Chevrolet Captiva 2007 Manual Service [PDF]

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

CHEVROLET CAPTIVA BODY REPAIR MANUAL MY 2007

General Motors Company

SECTION INDEX

Section

PREFACE

00

GENERAL INFORMATION

01

BODY HARDWARE AND TRIM

02

BODY REPAIR

03

BODY SYSTEMS

04

ROOF

05

SEATS

06

STEERING

07

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Preface Cautions and Notices ABS Component Handling Caution Approved Equipment for Collision Repair Caution Assistant Driving Caution Batteries Produce Explosive Gases Caution Battery Disconnect Caution Brake Dust Caution Brake Fluid Effects on Paint and Electrical Components Notice Brake Fluid Irritant Caution Cleaning Solvent Caution Clearcoat/Ultraviolet Screeners Notice Component Fastener Tightening Notice Cracked Window Caution Damaged Fan Blade Caution Definition of Caution, Notice, and Important Defroster Outlet Caution DOT 4 Brake Fluid Caution Exhaust Service Caution Exterior Trim Emblem Removal Notice Eye Protection Caution Fastener Notice Fuel Pipe Fitting CautionGasoline/Gasoline Vapours Caution Glass and Sheet Metal Handling Caution Halogen Bulb Caution Machined Surface Damage Notice Moving Parts and Hot Surfaces Caution Radiator Cap Removal Caution Relieving Fuel Pressure Caution Road Test Caution Safety Glasses Caution Sensing and Diagnostic Module Handling Caution Sensing and Diagnostic Module Voltage after Ignition is Turned Off Caution Servicing the SIR System Caution SIR Caution SIR Deployed Inflator Modules Are Hot Caution SIR Inflatable Module Deployment Outside Vehicle Caution SIR Inflator Module Disposal Caution SIR Inflator Module Handling and Storage Caution SIR Seatbelt Pretensioner Handling Caution SIR Special Tool Caution Window Edge Damage Notice Window Retention Caution

Section00

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ABS Component Handling Caution Caution: Certain components in the Antilock Brake System (ABS) are not intended to be serviced individually. Attempting to remove or disconnect certain system components may result in personal injury and/or improper system operation. Only those components with approved removal and installation procedures should be serviced.

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Approved Equipment for Collision Repair Caution Caution: To avoid personal injury when exposed to welding flashes or to galvanized (Zinc Oxide) metal toxic fumes while grinding/cutting on any type of metal or sheet molded compound, you must work in a properly ventilated area, wearing an approved respirator, eye protection , earplugs, welding gloves, and protective clothing.

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Assistant Driving Caution Caution: An assistant should drive the vehicle while the technician checks for the location of the reported condition. Otherwise, personal injury could result.

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Batteries Produce Explosive Gases Caution Caution: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: • Always shield your eyes.

• Avoid leaning over the battery whenever possible. • Do not expose the battery to open flames or sparks. • Do not allow battery acid to contact the eyes or the skin. - Flush any contacted areas with water immediately and thoroughly. - Get medical help.

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Battery Disconnect Caution Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

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Brake Dust Caution Caution: Avoid taking the following actions when you service wheel brake parts: • Do not grind brake linings.

• Do not sand brake linings. • Do not clean wheel brake parts with a dry brush or with compressed air. Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne.

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Brake Fluid Effects on Paint and Electrical Components Notice Notice: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to wipe away the fluid.

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Brake Fluid Irritant Caution Caution: Brake fluid may irritate eyes and skin. In case of contact, take the following actions: • Eye contact--rinse thoroughly with water.

• Skin contact--wash with soap and water. • If ingested--consult a physician immediately.

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Cleaning Solvent Caution Caution: Bodily injury may occur if the cleaning solvent is inhaled or exposed to the skin.

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Clearcoat/Ultraviolet Screeners Notice Notice: Removing more than 0.5 mils of the clearcoat can result in early paint failure. The clearcoat contains ultraviolet screeners. Do not finesse sand more than what is required to remove the defect.

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Component Fastener Tightening Notice Notice: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.

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Cracked Window Caution Caution: If a window is cracked but still intact, crisscross the window with masking tape in order to reduce the risk of damage or personal injury.

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Damaged Fan Blade Caution Caution: To help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan blade or housing should always be replaced.

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Definition of Caution, Notice, and Important The diagnosis and repair procedures in the GM Service Manual contain both general and specific Cautions, Notices, and Importants. GM is dedicated to the presentation of service information that helps the technician to diagnose and repair the systems necessary for the proper operation of the vehicle, however, certain procedures may present a hazard to the technician if they are not followed in the recommended manner . Cautions, Notices, and Importants are elements designed to prevent these hazards, however, not all hazards can be foreseen. This information is placed at strategic locations within the service manual. This information is designed to prevent the following from occurring: • Serious bodily injury to the technician • Damage to the vehicle • Unnecessary vehicle repairs • Unnecessary component replacement • Improper repair or replacement of vehicle components. Any caution or notice that appears in general information is referenced from the individual service categories.

CAUTION Defined When encountering a CAUTION, you will be asked to take a necessary action or not to take a prohibited action. If a CAUTION is not heeded, the following consequences may occur: • Serious bodily injury to the technician • Serious bodily injury to other technicians in the workplace area • Serious bodily injury to the driver and/or passenger(s) of the vehicle, if the vehicle has been improperly repaired

NOTICE Defined Notices call special attention to a necessary action or to a prohibited action. If a NOTICE is not heeded, the following consequences may occur: • Damage to the vehicle • Unnecessary vehicle repairs • Unnecessary component replacement • Improper operation or performance of the system or component under repair • Damage to any systems or components which are dependent upon the proper operation of the system or component under repair • Improper operation or performance of any systems or components which are dependent upon the proper operation or performance of the system or component under repair • Damage to fasteners, basic tools, or special tools • The leakage of coolant, lubricant, or other vital fluids

IMPORTANT Defined IMPORTANT statements emphasize a necessary characteristic of a diagnostic or repair procedure. IMPORTANT statements are designed to do the following: • Clarify a procedure • Present additional information for accomplishing a procedure • Give insight into the reason or reasons for performing a procedure in the manner recommended • Present information that will help to accomplish a procedure in a more effective manner • Present information that gives the technician the benefit of past experience in accomplishing a procedure with greater ease

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Defroster Outlet Caution Caution: If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury.

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DOT 4 Brake Fluid Caution Caution: Use only GM Vehicle Care Brake and Clutch Fluid Super DOT-4, GM P/N 88958860 (Canadian P/N 88901244), or equivalent DOT-4 brake fluid from a clean, sealed container. This polyglycol brake fluid is hygroscopic and absorbs moisture. Do not use fluid from an open container that may be contaminated with water. Improper or contaminated fluid could result in system failure, loss of vehicle control, and possible injury.

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Exhaust Service Caution Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

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Exterior Trim Emblem Removal Notice Notice: Use a plastic, flat-bladed tool to prevent paint damage when removing an emblem/name plate.

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Eye Protection Caution Caution: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury.

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Fastener Notice Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

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Fuel Pipe Fitting Caution Caution: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.

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Gasoline/Gasoline Vapors Caution Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

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Glass and Sheet Metal Handling Caution Caution: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury.

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Halogen Bulb Caution Caution: Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury: • Turn off the lamp switch and allow the bulb to cool before changing the bulb.

• • • • • •

Leave the lamp switch OFF until the bulb change is complete. Always wear eye protection when changing a halogen bulb. Handle the bulb only by its base. Avoid touching the glass. Keep dirt and moisture off the bulb. Properly dispose of the used bulb. Keep halogen bulbs out of the reach of children.

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Machined Surface Damage Notice Notice: Do not nick, scratch or damage the sealing surface. The sealing surface is a machined surface. Damage to the machined surface can cause leakage.

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Moving Parts and Hot Surfaces Caution Caution: Avoid contact with moving parts and hot surfaces while working around a running engine in order to prevent physical injury.

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Radiator Cap Removal Caution Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.

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Relieving Fuel Pressure Caution Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

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Road Test Caution Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage.

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Safety Glasses Caution Caution: Wear safety glasses in order to avoid eye damage.

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Sensing and Diagnostic Module Handling Caution CAUTION: Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: • Remove any dirt, grease, etc. from the mounting surface

• Position the SDM horizontally on the mounting surface • Point the arrow on the SDM toward the front of the vehicle • Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs.

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Sensing and Diagnostic Module Voltage after Ignition is Turned Off Caution Caution: The sensing and the diagnosis module (SDM) can maintain sufficient voltage to deploy the airbags and pretensioners for up to 1 minute after the ignition has been turned OFF and the fuse has been removed. If the airbags and pretensioners are not disconnected, do not begin service until one minute has been passed after disconnecting power to the SDM. Failure to do so may cause personal injury.

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Servicing the SIR System Caution Caution: When performing service on or around the SIR components or the SIR wiring, follow the procedures listed below in order to temporarily disable the SIR system. Failure to follow the procedures could result in the following: • Air bag deployment

• Personal injury • Otherwise unneeded SIR system repairs

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SIR Caution Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling . Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs.

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SIR Deployed Inflator Modules Are Hot Caution Caution: After deployment, the metal surfaces of the SIR component may be very hot. To help avoid a fire or personal injury: • Allow sufficient time for cooling before touching any metal surface of the SIR component.

• Do not place the deployed SIR component near any flammable objects.

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SIR Inflatable Module Deployment Outside Vehicle Caution Caution: When deploying a SIR component for disposal, perform the deployment procedures in the order listed. Failure to observe the procedures in the order listed may result in personal injury.

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SIR Inflator Module Disposal Caution Caution: In order to prevent accidental deployment and the risk of personal injury, do not dispose of an undeployed inflator module as normal shop waste. Undeployed inflator modules contain substances that could cause severe illness or personal injury if their sealed containers are damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to observe the following disposal methods may be a violation of federal, state, or local laws.

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SIR Inflator Module Handling and Storage Caution Caution: When carrying an undeployed inflator module: • Do not carry the inflator module by the wires or connector.

• Make sure the air bag opening points away from you. When storing an undeployed inflator module: • Make sure the air bag opening points away from the surface on which the inflator module rests.

• Provide free space for the air bag to expand in case of an accidental deployment. • When storing a steering column, do not rest the column with the air bag opening facing down and the column vertical. Lay the column on its side. Failure to observe these guidelines may result in personal injury.

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SIR Seatbelt Pretensioner Handling Caution Caution: When carrying an undeployed inflatable restraint seat belt pretensioner: • Do not carry the seat belt pretensioner by the wires or connector.

• Carry the seat belt pretensioner by the piston tube, keeping hands and fingers away from the cable. • Make sure the open end of the seat belt pretensioner piston tube points away from you and other people. • Do not cover the seat belt pretensioner piston tube opening with your hand. Failure to observe these guidelines may result in personal injury.

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SIR Special Tool Caution Caution: Failure to observe the special tool recommendations and instructions could cause SIR deployment, personal injury, or unnecessary SIR system repairs.

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Window Edge Damage Notice Notice: Avoid damage to the window from impacting objects due to an exposed edge. The window must be 1 mm (0.025 in) below the surface of the sheet metal to avoid window damage.

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Window Retention Caution Caution: When replacing stationary windows, use Urethane Adhesive Kit GM P/N 12346392 (Canadian P/N 10952983), or a urethane adhesive system meeting GM Specification GM3651G, to maintain original installation integrity. Failure to use the urethane adhesive kit will result in poor retention of the window which may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.

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General Information General Repair Instructions Fasteners

Lifting and Jacking the Vehicle

Section01

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General Repair Instructions • If a floor jack is used, park the vehicle on level ground, "block" the front or rear wheels, set the jack against the frame, raise the vehicle and support it with chassis stands and then perform the service operation. • Before performing the service operation, disconnect the negative battery cable in order to reduce the chance of cable damage and burning due to short-circuiting. • Use a cover on the body, the seats and the floor to protect them against damage and contamination. • Handle brake fluid and antifreeze solution with care as they can cause paint damage. • The use of proper tools, and the recommended essential and available tools where specified, are important for efficient and reliable performance of the service repairs. • Use genuine parts. • Discard used cotter pins, gaskets, O-rings, oil seals, lock washers, angle-torqued fastener and self-locking nuts. Prepare new ones for installation. Normal function of these parts cannot be maintained if these parts are reused. • Keep the disassembled parts neatly in groups to facilitate proper and smooth reassembly. • Keep attaching bolts and nuts separated, as they vary in hardness and design depending on the position of the installation. • Clean the parts before inspection or reassembly. • Also clean the oil parts, etc. Use compressed air to make certain they are free of restrictions. • Lubricate rotating and sliding faces of parts with oil or grease before installation. • When necessary, use a sealer on gaskets to prevent leakage. • Carefully observe all specifications for bolt and nut torques. When service operation is complete, make a final check to be sure service was done properly and the problem was corrected.

