Body Repair ManualCaptiva ROOF, BACK PANEL ANDREAR FLOOR PANEL

ROOF, BACK PANEL ANDREAR FLOOR PANEL

ROOF

GENERAL DESCRIPTION

Deformation of the roof panel is highly noticeable interms of the vehicle's outer appearance. Before replacing the roof, make sure that the body is horizontal.Before welding the roof panel, adjust the frame dooropening flanges so that they contact the roof panel. Payparticular attention to twists and parallelism.

Spot Weld Sealer

REPAIR PROCEDURE

Remove the related parts.

Room lamp, door weatherstrip and pillar trims.
Headlining and wiring harness.
Wiper, cowl and windshield.
Tailgate and others.

Pull out and straighten the damaged area to approximately the original shape.

Note : Use heat-resistant protective cover for protect painting areas, seats, carpets and other parts.

Attach the car to the frame straightener by tightening the underbody clamps at the horizontalpinch welds.
Before cutting off the roof panel, pull them out so that they are restored to the original shape.
Do not pull out more than necessary.
Pull out and straighten the related damaged partsto approximately their original shape.

Note : Make sure that the right and left pillars areparallel with the windshield surface. Check the doorfor proper opening and closing.

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 roof panel.

Cut the roof weld flanges with a hand saw andsnips at the roof panel and roof frames.

Using a chisel, pry off the roof panel along thebold lines as shown.
Center punch around the spot weld imprints ofthe roof welded flange.
Drill holes using the spot cutter.
Using a chisel and a disc sander, pry off thewelded flange from the front, rear body pillar androof panel.
Level and finish the burrs of welded flanges witha disc sander.

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

Peel off the sealer.

Peel off the sealer with a steel spatula at the welding areas of the frame door opening.

Mold damaged related parts.

Use a hammer and dolly to mold damaged areasof the front, rear body pillar inner and frame dooropening.
Even out the welding flanges with a hammer anddolly for close fit with the roof panel weldingflange.
Fill any holes drilled by welding.

Set the new panels.

Grind both sides of the welding section of the railwindshield header, support roof panel, frame rearroof panel and roof panel with a disc sander toremove the paint and expose the steel plate.

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

Temporarily set the roof panel and clamp with the vise grips.

Note : Check that the flange surface fit closely. Becareful not to twist or deform the roof panel.

Measure the dimensions diagonally at the windshield area and rear glass area with a tracking gauge or convex rule as shown to check it for twisting or bending.

Perform the main welding and finish.

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.
Use a hammer and dolly to smooth the spot weldareas on the windshield and rear glass.
Cut off the irregular and unuseful flanges andeven out the flanges for a close fit with the surface of the roof panel.

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

Apply the sealer to the welded areas.

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 appropriate clothing when painting.
Caution : Paint is flammable. Store in a safe place, and keepit away from sparks, flames or cigarettes.
Install the related parts.

Windshield and rear glass.
Cowl, wiper and related parts.
Wiring harness and headlining.
Pillar trims, door weatherstrip and others.
Install in the reverse order in which they were removed.

Check and adjust.

Clean the passenger compartment.
Check the windshield and rear glass for waterleaks.
Wiring harness and headlining.

READ END PANEL

GENERAL DESCRIPTION

The rear end panel is joined to the side panel, underbody rear side rail and rear floor. Itforms the base for the rear combination lamps andother parts and maintains the rigidity of the rear body.Pay particular attention to twists and parallelism andcheck mounting of related parts when welding.

REPAIR PROCEDURE

Remove the related parts.

Rear and tailgate trims
Tailgate lock and related parts.
Rear combination lamps and wiring harness.
Rear bumper and related parts.
Other related parts.

Roughly pull out and straighten the damaged area.

Check the damage and roughly pull out and repair the related side panel inner, spare wheel well panel, underbody rear side rail and other damaged parts with theframe straightener before removing the backpanel.
Attach the car to the frame straightener by tightening the underbody clamps located at the jackup designated points on the bottom of the framedoor opening.

Cut and pry off the rear and panel.

Center punch around the spot weld imprints withthe rear side outer and sapare wheel well panel.
Use the special spot cutter to drill holes at thespot weld nuggets on the rear side outer andsapare wheel well panel.

Note : When drilling holes be careful not to drill downto the side outer and spare wheel well panel themselves.

Cut off the rear end panel with an air chisel, leavingthe welding flanges intact.
Level and finish the burrs from the fried off spotwelds with disc sander and repair all cracks, holesor other defects by welding also repair the floorpanel if necessary.

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

Peel off the undercoat and sealer.

Heat the undercoat and sealer at the weldingareas of the rear side outer panel andsapare wheel well panel with a gas torch and peel off the undercoat and sealer with a steel spatula.

Mold damaged related parts.

Use a hammer and dolly to mold damaged areasof the rear side outer and sapare wheel well panelpanel.
Even out the welding flanges with a hammer anddolly.
Fill any holes drilled by welding.

Set the new rear end panel.

Grind both sides of the welding section of the rear endpanel 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.
Weld the clamped sections for temporary installation.

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

Measure and check.

Measure the trunk compartment diagonally tocheck it for twisting or bending and its correctposition with the rear bumper installed.
Temporarily assemble the rear combination lampsand trunk, then check the clearances and leveldifferences.

