Perform a trial welding first, and check the welding condition.
Increase the number of spot by 20% for areas tobe spot welded.

Level the weld beads at the front compartment side rail butt jointsarea with disc sander.
Make the stiffener according to the form of front compartment side rail buttjoint areas and weld the stiffener at the front compartment side rail butt joint areas with MIG welder.

Finish the welding areas.

Level the gas or MIG welded areas with discsander.
Use a hammer and dolly to even out the wheelhouse and front compartment side rail flanges for a close fit.

Apply the sealer. Refer to Section 9, Sealing, Caulking and Deadener.

Apply the sealer to the joint areas of the dashpanel lower and floor panel areas.

Apply the undercoat. Refer to Section 10, Rust Prevention.

Undercoat to the joint and overlapped areas ofthe front compartment side rail under side and theinside of front, rear wheelhouse.

Apply the paint.
CAUTION

Ventilate when spraying paint. Most paint containssubstances that are harmful if inhaled or swallowed. Read the paint label before opening paint container.
Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriateclothing when painting.
Paint is flammable. Store in a safe place, andkeep it away from sparks, flames or cigarettes.

Coating the anti-rust agents. Refer to Section 10, Rust Prevention.

Coating the anti-rust agents.

Install the related parts.

Clean the passenger compartment.
Wiring harness, instrument panel and relatedparts.
Parts of the passenger compartment.
Chassis components.
Engine, radiator and related parts.
Aircon condenser and related parts.
Head lamps and fenders.
Heed, radiator grill, and bumper.
Others.
Install in the reverse order in which they were removed.

Note : After install the all related parts, rub in greaseo the moving parts and replenish cooling liquid,break oil, aircon gas and others.

Check and adjust

Check clearances and level differences.
Check the hood locking and unlocking condition.
Adjust the head lamp aim.
Check all operation.
Check for gas, oil and liquid leaks.
Check for water leaks in the passenger compartment.

Note : Use specified check sheet for operationcheck properly.

FRONT PILLAR

GENERAL DESCRIPTION

The front pillar area is part of the frame door openingpanel. It's connected to the roof, windshield, door hingesand floor frame and is important as a support for thefront side of the cabin. Connection of the front pillardetermines the position of the windshield and front door.Align the fender, door and windshield while the frontpillar is temporary mounted, and check the clearancesand level differences.

Spot weld sealer

REPAIR PROCEDURE

Remove the related parts.

Hood, radiator grill and front bumper.
Door and fender.
Wiper, cowl and windshield.
Weatherstrip and pillar trims.
Instrument panel and wiring harness.
Carpet and others.

Roughly pull out and straighten the damaged area.

Check the damage to the wheelhouse and roofbefore removing the front wheelhouse panel upper rail and frontpillar and determine the extent of the damage.
Use the frame straightener to roughly pull out andrepair the damaged front pillar before removingthe front wheelhouse panel upper rail and tie bar.

Note : Pull out until the pillar is lined up with thesurface of the windshield and do not pull out morethan necessary.

Remove the front wheelhouse panel upper rail.

Center punch around the spot weld imprints.
Use the special spot cutter to drill holes at thespot weld nuggets on the front wheelhouse panel upper rail.
Remove the MIG weld areas with a disc sander.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grind-ing.

Using a chisel, pry off the welded flange from thefront body pillar and wheelhouse.

Peel off the undercoat and sealer.

Heat the undercoat and sealer at the weldingareas of the wheelhouse and front compartment side rail with agas torch and peel off the undercoat and sealerwith a steel spatula.

Cut and pry off the front pillar.

Cut off the front pillar along the bold lines asshown in the figure below with a handsaw andsnips carefully.

Note : Be careful not to cut the inner section.

Center punch around the spot weld imprints withthe rear wheelhouse, front body pillar inner, rein-forcement front body pillar inner and floor panelside.
Use the special spot cutter to drill holes at thespot weld nuggets on the front pillar.

Note : When drilling holes be careful not to drill downto the front body pillar inner, reinforcement front bodypillar inner and floor panel side themselves.

Pry off the remaining flanges from the body withan air chisel and leaving the welding flanges.
Level and finish the burrs from the pried off spotwelds with a hammer, dolly and disc sander.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grind-ing.

Mold damaged related parts.

Fill any holes drilled by welding.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Use a hammer and dolly to mold damaged areasof the remaining inner panel and even out thewelding flanges.

Set the new front pillar.

Align the new part with the top section, then cutit with a hand saw.
Cut the floor panel side joint area so it will overlap by 30mm(1.18in.)(1) in the floor panel side witha hand saw.
Grind both sides of the welding section with a disksander to remove the paint and expose the steelplate.
Clamp the new panel in place with the vise grips.
Tack weld the clamped section for temporary installation.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Remove the vise grips and temporarily install thefender and doors, then check the clearances,level differences and outer appearance.

Perform the main welding.

Weld the frame door opening area and pillar atthe butt joints with a gas or MIG welder.
Spot weld the flanges of the front pillar as shown.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Perform a trial welding first, and check the welding condition.
Increase the number of spot by 20% for areas tobe spot welded.

Finish the welding areas.

Level the gas or MIG welded areas with a discsander, then even out high areas with a hammerbeing careful not to deform them.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding cutting or grinding.

Use a hammer and dolly to even out the spot weldedflanges for a close fit with the surface of the innerpanel.
Fill in deformations and level differences of thewelded areas with solder or putty, then finish.

Apply the sealer tape. Refer to Section 9, Sealing, Caulking and Deadener.
Weld the front wheelhouse panel upper rail.

Spot weld the front wheelhouse panel upper rail as shown.
Make MIG or gas welds at the door hinge areas.

Finish the welding areas.

Use a hammer and dolly to even out the front wheelhouse panel upper rail for a close fit with the surface of thewheelhouse.

Apply the sealer. Refer to Section 9, Sealing, Caulking and Deadener.

Apply the sealer to the matching and overlappedsurface.

Apply the undercoat. Refer to Section 10, Rust Prevention.

Undercoat to the inside of the front, rear wheelhouse and front compartment side rail.

Apply the paint.
CAUTION

Ventilate when spraying paint. Most paint containssubstances that are harmful if inhaled or swallowed.Read the paint label before opening paint container.
Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriateclothing when painting.
Paint is flammable. Store in a safe place, andkeep it away from sparks, flames or cigarettes.

Coating the anti-rust agents. Refer to Section 10, Rust Prevention.
Install the related parts.

Clean the passenger compartment.
Windshield, cowl and wiper.
Wiring harness, instrument panel and relatedparts.
Carpet, trims and weatherstrip.
Door
Fender and hood.
Radiator grill, bumper and others.
Install in the reverse order in which they were removed.

Check and adjust.

Check the door for proper installation and operation.
Check clearances and level differences.
Check the hood locking and unlocking condition.
Check all operation.
Check for water leaks in the passenger compartment.

Note : Use specified check sheet for operationcheck properly.