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Fasteners Table 1: Table 2:

Metric Prevailing Torque Fastener Minimum Torque Development English Prevailing Torque Fastener Minimum Torque Development

Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive® or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive® recess head screws. GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches. FIGURE Fastener Strength Identification(c)

(1) (2) (3) (4) (5) (6)

English Bolt, Grade 2 (Strength Class) English Bolt, Grade 5 (Strength Class) English Bolt, Grade 7 (Strength Class) English Bolt, Grade 8 (Strength Class) Metric Nut, Strength Class 9 Metric Bolts, Strength Class Increases as Numbers Increase

The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following: • Lower strength • No numbered head marking system • Wrong thread pitch The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications: • M6.0 X 1 • M8 X 1.25 • M10 X 1.5 • M12 X 1.75 • M14 X 2.00 • M16 X 2.00

Prevailing Torque Fasteners Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening. All Metal Prevailing Torque Fasteners

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These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener. Nylon Interface Prevailing Torque Fasteners These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads. Adhesive Coated Fasteners These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener.

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Prevailing Torque Nut, Center Lock Type Prevailing Torque Nut, Top Lock Type Prevailing Torque Nut, Nylon Patch Type Prevailing Torque Nut, Nylon Washer Insert Type Prevailing Torque Nut, Nylon Insert Type Prevailing Torque Bolt, Dry Adhesive Coating Type Prevailing Torque Bolt, Thread Profile Deformed Type Prevailing Torque Bolt, Nylon Strip Type Prevailing Torque Bolt, Out-of-Round Thread Area Type

A prevailing torque fastener may be reused ONLY if: • The fastener and the fastener counterpart are clean and not damaged • There is no rust on the fastener • The fastener develops the specified minimum torque against its counterpart prior to the fastener seating Metric Prevailing Torque Fastener Minimum Torque Development Specification Application

Metric

English

All Metal Prevailing Torque Fasteners z

6 mm

0.4 N·m

4 lb in

z

8 mm

0.8 N·m

7 lb in

z

10 mm

1.4 N·m

12 lb in

z

12 mm

2.1 N·m

19 lb in

z

14 mm

3 N·m

27 lb in

z

16 mm

4.2 N·m

37 lb in

z

20 mm

7 N·m

62 lb in

z

24 mm

10.5 N·m

93 lb in

Nylon Interface Prevailing Torque Fasteners z

6 mm

0.3 N·m

3 lb in

z

8 mm

0.6 N·m

5 lb in

z

10 mm

1.1 N·m

10 lb in

z

12 mm

1.5 N·m

13 lb in

z

14 mm

2.3 N·m

20 lb in

z

16 mm

3.4 N·m

30 lb in

z

20 mm

5.5 N·m

49 lb in

8.5 N·m

75 lb in

24 mm English Prevailing Torque Fastener Minimum Torque Development z

Specification Application

Metric

English

All Metal Prevailing Torque Fasteners z

1/4 in

0.5 N·m

4.5 lb in

z

5/16 in

0.8 N·m

7.5 lb in

z

3/8 in

1.3 N·m

11.5 lb in

z

7/16 in

1.8 N·m

16 lb in

z

1/2 in

2.3 N·m

20 lb in

z

9/16 in

3.2 N·m

28 lb in

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z

5/8 in

4 N·m

36 lb in

z

3/4 in

7 N·m

54 lb in

Nylon Interface Prevailing Torque Fasteners z

1/4 in

0.3 N·m

3 lb in

z

5/16 in

0.6 N·m

5 lb in

z

3/8 in

1 N·m

9 lb in

z

7/16 in

1.3 N·m

12 lb in

z

1/2 in

1.8 N·m

16 lb in

z

9/16 in

2.5 N·m

22 lb in

z

5/8 in

3.4 N·m

30 lb in

z

3/4 in

5 N·m

45 lb in

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Lifting and Jacking the Vehicle Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Caution: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure: • Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure.

• • • •

The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.

Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Vehicle Lifting Points

(1) Frame Contact Lift - Front (2) Frame Contact Lift - Rear

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Body Hardware and Trim Floor Coverings and Headlinings

Instrument Panel and Console Trim

Exterior Trim

Interior Trim and Paneling

Section02

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Floor Coverings and Headlinings Floor Carpet Drying

Headlining Trim Panel Replacement (C105/Short Body)

Floor Panel Carpet Replacement

Fastener Tightening Specifications

Headlining Trim Panel Replacement (C100/Long Body)

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Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components. • For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly. • For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the method described below. • For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below. • For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below. Drying Method 1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible. 3. Point a fan at the affected area and air dry the carpet.

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Floor Panel Carpet Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in the Preface section. 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 2. Remove the rear seat . Refer to Rear Seat Replacement and Rear Number 2 Folding Seat Replacement . 3. Remove the left and the right rear door sill plates. Refer to Rear Side Door Sill Plate Replacement .

4. 5. 6. 7. 8.

Remove the bolts (2) and the left and the right lower front seat belt anchors (1) from the center pillar garnish molding. Remove the left and the right front door sill plates. Refer to Front Side Door Sill Plate Replacement . Remove the left and the right center pillar lower garnish molding. Refer to Center Pillar Lower Garnish Molding Replacement . Remove the front seats. Refer to Bucket Seat Replacement . Remove the floor console. Refer to Console Replacement .

9. Remove the gearshift housing bolts and reposition the gearshift housing. 10. Remove the floor carpet retaining clips.

11. Remove the floor carpet.

Installation Procedure

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1. Install the floor carpet. 2. Install the floor carpet retaining clips. Notice: Refer to Fastener Notice in the Preface section.

3. Install the gearshift housing with the bolts. Tighten Tighten the gearshift housing bolts to 8 N·m (70 lb in). 4. 5. 6. 7.

Install the floor console. Refer to Console Replacement . Install the front seats. Refer to Bucket Seat Replacement . Remove the left and the right center pillar lower garnish molding. Refer to Center Pillar Lower Garnish Molding Replacement . Install the left and the right front door sill plates. Refer to Front Side Door Sill Plate Replacement .

8. Install the left and the right lower front seat belt anchors (1) to the center pillar garnish molding with the bolts (2). Tighten Tighten the seat belt anchor bolts to 38 N·m (28 lb ft). 9. Install the left and the right rear door sill plates. Refer to Rear Side Door Sill Plate Replacement . 10. Install the rear seat . Refer to Rear Seat Replacement and Rear Number 2 Folding Seat Replacement . 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Headlining Trim Panel Replacement (C100/Long Body) Removal Procedure

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the sunroof molding, if equipped. Remove the passenger assist handles. Refer to Assist Handle Replacement . Remove the plastic retaining clips in the headliner on the driver’s side. Remove the sun visors. Refer to Sunshade Replacement . Remove the power sunroof control switch, if equipped. Refer to Sunroof Switch Replacement . Remove the windshield garnish molding. Refer to Windshield Garnish Molding Replacement . Remove the center pillar upper garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement . Remove the quarter window garnish molding. Refer to Body Side Window Rear Garnish Molding Replacement . Remove the plastic retainers in the headliner. Recline both front seats. Remove the headliner through a rear door.

Installation Procedure

1. 2. 3. 4.

5. 6. 7. 8. 9. 10. 11. 12. 13.

Recline both front seats. Insert the headliner through a rear door. Install the headliner behind the seats around the doors. Install the plastic retainers.

Install the windshield garnish molding. Refer to Windshield Garnish Molding Replacement . Instal the center pillar upper garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement . Install the quarter window garnish molding. Refer to Body Side Window Rear Garnish Molding Replacement . Install the power sunroof control switch, if equipped. Refer to Sunroof Switch Replacement . Install the sun visors. Refer to Sunshade Replacement . Install the plastic retainers in the headliner on the driver’s side. Install the passenger assist handles. Refer to Assist Handle Replacement . Install the sunroof molding, if equipped. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Headlining Trim Panel Replacement (C105/Short Body) Removal Procedure

1. 2. 3. 4. 5. 6. 7. 8. 9.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the sunroof molding, if equipped. Remove the passenger assist handles. Refer to Assist Handle Replacement . Remove the dome lamp. Refer to Dome Lamp Replacement . Remove the sun visors. Refer to Sunshade Replacement . Remove the power sunroof control switch, if equipped. Refer to Sunroof Switch Replacement . Remove the windshield garnish molding. Refer to Windshield Garnish Molding Replacement . Remove the center pillar upper garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement . Remove the quarter window garnish molding. Refer to Body Side Window Rear Garnish Molding Replacement .

10. Remove the plastic retainers in the headliner. 11. Recline both front seats. 12. Remove the headliner through a rear door.

Installation Procedure

1. Recline both front seats.

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2. Insert the headliner through a rear door. 3. Install the headliner behind the seats around the doors. 4. Install the plastic retainers.

. 6. Instal the center pillar upper garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement 5. Install the windshield garnish molding. Refer to Windshield Garnish Molding Replacement 7. 8. 9. 10. 11. 12. 13. 14.

. Install the quarter window garnish molding. Refer to Body Side Window Rear Garnish Molding Replacement . Install the power sunroof control switch, if equipped. Refer to Sunroof Switch Replacement . Install the sun visors. Refer to Sunshade Replacement . Install the dome lamp. Refer to Dome Lamp Replacement . Install the plastic retainers in the headliner on the driver’s side. Install the passenger assist handles. Refer to Assist Handle Replacement . Install the sunroof molding, if equipped. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Fastener Tightening Specifications Specification Application

Metric

English

Gearshift Housing Bolts

8 N·m

70 lb in

Seatbelt Anchor Bolts

38 N·m

28 lb ft

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Exterior Trim Front Door Frame Applique Replacement (C100/Long Body) Front Door Frame Applique Replacement (C105/Short Body) Liftgate Applique Replacement Liftgate Upper Applique Replacement (C100/Long Body) Liftgate Upper Applique Replacement (C105/Short Body) Rear Door Frame Applique Replacement (C100/Long Body) Rear Door Frame Applique Replacement (C105/Short Body) Grille Replacement (C100/Long Body) Grille Replacement (C105/Short Body) Front Side Door Lower Molding Replacement Front Fender Wheel Opening Molding Replacement Rear Side Door Lower Molding Replacement Rear Wheel Opening Molding Replacement Rocker Panel Molding Replacement Roof Panel Joint Finish Molding Replacement Fastener and Tightening Specifications

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Front Door Frame Applique Replacement (C100/Long Body) Removal Procedure

1. Reposition the weatherstrip in order to access the screws. 2. Remove the screws and the front side door window frame applique.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the screws and the Front side door window frame applique. Tighten Tighten the front side door window frame applique screws to 1.3 N·m (12 lb in). 2. Install the weatherstrip to its original position.

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Front Door Frame Applique Replacement (C105/Short Body) Removal Procedure

1. Remove the front door applique screws. 2. Remove the front door frame applique.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the front door frame applique. 2. Install the screws to the front door frame applique. Tighten Tighten the front door applique screws to 1.3 N·m (12 lb in).

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Liftgate Applique Replacement Removal Procedure

1. Remove the nuts from the applique. 2. Remove the liftgate applique from the vehicle.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

Install the liftgate applique with the nuts. Tighten Tighten the liftgate applique nuts to 6 N·m (53 lb in).

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Liftgate Upper Applique Replacement (C100/Long Body) Removal Procedure

1. Open the liftgate. 2. Remove the nuts from the liftgate upper applique.

3. Close the liftgate. 4. Remove the liftgate upper applique from the vehicle.

Installation Procedure

1. Position the upper applique to the liftgate. Notice: Refer to Fastener Notice in the Preface section. 2. Install the liftgate upper applique nuts. Tighten Tighten the liftgate upper applique nuts to 6 N·m (53 lb in).

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Liftgate Upper Applique Replacement (C105/Short Body) Removal Procedure

1. 2. 3. 4.