Perform the main welding.

Make MIG or gas welds at the butt joints.
Spot weld the back panel 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 discsander, then even out high areas with a hammerbeing careful not to deform them.
Use a hammer and dolly to even out the rear sideouter and extension rear floor panel flanges for aclose fit with the surface of the rear end panel.

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

Apply the sealer to the rear side outer joint andaround the rear lamps areas of the rear end panel.
Apply the sealer to the sapare wheel well panel paneland rear end panel joint.

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

Undercoat to the joint and overlapped areas ofthe rear floor under side.

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.

Install the related parts.

Clean the luggage compartment.
Install in the reverse order in which they were removed.

Check and adjust.

Check clearances and level differences.
Check the trunk locking and unlocking condition.
Check all operation.
Check for water leaks in the trunk compartment.

Note : Use specified check sheet for operationcheck properly.

REAR SIDE RAIL

GENERAL DESCRIPTION

The rear side rail is joined to the rear compartment and spare wheel well panel, it forms the base for the rear underbody and others. Therefore, replacement of the component affects the rear wheel alignmentand maintains the rigidity of the rear 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.

Rear seats, 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 rear 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 rear side rail.

Center punch around the spot weld imprints on therear compartment panel 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.

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

Set the new rear side rail.

Grind both sides of the welding section of the rear side rail and rear compartment panel 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 rear side rail against remaining parts with the vise grips and pliers.
Place a jack under the rear side rail end andsupport it, and measure the positions for correctsetting.

Note : Use of jigs is recommended for correct positions and check that the rear side rail is parallel.

Tack weld the clamped section for temporary installation.

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 undercoat. Refer to Section 10, Rust Prevention.

Undercoat to the joint and overlapped areas ofthe front floor, 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.

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.

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

Coating the anti-rust agents to the end of frontpanel side and the front door hinge areas.

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.

FLOOR PANEL AND SPARE WHEEL WELL PANEL

GENERAL DESCRIPTION

The floor panel is the base of the underbody and itis critical for the rigidity of the underbody. During replacement, refer to the body dimension chart or body repairchart and determine the position to set the panelproperly.

Be sure that the panel is not bent or deformed. Weldsecurely to maintain the rigidity of the underbody.

Spot Weld Sealer

REPAIR PROCEDURE

Remove the related parts.

Parts to be removed when removing the backpanel.
Rear seat belt and rear seat.
Muffler, fuel tank and related parts.
Chassis parts.
Other related parts.

Caution : Do not smoke while working near the fuelsystem. Keep open flame away from the fuel system. If necessary, remove the fuel tank and off lines.

Roughly pull out and straighten the damaged area.

Check the damage and roughly pull out and repair the related back panel, side panel, wheelhouse inner, rear longitudinal and other damagedparts with the frame straightener before removing the rear floor panel, rear floor paneand back panel.
Attach the car to the frame straightener by tightening the underbody clamps located at the jackup designated points on the bottom of the framedoor opening.

Note : Measure in reference to the dimensions onthe body repair chart.

Cut and pry off the rear end panel.

The rear end panel to be cut and pried off when removing the rear end panel.

Cut and pry off the floor and spare wheel well panel.

Center punch around the spot weld imprints withthe rear longitudinaland web plate.
Use the special spot cutter to drill holes at thespot weld nuggets on the center punched areas.

Note : When drilling holes be careful not to drill downto the rear longitudinal, extension rear longitudinaland web plate themselves.

Cut and pry off the remaining floor panel with an air chisel, leavingthe welding flanges intact.
Level and finish the burrs from the pried off spotwelds with disc sander and repair all cracks, holesor other defects by welding also repair the rearlongitudinal if necessary.

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

Peel off the undercoat and sealer.

Heat the undercoat and sealer at the weldingareas with a gas torch and peel off the undercoatand sealer with a steel spatula.

Mold damaged related parts.

Use a hammer and dolly to mold damaged areasof the underbody rear side rail.
Even out the welding flanges with a hammer anddolly.
Fill any holes drilled by welding.

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

Level and finish the burrs from the pried off spotwelds with disc sander.
Sand off the paint and undercoat from both sidesof the flange to be welded.

Cut the new floor and spare wheel well panel.

Grind both sides of the welding section with a disk sanderto remove the paint and expose the steel plate.

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

Set and clamp the new panel in place with the vise grips.

Note : Use of jigs is recommended for correct positions and check that the both rear logitudinal is parallel.

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 therear end panel, then check the alignment, level differences and outer appearance.

Perform the main welding.

Weld the rear floor and rear seat crossmember with a MIG welder fillet weldings 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.

Weld the rear end panel.

The back panel to be welded when replacementthe back panel.

Use a hammer and dolly to even out the spotwelded areas for a close fill the flange surfacetogether.

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

Apply the sealer at the overlapped areas of therear floor and weldedsurfaces of the matching panel and all sealinggaps completely.

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

Undercoat to the rear wheelhouse and designated floor.

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.

Install in the reverse order in which they were removed.

Check and adjust

Check clearances and level differences.
Check the tailgate locking and unlocking condition.
Check all operation.
Check for water leaks in the luggage compartment.

Note : Use specified check sheet for operationcheck properly.