Open the liftgate. Remove the nuts from the liftgate upper applique. Close the liftgate. Remove the liftgate upper applique from the vehicle.

Installation Procedure

1. Position the upper applique to the liftgate. Notice: Refer to Fastener Notice in the Preface section. 2. Install the liftgate upper applique nuts. Tighten Tighten the liftgate upper applique nuts to 6 N·m (53 lb in).

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Rear Door Frame Applique Replacement (C100/Long Body) Removal Procedure

1. Reposition the weatherstrip in order to access the screws. 2. Remove the screws and the rear side door window frame applique.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the screws and the reart side door window frame applique. Tighten Tighten the rear side door window frame applique screws to 1.3 N·m (12 lb in). 2. Install the weatherstrip to its original position.

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Rear Door Frame Applique Replacement (C105/Short Body) Removal Procedure 1. Open the rear door.

2. Remove the rear door upper trim panel.

3. Remove the rear door frame applique screws.

4. Remove the rear door frame applique.

Installation Procedure

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1. Install the rear door frame applique. Notice: Refer to Fastener Notice in the Preface section.

2. Install the screws to the rear door frame applique. Tighten Tighten the rear door frame applique screws to 1.3 N·m (12 lb in).

3. Install the rear door upper trim panel.

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Grille Replacement (C100/Long Body) Removal Procedure

1. Open the hood. 2. Remove the nuts and the radiator grille.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the radiator grille with the nuts. Tighten Tighten the radiator grille nuts to 4.5 N·m (40 lb in). 2. Close the hood.

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Grille Replacement (C105/Short Body) Removal Procedure

1. Open the hood. 2. Remove the nuts and the radiator grille.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the radiator grille with the nuts. Tighten Tighten the radiator grille nuts to 4.5 N·m (40 lb in). 2. Close the hood.

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Front Side Door Lower Molding Replacement Removal Procedure

Remove the nut and the front side door lower molding.

Installation Procedure

Notice: Refer to Fastener Notice in Cautions and Notices. Install the front side door lower molding with the nut. Tighten Tighten the front side door lower molding nut to 4.5 N·m (40 lb in).

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Front Fender Wheel Opening Molding Replacement Removal Procedure

1. Remove the front mud guards. 2. Remove the screws and front fender wheel opening molding.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the front fender wheel opening molding with the screws. Tighten Tighten the front fender wheel opening molding screws to 4 N·m (35 lb in). 2. Install the front mud guard.

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Rear Side Door Lower Molding Replacement Removal Procedure

Remove the nut and the rear side door lower molding.

Installation Procedure

Notice: Refer to Fastener Notice in Cautions and Notices. Install the rear side door lower molding with the nut. Tighten Tighten the rear side door lower molding nut to 4.5 N·m (40 lb in).

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Rear Wheel Opening Molding Replacement Removal Procedure

Remove the rear wheel opening molding.

Installation Procedure

Install the rear wheel opening molding.

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Rocker Panel Molding Replacement Removal Procedure

1. Remove the front mud guards. 2. Remove the clips and the rocker panel molding.

Installation Procedure

1. Install the rocker panel molding with the clips. 2. Install the front mud guards.

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Roof Panel Joint Finish Molding Replacement Removal Procedure

Remove the roof molding from the metal clips.

Installation Procedure

Press the roof molding onto the metal clips.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Fastener Tightening Specifications Specification Application

Metric

English

4 N·m

35 lb in

Front Side Door Lower Molding

4.5 N·m

40 lb in

Front Side Door Window Frame Rear Applique

1.3 N·m

12 lb in

2 N·m

18 lb in

4.5 N·m

40 lb in

Front Fender Wheel Opening Molding

Mud Guard Bolts Rear Side Door Lower Molding

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Instrument Panel and Console Trim Knee Bolster Replacement Instrument Panel Upper Trim Panel Replacement Instrument Panel Accessory Bezel Replacement Driver Information Display Bezel Replacement Instrument Panel Lower Trim Panel Replacement - Left Side Instrument Panel Storage Compartment Replacement Instrument Panel Lower Compartment Replacement Instrument Panel Assembly Replacement (C105/Short Body) Instrument Panel Assembly Replacement (C100/Long Body) Console Replacement Fastener and Tightening Specifications

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Knee Bolster Replacement Removal Procedure Important: Left - Hand Drive Shown, Right - Hand Drive Similar.

1. Remove the instrument panel lower left trim. Refer to Instrument Panel Lower Trim Panel Replacement - Left Side . 2. Remove the screws and bolts. 3. Remove the driver knee bolster.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the driver knee bolster with the screws and bolts. Tighten • Tighten the driver knee bolster screws to 2.5 N·m (23 lb in). • Tighten the driver knee bolster bolts to 20 N·m (15 lb ft). 2. Install the instrument panel lower left trim. Refer to Instrument Panel Lower Trim Panel Replacement - Left Side .

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Instrument Panel Upper Trim Panel Replacement Removal Procedure

1. Remove the bolts from the left and right sides of the instrument panel upper I/P trim panel. 2. Remove the upper I/P trim panel from the instrument panel.

Installation Procedure

1. Position the upper I/P trim panel to the instrument panel . Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts securing the sides of the upper I/P trim panel to the instrument panel. Tighten Tighten the upper I/P trim panel bolts to 2 N·m (18 lb in).

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Instrument Panel Accessory Bezel Replacement Removal Procedure

Important: Use tape around center trim bezel and the end of the flat bladed tool to protect from scratches. 1. Using a flat bladed tool, unfasten the center trim bezel clips from the instrument panel. 2. Remove the center trim bezel from the instrument panel.

Installation Procedure

1. Position the center trim bezel to the instrument panel. 2. Press the center trim bezel to the instrument panel making sure the clips are fully seated.

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Driver Information Display Bezel Replacement Removal Procedure 1. Remove the instrument panel center trim bezel. Refer to Instrument Panel Accessory Bezel Replacement .

2. Remove the screws and the driver information bezel.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the driver information bezel with the screws. Tighten Tighten the driver information bezel screws to 2 N·m (18 lb in). 2. Install the instrument panel center trim bezel. Refer to Instrument Panel Accessory Bezel Replacement .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Instrument Panel Lower Trim Panel Replacement - Left Side Removal Procedure Important: Left - Hand Drive Shown, Right - Hand Drive Similar.

1. Remove the hood prime latch release handle. Refer to Hood Latch Release Cable Replacement . 2. Remove the screw and the instrument panel lower left trim.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the instrument panel lower left trim. Tighten Tighten the instrument panel steering column opening pillar screw to 2 N·m (18 lb in). 2. Install the hood prime latch release handle. Refer to Hood Latch Release Cable Replacement .

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Instrument Panel Storage Compartment Replacement Removal Procedure Important: Left - Hand Drive Shown, Right - Hand Drive Similar. 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

2. 3. 4. 5.

Remove the screws at the base of the storage compartment. Open and remove the screws. Disconnect the electrical connector. Remove the storage compartment.

Installation Procedure

1. Position the storage compartment in the instrument panel. 2. Connect the electrical connector. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the storage compartment with the screws. Tighten Tighten the storage compartment screws to 2 N·m (18 lb in). 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Instrument Panel Lower Compartment Replacement Removal Procedure 1. Remove the instrument panel center trim bezel. Refer to Instrument Panel Accessory Bezel Replacement . 2. Remove the driver information center bezel. Refer to Driver Information Display Bezel Replacement .

3. Remove the screws and the instrument panel lower compartment.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the instrument lower compartment with the screws. Tighten Tighten the instrument lower compartment with the screws to 2 N·m (18 lb in). 2. Install the instrument panel driver information center bezel. Refer to Driver Information Display Bezel Replacement . 3. Install the instrument panel center trim bezel. Refer to Instrument Panel Accessory Bezel Replacement .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Instrument Panel Assembly Replacement (C105/Short Body) Removal Procedure Caution: Refer to Battery Disconnect Caution in the Preface section. Important: Left - Hand Drive Shown, Right - Hand Drive Similar.

1. 2. 3. 4. 5. 6. 7.

8. 9. 10. 11. 12.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the instrument panel lower left trim. Refer to Instrument Panel Lower Trim Panel Replacement - Left Side . Remove the front, rear floor console. Refer to Console Replacement . Remove the radio . Refer to Radio Replacement . Remove the headlamp leveling switch assembly. Refer to Headlamp Leveling Switch Replacement . Remove the instrument cluster trim panel. Remove the automatic temperature controls assembly. Refer to Heater and Air Conditioning Control Replacement .

Remove the instrument cluster. Refer to Instrument Cluster Replacement . Remove the kick panels. Remove the storage compartment. Refer to Instrument Panel Storage Compartment Replacement . Disconnect the instrument compartment electrical connectors. Remove the knee bolster. Refer to Knee Bolster Replacement .

13. Remove the instrument panel side covers.

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14. 15. 16. 17.

Remove the body control module. Refer to Body Control Module Replacement . Remove the steering wheel. Refer to Steering Wheel Replacement . Remove the headlamp switch. Refer to Headlamp Switch Replacement . Remove the wiper/washer switch. Refer to Windshield Wiper and Washer Switch Replacement .

18. 19. 20. 21.

Remove the nuts and the bolts securing the steering column. Disconnect the steering column electrical connector. Lower the steering column. Remove the A-pillar trim.

22. Remove the instrument panel bolts below the windshield.

23. Remove the screws (1) and the left lower instrument panel retaining bolt (2).

24. Remove the screws (1) securing the instrument panel center.

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25. Remove the instrument panel left and right side screws (1) and bolt (2).

26. 27. 28. 29. 30.

Remove the screws (1) near the instrument panel compartment. Remove the air bag retaining bolts (2). Remove the screw (5) near the blower motor. Remove the right lower instrument panel retaining bolt (4). Remove the nut (3) securing the instrument panel backside.

31. Lift up the instrument panel and remove the instrument panel to T-bar nuts. 32. Disconnect the electrical connectors. 33. Remove the instrument panel from the vehicle.

Installation Procedure

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1. Position the instrument panel in the vehicle. 2. Connect the instrument panel electrical connectors. Notice: Refer to Fastener Notice in the Preface section. 3. Lift up the instrument panel and install the instrument panel to T-bar nuts. Tighten Tighten the instrument panel to T-bar nuts to 10 N·m (89 lb in).

4. Install the nut (3) securing the instrument panel backside. Tighten Tighten the instrument panel backside nut to 10 N·m (89 lb in). 5. Install the right lower instrument panel retaining bolt (4). Tighten Tighten the right lower instrument panel retaining bolt to 10 N·m (89 lb in). 6. Install the screw (5) near the blower motor and the screws (1) near the instrument panel compartment. Tighten Tighten the screws near the blower motor and the instrument panel compartment to 2 N·m (18 lb in). 7. Install the air bag retaining bolts (2). Tighten Tighten the air bag retaining bolts to 10 N·m (89 lb in).

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8. Install the instrument panel left and right side screws (1). Tighten Tighten the left and right side instrument panel screws to 2 N·m (18 lb in). 9. Install the instrument panel bolt (2). Tighten Tighten the instrument panel bolt to 10 N·m (89 lb in).

10. Install the screws (1) securing the instrument panel center. Tighten Tighten the instrument panel center screws to 2 N·m (18 lb in).

11. Install the instrument panel screws (1). Tighten Tighten the instrument panel screws to 10 N·m (89 lb in). 12. Install the instrument panel retaining bolt (2). Tighten Tighten the instrument panel retaining bolt to 10 N·m (89 lb in).

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13. Install the instrument panel bolts below the windshield. Tighten Tighten the instrument panel bolts below the windshield to 23 N·m (17 lb ft). 14. Install the A-pillar trim.

15. Raise the steering column. 16. Connect the steering column electrical connector. 17. Install the bolts securing the steering column. Tighten Tighten the steering column bolts to 22 N·m (16 lb ft). 18. Install the headlamp switch. Refer to Headlamp Switch Replacement . 19. Install the wiper/washer switch. Refer to Windshield Wiper and Washer Switch Replacement . 20. Install the steering wheel. Refer to Steering Wheel Replacement .

21. Install the body control module. Refer to Body Control Module Replacement . 22. Install the instrument panel side covers.

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23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Install the knee bolster. Refer to Knee Bolster Replacement . Install the instrument panel lower left trim. Refer to Instrument Panel Lower Trim Panel Replacement - Left Side . Connect the instrument compartment electrical connectors. Install the storage compartment. Refer to Instrument Panel Storage Compartment Replacement . Install the kick panels. Install the instrument cluster. Refer to Instrument Cluster Replacement . Install the automatic temperature controls assembly. Refer to Heater and Air Conditioning Control Replacement . Install the instrument cluster trim panel. Install the headlamp leveling switch assembly. Refer to Headlamp Leveling Switch Replacement . Install the radio . Refer to Radio Replacement . Install the ambient light sensor . Refer to Ambient Light Sensor Replacement Install the floor console. Refer to Console Replacement . Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Instrument Panel Assembly Replacement (C100/Long Body) Removal Procedure Caution: Refer to Battery Disconnect Caution in the Preface section.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the instrument panel lower left trim. Refer to Instrument Panel Lower Trim Panel Replacement - Left Side . Remove the front, rear floor console. Refer to Console Replacement . Remove the ambient light sensor . Refer to Ambient Light Sensor Replacement . Remove the radio . Refer to Radio Replacement . Remove the headlamp leveling switch assembly. Refer to Headlamp Leveling Switch Replacement . Remove the instrument cluster trim panel. Remove the automatic temperature controls assembly. Refer to Heater and Air Conditioning Control Replacement . Remove the instrument cluster. Refer to Instrument Cluster Replacement . Remove the kick panels. Disconnect the necessary instrument compartment electrical connectors. Remove the knee bolster. Refer to Knee Bolster Replacement .

13. Remove the left and right upper instrument panel bolt covers. 14. Remove the body control module. Refer to Body Control Module Replacement .

15. Remove the nuts and the bolts securing the steering column and lower the steering column. Refer to Steering Column Replacement

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16. Remove the bolts on the left and right sides of the instrument panel.

17. Remove the instrument panel bolts below the windshield.

18. Remove the necessary fixing screws securing the instrument panel.

19. Remove the bolts securing the sides of the instrument panel to the body. 20. Disconnect the necessary instrument panel electrical connectors. 21. Remove the instrument panel by pulling back to release the three upper retainers..

Installation Procedure

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1. Position the instrument panel in the vehicle, making sure the three upper retainers are fastened. 2. Connect the necessary instrument panel electrical connectors. Notice: Refer to Fastener Notice in the Preface section. 3. Install the bolts securing the sides of the instrument panel to the body. Tighten Tighten the instrument panel-to-body bolts to 23 N·m (17 lb ft).

4. Install the necessary fixing screws securing the instrument panel.

5. Install the instrument panel bolts below the windshield. Tighten Tighten the instrument panel bolts below the windshield to 23 N·m (17 lb ft).

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

6. Raise the steering column and install the nuts and bolts. Refer to Steering Column Replacement . 7. Install the bolts securing the left and right sides of the instrument panel. Tighten Tighten the bolts on the left and right sides of the instrument panel to 10 N·m (89 lb in).

8. Install the left and right upper instrument panel bolt covers. 9. Install the body control module. Refer to Body Control Module Replacement .

10. 11. 12. 13. 14. 15.

Install the knee bolster. Refer to Knee Bolster Replacement . Install the instrument panel lower left trim. Refer to Instrument Panel Lower Trim Panel Replacement - Left Side . Connect the necessary instrument compartment electrical connectors. Install the kick panels. Install the instrument cluster. Refer to Instrument Cluster Replacement . Install the automatic temperature controls assembly. Refer to Heater and Air Conditioning Control Replacement .

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16. 17. 18. 19. 20. 21.

Install the instrument cluster trim panel. Install the headlamp leveling switch assembly. Refer to Headlamp Leveling Switch Replacement . Install the radio . Refer to Radio Replacement . Install the ambient light sensor . Refer to Ambient Light Sensor Replacement . Install the floor console. Refer to Console Replacement . Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Console Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices.

1. 2. 3. 4. 5.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the instrument compartment lower. Refer to Instrument Panel Lower Compartment Replacement . Remove the radio. Refer to Radio Replacement . Remove the front seats. Refer to Bucket Seat Replacement Remove the screws and cup holder, console cover.

6. Disconnect the electrical connector. 7. Remove the bolts from the floor console. 8. Remove the instrument panel storage compartment. Refer to Instrument Panel Storage Compartment Replacement .

9. Remove the floor console. 10. Remove the screws from the front console retainer.

Installation Procedure

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1. Connect the electrical connectors. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the front console retainer with screws. Tighten Tighten the front console retainer screws to 8 N·m (71 lb in). 3. Install the floor console with the bolts. Tighten Tighten the front console screw to 8 N·m (71 lb in). 4. Install the instrument panel storage compartment. Refer to Instrument Panel Storage Compartment Replacement .

5. Connect the electrical connectors. 6. Install the cupholder and console cover.

7. 8. 9. 10.

Install the instrument compartment lower . Refer to Instrument Panel Lower Compartment Replacement . Install the front seats. Refer to Bucket Seat Replacement . Install the radio. Refer to Radio Replacement . Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Fastener Tightening Specifications Specification Application

Metric

English

Floor Console Screws

8 N·m

71 lb in

Instrument Panel Accessory Bezel Screws

2 N·m

18 lb in

Instrument Panel Lower Compartment Screws

2 N·m

18 lb in

Instrument Panel Lower Left Trim Panel Screws

2 N·m

18 lb in

Instrument Panel Compartment Screws

2 N·m

18 lb in

Instrument Panel-to-Body Bolts

23 N·m

17 lb ft

Knee Bolster Bolts

20 N·m

15 lb ft

Knee Bolster Screws

2.5 N·m

23 lb in

Steering Column Bolts

22 N·m

16 lb ft

Steering Column Nuts

22 N·m

16 lb ft

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Interior Trim and Paneling Front Side Door Trim Panel Replacement (C 100/Long Body) Front Side Door Trim Panel Replacement (C 105/Short Body) Door Water Deflector Replacement Rear Door Trim Panel Replacement (C 105/Short Body) Rear Door Trim Panel Replacement (C 100/Long Body) Front Side Door Sill Plate Replacement Rear Side Door Sill Plate Replacement Assist Handle Replacement Sunshade Replacement (C 105/Short Body) Sunshade Replacement (C 100/Long Body) Windshield Garnish Molding Replacement Center Pillar Upper Garnish Molding Replacement Center Pillar Lower Garnish Molding Replacement Rear Quarter Lower Trim Panel Replacement (C 100/Long Body) Rear Quarter Lower Trim Panel Replacement (C 105/Short Body) Rear Storage Compartment Replacement Liftgate Garnish Molding Replacement (Side - C 100/Long Body) Liftgate Garnish Molding Replacement (Side - C 105/Short Body) Liftgate Garnish Molding Replacement (Upper) Liftgate Trim Panel Replacement Rear Compartment Sill Trim Plate Replacement Body Side Window Rear Garnish Molding Replacement (C 105/Short Body) Body Side Window Rear Garnish Molding Replacement (C 100/Long Body) Fastener and Tightening Specifications Special Tools

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Front Side Door Trim Panel Replacement (C 100/Long Body) Tools Required KM 475-A Trim Remover

Removal Procedure 1. Lower the front window.

2. Remove the front door handle cover. 3. Remove the front door trim panel screws.

4. Pry off the front door trim panel KM 475-A . 5. Disconnect the electrical connectors.

Installation Procedure

1. Install the front door trim panel. 2. Connect the electrical connectors. Notice: Refer to Fastener Notice in the Preface section.

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3. Install the front door trim screws. Tighten Tighten the front door trim screws to 3 N·m (27 lb in). 4. Install the front door handle cover. 5. Raise the front window.

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Front Side Door Trim Panel Replacement (C 105/Short Body) Tools Required KM 475-A Trim Remover

Removal Procedure

1. Lower the front window. 2. Remove the front door trim panel screws.

3. Pry off the front door trim panel using the trim remover KM 475-A . 4. Remove the door inner handle cable. 5. Disconnect the electrical connectors.

Installation Procedure

1. Connect the electrical connectors. 2. Install the door inner handle cable. 3. Install the front door trim panel.

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4. Install the front door trim screws. Tighten Tighten the front door trim screws to 3 N·m (27 lb in). 5. Raise the front window.

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Door Water Deflector Replacement Removal Procedure

1. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement or Rear Door Trim Panel Replacement . 2. Remove the door water deflector.

Installation Procedure

1. Install the door water deflector. 2. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement or Rear Door Trim Panel Replacement .

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Rear Door Trim Panel Replacement (C 105/Short Body) Tools Required KM 475-A Trim Remover

Removal Procedure

1. Lower the rear window. 2. Remove the rear door upper trim panel.

3. Remove the rear door handle screws.

4. Pry off the trim panel using the trim remover KM 475-A . 5. Remove the door inner handle cable. 6. Disconnect the electrical connectors.

Installation Procedure

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1. Connect the electrical connectors. 2. Install the rear door inner handle cable. 3. Install the rear door trim panel.

4. Install the rear door trim screws. Tighten Tighten the rear door trim screws to 3 N·m (27 lb in).

5. Install the rear door upper trim panel. 6. Raise the rear window.

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Rear Door Trim Panel Replacement (C 100/Long Body) Tools Required KM 475-A Trim Remover

Removal Procedure

1. Lower the rear window. 2. Remove the rear door handle cover. 3. Remove the rear door handle screws.

4. Pry off the trim panel KM 475-A . 5. Disconnect the electrical connectors.

Installation Procedure

1. Install the rear door trim panel. 2. Connect the electrical connectors.

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Notice: Refer to Fastener Notice in the Preface section.

3. Install the rear door trim screws. Tighten Tighten the rear door trim screws to 3 N·m (27 lb in). 4. Install the rear door handle cover. 5. Raise the rear window.

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Front Side Door Sill Plate Replacement Removal Procedure

Remove the front side door retainer.

Installation Procedure

Install the front side door retainer.

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Rear Side Door Sill Plate Replacement Removal Procedure

Remove the rear side door retainer.

Installation Procedure

Install the rear side door retainer.

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Assist Handle Replacement Removal Procedure

1. Reveal the assist handle screws. 2. Remove the screws and the assist handle from the headliner.

Installation Procedure

1. Position the assist handle to the headliner . Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws. Tighten Tighten the passenger assist handle screws 3 N·m (27 lb in).

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Sunshade Replacement (C 105/Short Body) Removal Procedure

1. 2. 3. 4.

Remove the sunshade bracket cover. Remove the screws and the sunshade from the headliner. Disconnect the vanity mirror electrical connector. Remove the screw and the sunshade support from the headliner.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the sunshade support to the headliner with the screw. Tighten Tighten the sunshade support screws 3 N·m (27 lb in). 2. Connect the vanity mirror electrical connector. 3. Install the sunshade bracket to the headliner with the screws. Tighten Tighten the sunshade screws to 3 N·m (27 lb in). 4. Install the sunshade bracket cover.

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Sunshade Replacement (C 100/Long Body) Removal Procedure

1. Remove the screws and the sunshade from the headliner. 2. Disconnect the vanity mirror electrical connector. 3. Remove the screw and the sunshade support from the headliner.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the sunshade support to the headliner with the screw. Tighten Tighten the sunshade support screws 3 N·m (27 lb in). 2. Connect the vanity mirror electrical connector. 3. Install the sunshade to the headliner with the screws. Tighten Tighten the sunshade screws to 3 N·m (27 lb in).

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Windshield Garnish Molding Replacement Removal Procedure

Remove the bolt and the windshield garnish molding.

Installation Procedure

Notice: Refer to Fastener Notice in Cautions and Notices. Install the windshield garnish molding with the bolt. Tighten Tighten the windshield garnish molding bolt to 2 N·m (18 lb in).

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Center Pillar Upper Garnish Molding Replacement Removal Procedure

1. Remove the bolt and the upper front seat belt anchor. 2. Reposition the upper portion of the center pillar lower garnish molding. 3. Remove the screw and pry off the center pillar upper garnish molding.

Installation Procedure

1. Install the center pillar upper garnish molding. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the upper portion of the center pillar lower garnish molding. Tighten Tighten the center pillar lower garnish molding screw to 22 N·m (16 lb ft). 3. Install the upper front seat belt anchor with the bolt. Tighten Tighten the seat belt anchor bolt to 38 N·m (28 lb ft).

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Center Pillar Lower Garnish Molding Replacement Removal Procedure

1. Reposition the rear portion of the front side door retainer and the front portion of the rear side door retainer. 2. Remove the center pillar lower garnish molding.

Installation Procedure

1. Install the center pillar lower garnish molding. 2. Install the front side door retainer and the rear side door retainer to their original positions.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Rear Quarter Lower Trim Panel Replacement (C 100/Long Body) Removal Procedure

1. Remove the rear seat lower bolts. Refer to Seat Belt Retractor Replacement - No. 1 Rear and Seat Belt Retractor Replacement - No. 2 Rear . 2. Remove the rear compartment stow tray. Refer to Rear Storage Compartment Replacement . 3. Remove the screws and the rear quarter lower trim panel.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the rear quarter lower trim panel with the screws. Tighten Tighten the rear trim panel screws to 2 N·m (18 lb in). 2. Install the rear compartment stow tray. Refer to Rear Storage Compartment Replacement . 3. Install the rear seat lower bolts. Refer to Seat Belt Retractor Replacement - No. 1 Rear and Seat Belt Retractor Replacement - No. 2 Rear .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Rear Quarter Lower Trim Panel Replacement (C 105/Short Body) Removal Procedure

1. Remove the rear seat lower bolts. Refer to Seat Belt Retractor Replacement - No. 1 Rear and Seat Belt Retractor Replacement - No. 2 Rear . 2. Remove the rear compartment stow tray. Refer to Rear Storage Compartment Replacement . 3. Remove the screws and the rear quarter lower trim panel.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the rear quarter lower trim panel with the screws. Tighten Tighten the rear trim panel screws to 2 N·m (18 lb in). 2. Install the rear compartment stow tray. Refer to Rear Storage Compartment Replacement . 3. Install the rear seat lower bolts. Refer to Seat Belt Retractor Replacement - No. 1 Rear and Seat Belt Retractor Replacement - No. 2 Rear .

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Rear Storage Compartment Replacement Removal Procedure

Remove the bolts and the rear compartment stow tray.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

Install the rear compartment stow tray with the bolts. Tighten Tighten the rear compartment stow tray bolts to 8 N·m (11 lb ft).

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Liftgate Garnish Molding Replacement (Side - C 100/Long Body) Removal Procedure

1. Open the liftgate. 2. Remove the liftgate window side garnish molding

Installation Procedure

1. Install the liftgate window side garnish molding. 2. Close the liftgate.

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Liftgate Garnish Molding Replacement (Side - C 105/Short Body) Removal Procedure

1. Open the liftgate. 2. Remove the liftgate window side garnish molding

Installation Procedure

1. Install the liftgate window side garnish molding. 2. Close the liftgate.

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Liftgate Garnish Molding Replacement (Upper) Removal Procedure

1. Open the liftgate. 2. Remove the liftgate window upper garnish molding.

Installation Procedure

1. Install the liftgate window upper garnish molding. 2. Close the liftgate.

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Liftgate Trim Panel Replacement Removal Procedure

1. Remove the screws and the liftgate inside pull handle.

2. Remove the retainers from liftgate trim. 3. Remove the liftgate trim from the vehicle.

Installation Procedure

1. Install the liftgate trim with the retainers.

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2. Install the liftgate inside pull handle with the screws.

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Rear Compartment Sill Trim Plate Replacement Removal Procedure

Remove the floor panel rear extension.

Installation Procedure

Install the floor panel rear extension.

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Body Side Window Rear Garnish Molding Replacement (C 105/Short Body) Removal Procedure

1. Remove the rear seat lower belts. Refer to Seat Belt Retractor Replacement - No. 1 Rear or Seat Belt Retractor Replacement - No. 2 Rear . 2. Remove the screws and the quarter window garnish molding.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the quarter window garnish molding with the screws. Tighten Tighten the quarter window garnish molding screws to 2 N·m (18 lb in). 2. Install the rear seat lower belts. Refer to Seat Belt Retractor Replacement - No. 1 Rear or Seat Belt Retractor Replacement - No. 2 Rear .

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Body Side Window Rear Garnish Molding Replacement (C 100/Long Body) Removal Procedure

1. Remove the rear seat lower belts. Refer to Seat Belt Retractor Replacement - No. 1 Rear or Seat Belt Retractor Replacement - No. 2 Rear . 2. Remove the screws and the quarter window garnish molding.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the quarter window garnish molding with the screws. Tighten Tighten the quarter window garnish molding screws to 2 N·m (18 lb in). 2. Install the rear seat lower belts. Refer to Seat Belt Retractor Replacement - No. 1 Rear or Seat Belt Retractor Replacement - No. 2 Rear .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Fastener Tightening Specifications Specification Application

Metric

English

Center Pillar Lower Garnish Molding Screw

22 N·m

16 lb ft

Driver Knee Bolster Bolts

20 N·m

15 lb ft

Driver Knee Bolster Screws

2.5 N·m

23 lb in

Floor Console Bolts

8 N·m

71 lb in

Front Console Retainer Screw

2 N·m

18 lb in

Hood Latch Release Handle Mounting Screw

3 N·m

27 lb in

Quarter Window Garnish Molding Screw

2 N·m

18 lb in

Rear Compartment Stow Tray Bolts

8 N·m

71 lb in

Rear Wheelhouse Trim Panel Screws

2 N·m

18 lb in

Windshield Garnish Molding Screw

2 N·m

18 lb in

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Special Tools Illustration

Tool Number/Description

J-21104-B (KW-475-B) Weatherstrip Remover Universal

KM-475-A Trim Remover

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Body Repair Bolted Exterior Body Panels and Closures Bumpers and Fascias Collision Repair Frame and underbody Paint and Coatings Plastic Panel Information and Repair R

Section03

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Bolted Exterior Body Panels and Closures Hood Primary Latch Release Cable Replacement Front Side Door Replacement Fuel Tank Filler Door Replacement Rear Door Replacement Front Fender Replacement (C 105/Short Body) Front Fender Replacement (C 100/Long Body) Liftgate Replacement Hood Hinge Replacement Hood Replacement Front Fender Insulator Replacement Hood Insulator Replacement Liftgate Latch Replacement Hood Primary Latch Replacement Door Check Link Replacement (C 105/Short Body) Door Check Link Replacement (C 100/Long Body) Hood Strut Replacement Door Bottom Auxiliary Sealing Strip Replacement Liftgate Strut Replacement Door Weatherstrip Replacement Front Door Opening Weatherstrip Replacement Liftgate Weatherstrip Replacement Rear Door Opening Weatherstrip Replacement Liftgate Garnish Molding Replacement Upper Liftgate Garnish Molding Side Replacement C100/Long body Liftgate Garnish Molding Side Replacement C105/Short body Liftgate Trim Panel Replacement Door Water Deflector Replacement Fastener Tightening Specifications

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Hood Primary Latch Release Cable Replacement Removal Procedure Important: Left - Hand Drive Shown, Right - Hand Drive Similar.

1. 2. 3. 4. 5.

Remove the hood release handle screws. Remove the knee bolster and the hood release handle. Remove the cable from the hood release handle. Remove the hood secondary latch. Refer to Hood Primary Latch Replacement . Remove the cable from the engine compartment.

Installation Procedure

1. Install the cable through the engine compartment. 2. Install the hood secondary latch. Refer to Hood Primary Latch Replacement . 3. Install the cable to the hood release handle. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the hood release handle and the knee bolster with the screw. Tighten Tighten the hood release handle screw to 2 N·m (18 lb in).

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Front Side Door Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

2. Remove the bolt and the door hold-open link from the body.

3. With the aid of another technician, remove the door hinge bolts and the front door. 4. Disconnect the body-to-door rubber grommet and the electrical connector.

Installation Procedure

1. Connect the electrical connector and the body-to-door rubber grommet. 2. With the aid of another technician, lightly secure the front door with the door hinge bolts. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Adjust the door for proper fit. Tighten Tighten the door hinge-to-body bolts to 27.5 N·m (20 lb ft).

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4. Install the door hold-open link to the body with the bolts. Tighten Tighten the door hold-open link-to-body bolt to 20 N·m (15 lb ft). 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 6. Perform the waterleak test. Refer to Water Hose Test . 7. Check for windnoise. Refer to Exterior Windnoise .

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Fuel Tank Filler Door Replacement Removal Procedure

Remove the screws and the fuel filler door.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

Install the fuel filler door with the screws. Tighten Tighten the fuel filler door screws to 4 N·m (35 lb in).

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Rear Door Replacement Removal Procedure

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 2. Remove the bolt and the door hold-open link from the body.

3. With the aid of another technician, remove the door hinge bolts and the rear door. 4. Disconnect the body-to-door rubber grommet and the electrical connector.

Installation Procedure

1. Connect the electrical connector and the body-to-door rubber grommet. 2. With the aid of another technician, lightly secure the rear door with the door hinge bolts. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Adjust the door for proper fit. Tighten

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Tighten the door hinge-to-body bolts to 27.5 N·m (20 lb ft).

4. Install the door hold-open link to the body with the bolts. Tighten Tighten the door hold-open link-to-body bolt to 20 N·m (15 lb ft). 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 6. Perform the waterleak test. Refer to Water Hose Test . 7. Check for windnoise. Refer to Exterior Windnoise .

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Front Fender Replacement (C 105/Short Body) Removal Procedure

1. Remove the front fender liner. Refer to Fender Liner Replacement . 2. Remove the bolts securing the front fascia to the fender.

3. 4. 5. 6.

Reposition the front fascia. Remove the fender bolts behind the front fascia. Remove the rocker panel molding. Refer to Rocker Panel Molding Replacement . Remove the bolts at the base of the fender.

7. Open the front door and remove the bolt at the base of the A-pillar.

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8. Remove the fender center molding from the fender by disengaging the four retainer clips. 9. Remove the fender bolts.

10. Remove the upper fender bolts and the fender.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the fender with the upper fender bolts. Tighten Tighten the upper fender bolts to 10 N·m (89 lb in).

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2. Install the bolt at the base of the A-pillar. Tighten Tighten the A-pillar fender bolt to 10 N·m (89 lb in).

3. Install the bolts at the base of the fender. Tighten Tighten the lower fender bolts to 10 N·m (89 lb in). 4. Install the rocker panel molding. Refer to Rocker Panel Molding Replacement . 5. Install the front fender bolts behind the front fascia. Tighten Tighten the front fender bolts to 10 N·m (89 lb in).

6. Install the fender bolts. Tighten Tighten the front fender bolts to 10 N·m (89 lb in). 7. Install the fender center molding.

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8. Install the front fascia to its original position. 9. Install the bolts securing the front fascia to the fender. Tighten Tighten the front fascia-to-fender bolts to 2.5 N·m (22 lb in). 10. Install the front fender liner. Refer to Fender Liner Replacement .

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Front Fender Replacement (C 100/Long Body) Removal Procedure

1. Remove the two fender liner screws.

2. Remove the screw (1) securing the front fascia to the fender.

3. Reposition the front fascia from the fender by pulling the side of the front fascia outward.

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4. Pull back on front fascia (3) and remove the bolt (1) that secures the front fascia to fender bracket (2) 5. Pull back and remove the front fascia to fender bracket (2) from the fender.

6. Remove the two bolts (1) from the front of the fender behind the front fascia.

7. Remove the rocker panel molding. Refer to Rocker Panel Molding Replacement . 8. Remove the bolts at the base of the fender.

9. Open the front door and remove the bolt at the base of the A-pillar.

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10. 11. 12. 13.

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Remove the upper fender bolts and the fender. Remove the fender wheel opening molding, if equipped. Refer to Front Fender Wheel Opening Molding Replacement . Remove the fender insulator, if necessary. Refer to Front Fender Insulator Replacement . Remove the fender vent grille, if necessary.

Installation Procedure 1. Install the fender vent grille, if removed. 2. Install the fender insulator, if removed. Refer to Front Fender Insulator Replacement . 3. Install the fender wheel opening molding, if removed. Refer to Front Fender Wheel Opening Molding Replacement . Notice: Refer to Fastener Notice in the Preface section.

4. Install the fender with the upper fender bolts. Tighten Tighten the upper fender bolts to 10 N·m (89 lb in).

5. Install the bolt at the base of the A-pillar. Tighten Tighten the A-pillar fender bolt to 10 N·m (89 lb in).

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6. Install the bolts at the base of the fender. Tighten Tighten the lower fender bolts to 10 N·m (89 lb in). 7. Install the rocker panel molding. Refer to Rocker Panel Molding Replacement .

8. Install the two fender bolts (1) behind the front fascia. Tighten Tighten the two fender bolts to 10 N·m (89 lb in).

9. Reposition the front fascia (3) and install the front fascia to fender bracket (2) to the fender. 10. Install the front fascia to fender bracket bolt (1). Tighten Tighten the front fascia bracket to fender bolt to 10 N·m (89 lb in).

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11. Install the front fascia to its original position.

12. install the screw (1) securing the front fascia to the fender. Tighten Tighten the front fascia-to-fender screw to 2.5 N·m (22 lb in).

13. Install the two fender liner screws.

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Liftgate Replacement Removal Procedure 1. Remove the liftgate window upper garnish molding. Refer to Liftgate Garnish Molding Replacement .

2. 3. 4. 5. 6. 7. 8. 9.

Open the liftgate and support. Disconnect the liftgate wiring connectors. Disconnect the rear washer hose. Pull the liftgate wiring grommet, the connectors and the rear washer hose out of the rear header. Remove the liftgate struts. Refer to Liftgate Strut Replacement . Mark the location of the liftgate hinges to the body with a grease pencil. Remove the liftgate hinge attachment bolts. With the aid of an assistant, remove the liftgate from the vehicle.

Installation Procedure

1. With the aid of an assistant, position the liftgate hinges to the marked location points on the body. Important: New hinge to body nuts must be used to ensure a proper seal. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the liftgate hinge attachment bolts. Tighten Tighten the liftgate hinge bolts to 25 N·m (18 lb in). 3. 4. 5. 6. 7. 8.

Verify the alignment of the liftgate. Adjust as necessary. Install the liftgate struts. Refer to Liftgate Strut Replacement . Install the liftgate wiring grommet, the connectors and the hose into the rear header. Connect the liftgate wiring connectors. Connect the rear washer hose. Install the liftgate window upper garnish molding. Refer to Liftgate Garnish Molding Replacement .

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Hood Hinge Replacement Removal Procedure

1. Remove the hood. Refer to Hood Replacement . 2. Remove the fender. Refer to Front Fender Replacement . 3. Remove the bolts and the hinge.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the hinge with the bolts. Tighten Tighten the hinge bolts to 24 N·m (18 lb ft). 2. Install the fender. Refer to Front Fender Replacement . 3. Install the hood. Refer to Hood Replacement .

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Hood Replacement Removal Procedure Important: Install protective coverings over the fenders and the windshield to prevent damage to the paint, the glass, and the moldings when removing and installing the hood.

1. 2. 3. 4. 5. 6.

Raise and support the hood. Mark the position of the hinge to the hood to aid in alignment during installation. Remove the washer hoses from the hood. Remove the hood struts. Refer to Hood Strut Replacement . Remove the bolts retaining the hood to both of the hinges. With the aid of another technician, remove the hood from the hinges.

Installation Procedure

1. With the aid of another technician, position the hood in the location marked during removal. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the two bolts securing the hood to each hinge. Tighten Tighten the hood-to-hinge bolts to 24 N·m (18 lb ft). 3. Install the hood struts. Refer to Hood Strut Replacement . 4. Inspect the hood for proper alignment. 5. Install the washer hoses to the hood.

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Front Fender Insulator Replacement Removal Procedure

1. 2. 3. 4.

Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the front wheel. Refer to Tire and Wheel Removal and Installation . Remove the front fender liner. Refer to Fender Liner Replacement . Remove the front fender insulator.

Installation Procedure

1. 2. 3. 4.

Install the front fender insulator. Install the front fender liner. Refer to Fender Liner Replacement . Install the front wheel. Refer to Tire and Wheel Removal and Installation . Lower the vehicle.

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Hood Insulator Replacement Removal Procedure

1. 2. 3. 4.

Open the hood. Remove the washer hose from the hood. Remove the retaining clips . Remove the hood insulation.

Installation Procedure

1. Install the hood insulation with the retaining clips. 2. Install the washer hose to the hood. 3. Close the hood.

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Liftgate Latch Replacement Removal Procedure 1. Remove the liftgate lower trim. Refer to Liftgate Trim Panel Replacement .

2. Disconnect the lock rod. 3. Disconnect the electrical connector. 4. Remove the bolts and the liftgate latch.

Installation Procedure

1. Connect the electrical connector. 2. Connect the lock rod. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Secure the liftgate latch with the bolts. Tighten Tighten the liftgate latch bolt to 10 N·m (89 lb in). 4. Install the liftgate lower trim. Refer to Liftgate Trim Panel Replacement .

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Hood Primary Latch Replacement Removal Procedure

1. 2. 3. 4. 5. 6.

Open the hood. Mark the position of the hood latch on the radiator support to aid in alignment during installation. Remove the radiator grille guide. Remove the front bumper. Refer to Front Bumper Fascia Replacement . Remove the bolts and the hood latch. Disconnect the hood release cable.

Installation Procedure

1. 2. 3. 4.

Connect the hood release cable to the latch. Position the hood latch in the location marked during removal. Install the front bumper. Refer to Front Bumper Fascia Replacement . Install the radiator grille guide. Notice: Refer to Fastener Notice in Cautions and Notices.

5. Install the hood latch with the bolts. Tighten Tighten the hood latch bolts to 12 N·m (106 lb in). 6. Close the hood.

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Door Check Link Replacement (C 105/Short Body) Removal Procedure 1. Remove the door water deflector. Refer to Door Water Deflector Replacement .

2. Remove the bolts on the door and on the body. 3. Remove the door hold-open link.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the door hold-open link to the door and the body with the bolts. Tighten • Tighten the door hold-open link-to-body bolt to 20 N·m (15 lb ft). • Tighten the door hold-open link-to-door bolts to 7 N·m (62 lb in). 2. Install the door water deflector. Refer to Door Water Deflector Replacement .

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Door Check Link Replacement (C 100/Long Body) Removal Procedure 1. Remove the door water deflector. Refer to Door Water Deflector Replacement .

2. Remove the bolts on the door and on the body. 3. Remove the door hold-open link.

Installation Procedure

1. Install the door hold-open link to the door and the body with the bolts. Tighten • Tighten the door hold-open link-to-body bolt to 20 N·m (15 lb ft). • Tighten the door hold-open link-to-door bolts to 9 N·m (80 lb in). Install the door water deflector. Refer to Door Water Deflector Replacement .

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Hood Strut Replacement Removal Procedure

1. Raise and support the hood. 2. Remove the retaining clips and the hood strut.

Installation Procedure

1. Install the retaining clips and the hood strut. 2. Close the hood.

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Door Bottom Auxiliary Sealing Strip Replacement Removal Procedure

1. Open the door. 2. Remove the door lower weather-strip from the door.

Installation Procedure

1. Install the door lower weather-strip. 2. Close door.

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Liftgate Strut Replacement Removal Procedure

1. 2. 3. 4. 5.

Raise and support the liftgate in the open position. Lift up and partially remove the spring clips on the strut using a small flat-bladed tool. Remove the upper end of the strut from the ball joint. Remove the lower end of the strut from the ball joint. Remove the strut from the liftgate.

Installation Procedure

1. Position the strut to the liftgate. 2. Install the upper end of the strut to the ball joint. Press in to place until fully seated. 3. Install the lower end of the strut to the ball joint. Press in to place until fully seated. 4. Remove the support from the liftgate. 5. Close the liftgate.

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Door Weatherstrip Replacement Removal Procedure

1. Remove the door hold-open link-to-body bolt and the door hold-open link.

2. Remove the door weather strip.

Installation Procedure

1. Install the door weather strip. Notice: Refer to Fastener Notice in Cautions and Notices.

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2. Install the door hold-open link to the body with the bolt. Tighten Tighten the door hold-open link-to-body bolt to 20 N·m (15 lb ft).

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Front Door Opening Weatherstrip Replacement Removal Procedure 1. Remove the front door sill plate. Refer to Front Side Door Sill Plate Replacement .

2. Remove the front door opening weather strip.

Installation Procedure

1. Install the front door opening weather strip. 2. Install the front door sill plate. Refer to Front Side Door Sill Plate Replacement .

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Liftgate Weatherstrip Replacement Removal Procedure

1. Open the liftgate. 2. Remove the weather strip from around the gutter.

Installation Procedure

1. Install the weather strip onto the gutter flange. 2. Inspect the weather strip. Make sure that the clinch is completely seated onto the flange. 3. Install the new weather strip onto the gutter flange.

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Rear Door Opening Weatherstrip Replacement Removal Procedure 1. Remove the rear door sill plate. Refer to Rear Side Door Sill Plate Replacement .

2. Remove the rear door opening weather strip.

Installation Procedure

1. Install the rear door opening weather strip. 2. Install the rear door sill plate. Refer to Rear Side Door Sill Plate Replacement .

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Liftgate Garnish Molding Replacement (Upper) Removal Procedure

1. Open the liftgate. 2. Remove the liftgate window upper garnish molding.

Installation Procedure

1. Install the liftgate window upper garnish molding. 2. Close the liftgate.

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Liftgate Garnish Molding Replacement (Side - C 100/Long Body) Removal Procedure

1. Open the liftgate. 2. Remove the liftgate window side garnish molding

Installation Procedure

1. Install the liftgate window side garnish molding. 2. Close the liftgate.

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Liftgate Garnish Molding Replacement (Side - C 105/Short Body) Removal Procedure

1. Open the liftgate. 2. Remove the liftgate window side garnish molding

Installation Procedure

1. Install the liftgate window side garnish molding. 2. Close the liftgate.

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Liftgate Trim Panel Replacement Removal Procedure

1. Remove the screws and the liftgate inside pull handle.

2. Remove the retainers from liftgate trim. 3. Remove the liftgate trim from the vehicle.

Installation Procedure

1. Install the liftgate trim with the retainers.

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2. Install the liftgate inside pull handle with the screws.

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Door Water Deflector Replacement Removal Procedure

1. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement or Rear Door Trim Panel Replacement . 2. Remove the door water deflector.

Installation Procedure

1. Install the door water deflector. 2. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement or Rear Door Trim Panel Replacement .

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Fastener Tightening Specifications Specification Application

Metric

English

A-Pillar Fender Bolt

10 N·m

89 lb in

Door Hinge to Body Bolts

2.5 N·m

22 lb in

Door Hold Open Link to Body Bolts

10 N·m

89 lb in

Front Fascia-to-Fender Bolts

20 N·m

15 lb ft

Front of Fender Bolts

20 N·m

15 lb ft

Fuel Filler Door Screws

12 N·m

106 lb in

Hinge Bolts

2 N·m

18 lb in

Hood Latch Bolts

10 N·m

89 lb in

Hood-to-Hinge Bolts

4.5 N·m

40 lb in

Hood Release Handle Screw

10 N·m

89 lb in

Lift Gate Hinge Bolts

27.5 N·m

20 lb ft

Lift Gate Latch Bolts

20 N·m

15 lb ft

Lower Fender Bolts

4 N·m

35 lb in

Radiator Grille Nuts

25 N·m

18 lb in

Upper Fender Bolts

10 N·m

89 lb in

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Bumpers and Fascias Front Bumper Fascia Energy Absorber Replacement (C 100/Long Body) Front Bumper Fascia Energy Absorber Replacement (C 105/Short Body) Front Bumper Impact Bar Replacement (C 105/Short Body) Front Bumper Impact Bar Replacement (C 100/Long Body) Front Bumper Fascia Replacement (C 100/Long Body) Front Bumper Fascia Replacement (C 105/Short Body) Rear Bumper Fascia Replacement (C 100/Long Body) Rear Bumper Fascia Replacement (C 105/Short Body) Rear Bumper Impact Bar Replacement Grille Replacement C 100/Long Body Grille Replacement C 100/ Short Body Fastener Tightening Specifications Description and Operation

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Front Bumper Fascia Energy Absorber Replacement (C 100/Long Body) Removal Procedure

1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement . 2. Remove the retaining clips on the energy absorber. 3. Remove the upper and lower energy absorbers from the front fascia.

Installation Procedure

1. Install the upper and lower energy absorbers to the front fascia. 2. Install the retaining clips to the energy absorbers. 3. Install the front bumper fascia Refer to Front Bumper Fascia Replacement .

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Front Bumper Fascia Energy Absorber Replacement (C 105/Short Body) Removal Procedure

1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement . 2. Remove the retaining clips (1) on the energy absorber. 3. Remove the energy absorber (2) from the front fascia.

Installation Procedure

1. Install the energy absorber (2) to the front fascia. 2. Install the retaining clips (1) to the energy absorbers. 3. Install the front bumper fascia Refer to Front Bumper Fascia Replacement .

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Front Bumper Impact Bar Replacement (C 105/Short Body) Removal Procedure

1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement . 2. Remove the bolts from the front end panel bracket. 3. Remove the bolts and the front bumper impact bar.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the front bumper impact bar with the bolts. Tighten Tighten the impact bar bolts to 22 N·m (16 lb ft). 2. Install the bolts to the front panel bracket. Tighten Tighten the front panel bracket bolts to 220 N·m (16 lb ft). 3. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .

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Front Bumper Impact Bar Replacement (C 100/Long Body) Removal Procedure

1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement . 2. Remove the power steering fluid return cooling pipe bracket securing bolts near the center of the impact bar, if equipped. 3. Remove the bolts and the front bumper impact bar.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the front bumper impact bar with the bolts. Tighten Tighten the impact bar bolts to 22 N·m (16 lb ft). 2. Install the power steering fluid return coolant pipe bracket securing bolts, if equipped. Tighten Tighten the power steering bracket bolts to 10 N·m (7 lb ft). 3. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .

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Front Bumper Fascia Replacement (C 100/Long Body) Removal Procedure Caution: Refer to Battery Disconnect Caution in the Preface section.

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 2. Remove the bolts from the front wheel well splash shields.

3. Remove the headlamps. Refer to Headlamp Replacement . 4. Disconnect the fog lamp electrical connector.

5. Remove the grille. Refer to Grille Replacement . 6. Remove the upper fascia retainers.

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7. Remove the front fascia from the front fender by pulling the side of the fascia outward. 8. Remove the front fascia from the vehicle.

Installation Procedure

1. Install the front fascia to the vehicle. 2. Install the side of the front fascia on the front fender.

3. Install the upper fascia retainers. 4. Install the grille. Refer to Grille Replacement . Notice: Refer to Fastener Notice in the Preface section.

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5. Install the lower fascia bolts. Tighten Tighten the lower fascia bolts to 10 N·m (7 lb ft). 6. Connect the fog lamp electrical connector. 7. Install the headlamps. Refer to Headlamp Replacement .

8. Install the bolts on the front wheel well splash shields. Tighten Tighten the splash shield bolts to 4 N·m (35 lb in). 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Front Bumper Fascia Replacement (C 105/Short Body) Removal Procedure Caution: Refer to Battery Disconnect Caution in the Preface section.

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 2. Remove the bolts and the retainers from the left and right front wheel well splash shields.

3. Remove the engine shield. Refer to Engine Shield Replacement . 4. Remove the bolts on the bottom of the left and right front wheel well splash shields.

5. Remove the radiator cover (2). 6. Remove the headlamps (1). Refer to Headlamp Replacement . 7. Disconnect the connector of the front object sensor wiring harness, if equipped.

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8. Remove the front fascia retainers.

9. Remove the front fascia from the front fender by pulling the side of the fascia outward. 10. Remove the front fascia from the vehicle.

Installation Procedure

1. Install the front fascia to the vehicle. 2. Install the retainers on the front fascia to prevent fascia falling down to the floor.

3. Install the side of the front fascia on the front fender. 4. Connect the connector of the front object sensor wiring harness, if equipped.

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5. Install the headlamps (1). Refer to Headlamp Replacement . 6. Install the radiator cover (2). Notice: Refer to Fastener Notice in the Preface section.

7. Install the front bolts of the left and right front splash shields. Tighten Tighten the front splash shield bolts to 10 N·m (7 lb ft). 8. Install the engine shield. Refer to Engine Shield Replacement .

9. Install the bolts and retainers on the left and right front wheel well splash shields. Tighten Tighten the splash shield bolts to 4 N·m (35 lb in). 10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Rear Bumper Fascia Replacement (C 100/Long Body) Removal Procedure

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 2. Disconnect the connector of the rear object sensor, if equipped.

3. Remove the bolts on the rear wheelhouse liner.

4. Remove the rear lower fascia retainers. 5. Remove the fascia.

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6. Remove the tail lamps. Refer to Tail Lamp Replacement . 7. Remove the upper fascia screws and retainers.

8. Remove the rear bumper fascia from the rear quarter panel by pulling the side of the fascia outward. 9. Remove the rear bumper fascia from the vehicle.

Installation Procedure

1. Install the rear bumper fascia to the vehicle. 2. Install the side of the rear bumper fascia to the rear quarter panel. Notice: Refer to Fastener Notice in the Preface section.

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3. Install the upper fascia screws and retainers. Tighten Tighten the rear upper fascia screws to 2 N·m (18 lb in). 4. Install the tail lamps. Refer to Tail Lamp Replacement

5. Install the lower fascia retainers.

6. Install the bolts on the rear wheelhouse liner. Tighten Tighten the rear wheelhouse liner bolts to 4 N·m (36 lb in).

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7. Connect the connector of the rear object sensor, if equipped. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Rear Bumper Fascia Replacement (C 105/Short Body) Removal Procedure

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 2. Disconnect the connector of the rear object sensor, if equipped.

3. Remove the bolts on the rear wheelhouse liner.

4. Remove the rear lower fascia retainers. 5. Remove the fascia.

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6. Remove the tail lamps. Refer to Tail Lamp Replacement . 7. Remove the upper fascia screws and retainers.

8. Remove the rear bumper fascia from the rear quarter panel by pulling the side of the fascia outward. 9. Remove the rear bumper fascia from the vehicle.

Installation Procedure

1. Install the rear bumper fascia to the vehicle. 2. Install the side of the rear bumper fascia to the rear quarter panel. Notice: Refer to Fastener Notice in the Preface section.

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3. Install the upper fascia screws and retainers. Tighten Tighten the rear upper fascia screws to 2 N·m (18 lb in). 4. Install the tail lamps. Refer to Tail Lamp Replacement

5. Install the lower fascia retainers.

6. Install the bolts on the rear wheelhouse liner. Tighten Tighten the rear wheelhouse liner bolts to 4 N·m (36 lb in).

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7. Connect the connector of the rear object sensor, if equipped. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Rear Bumper Impact Bar Replacement Removal Procedure

1. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement . 2. Remove the bolts and the rear impact bar.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the rear impact bar with the bolts. Tighten Tighten the rear impact bar bolts to 22 N·m (16 lb ft). 2. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .

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Grille Replacement (C100/Long Body) Removal Procedure

1. Open the hood. 2. Remove the nuts and the radiator grille.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the radiator grille with the nuts. Tighten Tighten the radiator grille nuts to 4.5 N·m (40 lb in). 2. Close the hood.

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Grille Replacement (C105/Short Body) Removal Procedure

1. Open the hood. 2. Remove the nuts and the radiator grille.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the radiator grille with the nuts. Tighten Tighten the radiator grille nuts to 4.5 N·m (40 lb in). 2. Close the hood.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Fastener Tightening Specifications Specification Application

Metric

English

Front Bumper Lower Fascia Bolts

22 N·m

16 lb ft

Front Impact Bar Bolts

10 N·m

7 lb ft

Power Steering Fluid Return Pipe Securing Bolts

2 N·m

18 lb in

Rear Bumper Upper Fascia Screws

22 N·m

16 lb ft

Rear Impact Bar Bolts

2 N·m

18 lb in

Wheelhouse Liner Bolts

10 N·m

7 lb ft

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Bumper and Fascia Description The bumper systems are designed to sustain a collision into a fixed barrier at speeds between 4 km/h (2.5 mph) and 8 km/h (5 mph) without damage. After absorbing the energy of a collision, these bumper systems restore themselves to their original position. Both the front and the rear bumpers feature an internal foam energy absorber and a polymer fascia cover. The rear bumper fascia must be removed before access can be gained to the energy absorber and the bumper. The front bumper assembly can be removed as a whole unit or the fascia cover can be removed separately.

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Collision Repair Tie Bar Replacement Front Wheelhouse Replacement Front Compartment Upper Side Rail Replacement Plenum Upper Panel Replacement Front Compartment Front Rail Replacement Front Hinge Pillar Body Sectioning Roof Outer Panel Replacement Floor Panel Replacement - Center Rear Floor Panel Replacement Body Rear End Panel Replacement Center Pillar Sectioning Quarter Panel Replacement Rear Rail Replacement Specifications: Dimensions C100 long body Dimensions C105 short body

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Tie Bar Replacement Removal Procedure Caution: Refer to Approved Equipment for Collision Repair Caution in Cautions and Notices.

1. 2. 3. 4. 5.

Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling . Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove all related panels and components. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body . Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

Important: Do not damage any inner panels or reinforcements. 6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the tie bar assembly.

7. Remove the damaged tie bar assembly.

Installation Procedure

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Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart. Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld. 1. Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the locations noted from the original panel. 2. Prepare all mating surfaces as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

4. Position the tie bar assembly to the vehicle using 3-dimensional measuring equipment. Clamp the tie bar assembly into place.

5. 6. 7. 8. 9. 10. 11.

Plug weld accordingly. Clean and prepare all welded surfaces. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair . Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems . Install all related panels and components. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Enable the SIR system. Refer to SIR Disabling and Enabling .

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Front Wheelhouse Replacement Removal Procedure Caution: Refer to Approved Equipment for Collision Repair Caution in Cautions and Notices.

1. 2. 3. 4. 5.

Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling . Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove all related panels and components. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body . Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

6. Remove the front tie bar. Refer to Tie Bar Replacement .

Important: Do not damage any inner panels or reinforcements. 7. Locate and drill out all factory welds. Note the number and location of the welds for installation of the front wheelhouse.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

8. Remove the damaged front wheelhouse.

Installation Procedure

Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart. Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld. 1. Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the locations noted from the original panel. 2. Prepare all mating surfaces as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

4. Position the front wheelhouse to the vehicle using 3-dimensional measuring equipment. Clamp the front wheelhouse into place.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

5. Plug weld accordingly.

6. 7. 8. 9. 10. 11. 12.

Replace the tie bar. Refer to Tie Bar Replacement . Clean and prepare all welded surfaces. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair . Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems . Install all related panels and components. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Enable the SIR system. Refer to SIR Disabling and Enabling .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Front Compartment Upper Side Rail Replacement Removal Procedure Caution: Refer to Approved Equipment for Collision Repair Caution in Cautions and Notices.

1. 2. 3. 4. 5.

Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling . Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove all related panels and components. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body . Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

Important: Do not damage any inner panels or reinforcements. 6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the front upper outer rail.

7. Remove the damaged front upper outer rail.

Installation Procedure

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart. Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld. 1. Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the locations noted from the original panel. 2. Prepare all mating surfaces as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

4. Position the front upper outer rail to the vehicle using 3-dimensional measuring equipment. Clamp the front upper outer rail into place.

5. 6. 7. 8. 9. 10. 11.

Plug weld accordingly. Clean and prepare all welded surfaces. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair . Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems . Install all related panels and components. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Enable the SIR system. Refer to SIR Disabling and Enabling .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Plenum Upper Panel Replacement Removal Procedure Caution: Refer to Approved Equipment for Collision Repair Caution in Cautions and Notices.

1. 2. 3. 4. 5.

Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling . Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove all related panels and components. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body . Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair . Important: Do not damage any inner panels or reinforcements.

6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the plenum top panel. 7. Remove the damaged plenum top panel.

Installation Procedure

Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart. Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the locations noted from the original panel. Prepare all mating surfaces as necessary. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. Position the plenum top panel to the vehicle using 3-dimensional measuring equipment. Clamp the plenum top panel into place. Plug weld accordingly. Clean and prepare all welded surfaces. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair . Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems . Install all related panels and components. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Enable the SIR system. Refer to SIR Disabling and Enabling .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Front Compartment Front Rail Replacement Removal Procedure Caution: Refer to Approved Equipment for Collision Repair Caution in Cautions and Notices.

1. 2. 3. 4. 5.

Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling . Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Remove all related panels and components. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body . Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

Important: Do not damage any inner panels or reinforcements. 6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the front lower rail.

7. Remove the damaged front lower rail.

Installation Procedure Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld. 1. Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the locations noted from the original panel. 2. Prepare all mating surfaces as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

4. Position the front lower rail to the vehicle using 3-dimensional measuring equipment. Clamp the front lower rail into place.

5. 6. 7. 8. 9. 10. 11.

Plug weld accordingly. Clean and prepare all welded surfaces. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair . Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems . Install all related panels and components. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Enable the SIR system. Refer to SIR Disabling and Enabling .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Front Hinge Pillar Body Sectioning Removal Procedure Important: Section in specified areas only. Sectioning outside of these areas may compromise the structural integrity of the vehicle. The door frame can be replaced at factory seams, but requires the removal of the windshield and the roof. The sectioning procedures have been developed as a more cost-effective alternative to complete replacement. The specific area to be sectioned is determined by the extent of the damage to the vehicle. Important: When replacing panels that involve servicing of stationary glass, refer to Urethane Adhesive Installation of Stationary Windows before performing any priming or refinishing. 1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling . 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

3. Remove all related panels and components. 4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body . Caution: Foam sound deadeners must be removed from areas within 152.4 mm (6 in) of where flame is to be used for body repairs. When reinstalling foam sound deadeners, avoid inhaling fumes as bodily injury may result. 5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

6. Remove the front upper rail. Refer to Front Compartment Upper Side Rail Replacement .

Important: Do NOT damage any inner panels or reinforcements. 7. Cut the panel where sectioning is to be performed.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

8. Locate and drill out all factory welds. Note the number and location of the welds for installations of the service part. 9. Remove the damaged windshield pillar section.

Installation Procedure 1. Cut the replacement windshield pillar section in corresponding locations to fit the original panel. The sectioning joint should be trimmed to allow 1½ times the metal thickness at the sectioning joint.

2. Create a 50-mm (2-in) backing plate (1) from the unused portion of the service part. Trim the backing plate as necessary to fit behind the sectioning joint where there is no reinforcement. 3. Drill 8-mm (5/16-in) plug weld holes along the sectioning cut on the remaining original part. Locate these holes 13 mm (1/2 in) from the edge and spaced 40 mm (1½ in) apart.

Important: In any area damaged beyond recognition, or if structural Weld-Thru adhesive is present, space the plug weld holes 40 mm (1½ in) apart. 4. Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the locations noted from the original panel and along the sectioning cut. 5. Prepare all mating surfaces, as necessary. 6. Apply 3M® Weld-Thru coating P/N 05916 or equivalent, to all mating surfaces.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

7. Fit the backing plate (2) halfway into the sectioning joint, clamp and plug weld to the vehicle. 8. Position the service part.

9. Plug weld accordingly. Important: To create a solid weld with minimum heat distortion make 25-mm (1-in) stitch welds along the seam with 25-mm (1-in) gaps between. Then go back and complete the stitch weld. 10. Stitch weld the sectioning joint. 11. Clean and prepare all welded surfaces.

12. 13. 14. 15. 16. 17.

Install the front upper rail. Refer to Front Compartment Upper Side Rail Replacement . Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair . Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems . Install all related panels and components. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Enable the SIR system. Refer to SIR Disabling and Enabling .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Roof Outer Panel Replacement Removal Procedure This repair procedure includes an installation procedure for either metal-inert gas welding or adhesive bonding. Caution: Refer to Approved Equipment for Collision Repair Caution in Cautions and Notices. Important: When replacing panels that involve servicing of stationary windows, refer to Urethane Adhesive Installation of Stationary Windows before performing any priming or refinishing. 1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling . 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

3. 4. 5. 6. 7.

Remove all related panels and components. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body . Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair . Remove the windshield. Refer to Windshield Replacement . Remove the liftgate. Refer to Liftgate Replacement .

8. Locate and drill out all factory welds. Note the number and location of welds for installation of the roof panel.

9. With the aid of an assistant, remove the roof panel.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Installation Procedure

1. Drill 8-mm (5/16-in) plug weld holes as necessary in locations noted from the original panel. Important: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (1½ in) apart. 2. Prepare all mating surfaces as necessary. 3. Apply 3M® Weld-Thru coating P/N 05916 or equivalent to all mating surfaces

4. With the aid of an assistant, position the roof panel to the body.

5. Plug weld accordingly. 6. Clean and prepare all welded surfaces.

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7. 8. 9. 10. 11. 12. 13.

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair . Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems . Install the windshield. Refer to Windshield Replacement . Install the liftgate. Refer to Liftgate Replacement . Install all related panels and components. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Enable the SIR system. Refer to SIR Disabling and Enabling .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Floor Panel Replacement - Center Removal Procedure Caution: Refer to Approved Equipment for Collision Repair Caution in Cautions and Notices.

1. 2. 3. 4. 5.

Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling . Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove all related panels and components. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body . Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

Important: Do not damage any inner panels or reinforcements. 6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the center floor panel .

7. Remove the damaged center floor panel .

Installation Procedure Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld. 1. Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the locations noted from the original panel. 2. Prepare all mating surfaces as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

4. Position the center floor panel to the vehicle using 3-dimensional measuring equipment. Clamp the center floor panel into place.

5. 6. 7. 8. 9. 10. 11.

Plug weld accordingly. Clean and prepare all welded surfaces. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair . Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems . Install all related panels and components. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Enable the SIR system. Refer to SIR Disabling and Enabling .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Rear Floor Panel Replacement Removal Procedure Caution: Refer to Approved Equipment for Collision Repair Caution in Cautions and Notices.

1. 2. 3. 4. 5.

Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling . Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove all related panels and components. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body . Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

Important: Do not damage any inner panels or reinforcements. 6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the rear floor panel . 7. Remove the damaged rear floor panel .

Installation Procedure

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart. Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the locations noted from the original panel. Prepare all mating surfaces as necessary. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. Position the rear floor panel to the vehicle using 3-dimensional measuring equipment. Clamp the rear floor panel into place. Plug weld accordingly. Clean and prepare all welded surfaces. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair . Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems . Install all related panels and components. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Enable the SIR system. Refer to SIR Disabling and Enabling .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Body Rear End Panel Replacement Removal Procedure Caution: Refer to Approved Equipment for Collision Repair Caution in Cautions and Notices.

1. 2. 3. 4. 5.

Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling . Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove all related panels and components. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body . Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

Important: Do not damage any inner panels or reinforcements. 6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the rear end panel.

7. Remove the damaged rear end panel.

Installation Procedure

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart. Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld. 1. Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the locations noted from the original panel. 2. Prepare all mating surfaces as necessary. 3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

4. Position the rear end panel to the vehicle using 3-dimensional measuring equipment. Clamp the rear end panel into place.

5. 6. 7. 8. 9. 10. 11.

Plug weld accordingly. Clean and prepare all welded surfaces. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair . Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems . Install all related panels and components. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Enable the SIR system. Refer to SIR Disabling and Enabling .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Center Pillar Sectioning Removal Procedure Important: Section in specified areas only. Sectioning outside of these areas may compromise the structural integrity of the vehicle. The door frame can be replaced at factory seams, but requires the removal of the windshield and the roof. The sectioning procedures have been developed as a more cost-effective alternative to complete replacement. The specific area to be sectioned is determined by the extent of the damage to the vehicle. 1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling . 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

3. Remove all related panels and components. 4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body . Caution: Foam sound deadeners must be removed from areas within 152.4 mm (6 in) of where flame is to be used for body repairs. When reinstalling foam sound deadeners, avoid inhaling fumes as bodily injury may result. 5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

6. On the original outer door frame, measure down from the lower edge of the door opening 135 mm (5.3 in) (A) and mark a horizontal line.

Important: Do NOT damage any inner panels or reinforcements. 7. Cut the panel where sectioning is to be performed.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

8. Locate and drill out all factory welds. Note the number and location of the welds for installations of the service part. 9. Remove the damaged center pillar section.

Installation Procedure 1. Cut the replacement center pillar section in corresponding locations to fit the original panel. The sectioning joint should be trimmed to allow 1½ times the metal thickness at the sectioning joint.

2. Create a 50-mm (2-in) backing plate (A) from the unused portion of the service part. Trim the backing plate as necessary to fit behind the sectioning joint where there is no reinforcement. 3. Drill 8-mm (5/16-in) plug weld holes along the sectioning cut on the remaining original part. Locate these holes 13 mm (1/2 in) from the edge and spaced 40 mm (1½ in) apart.

Important: In any area damaged beyond recognition, or if structural Weld-Thru adhesive is present, space the plug weld holes 40 mm (1½ in) apart. 4. Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the locations noted from the original panel and along the sectioning cut. 5. Prepare all mating surfaces as necessary. 6. Apply 3M® Weld-Thru coating P/N 05916 or equivalent, to all mating surfaces.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

7. Fit the backing plate halfway into the sectioning joint, clamp and plug weld to the vehicle. 8. Position the center pillar.

9. Plug weld accordingly. Important: To create a solid weld with minimum heat distortion make 25-mm (1-in) stitch welds along the seam with 25-mm (1-in) gaps between. Then go back and complete the stitch weld. 10. 11. 12. 13. 14. 15. 16.

Stitch the weld sectioning joint. Clean and prepare all welded surfaces. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair . Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems . Install all related panels and components. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Enable the SIR system. Refer to SIR Disabling and Enabling .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Quarter Panel Replacement Removal Procedure Important: Section in specified areas only. Sectioning outside of these areas may compromise the structural integrity of the vehicle. The door frame can be replaced at factory seams, but requires the removal of the windshield and the roof. The sectioning procedures have been developed as a more cost-effective alternative to complete replacement. The specific area to be sectioned is determined by the extent of the damage to the vehicle. Important: When replacing panels that involve servicing of stationary glass, refer to Urethane Adhesive Installation of Stationary Windows before performing any priming or refinishing. 1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling . 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

3. Remove all related panels and components. 4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body . Caution: Foam sound deadeners must be removed from areas within 152.4 mm (6 in) of where flame is to be used for body repairs. When reinstalling foam sound deadeners, avoid inhaling fumes as bodily injury may result. 5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

Important: Do NOT damage any inner panels or reinforcements. 6. Cut the panel where sectioning is to be performed.

7. Locate and drill out all factory welds. Note the number and location of the welds for installations of the service part. 8. Remove the damaged quarter panel.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Installation Procedure 1. Cut the replacement quarter panel in corresponding locations to fit the original panel. The sectioning joint should be trimmed to allow 1½ times the metal thickness at the sectioning joint.

2. Create two 50-mm (2-in) backing plates and one 100-mm (4-in) backing plate from the unused portion of the service part. Trim the backing plates as necessary to fit behind the sectioning joints where no reinforcements exist. 3. Drill 8-mm (5/16-in) plug weld holes along the sectioning cut on the remaining original part. Locate these holes 13 mm (1/2 in) from the edge and spaced 40 mm (1½ in) apart.

Important: In any area damaged beyond recognition, or if structural Weld-Thru adhesive is present, space the plug weld holes 40 mm (1½ in) apart. 4. 5. 6. 7. 8.

Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the locations noted from the original panel and along the sectioning cut. Prepare all mating surfaces, as necessary. Apply 3M® Weld-Thru coating P/N 05916 or equivalent, to all mating surfaces. Fit the backing plates halfway into the sectioning joints, clamp and plug weld to the vehicle. Position the quarter panel.

9. Plug weld accordingly. Important: To create a solid weld with minimum heat distortion make 25-mm (1-in) stitch welds along the seam with 25-mm (1-in) gaps between. Then go back and complete the stitch weld. 10. 11. 12. 13. 14. 15. 16.

Stitch the weld sectioning joint. Clean and prepare all welded surfaces. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair . Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems . Install all related panels and components. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Enable the SIR system. Refer to SIR Disabling and Enabling .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Rear Rail Replacement Removal Procedure Caution: Refer to Approved Equipment for Collision Repair Caution in Cautions and Notices.

1. 2. 3. 4. 5.

Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling . Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove all related panels and components. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body . Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair . Important: Do not damage any inner panels or reinforcements.

6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the rear rail lower. 7. Remove the damaged rear rail.

Installation Procedure

Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart. Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the locations noted from the original panel. Prepare all mating surfaces as necessary. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. Position the rear rail lower to the vehicle using 3-dimensional measuring equipment. Clamp the rear rail lower into place. Plug weld accordingly. Clean and prepare all welded surfaces. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair . Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems . Install all related panels and components. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Enable the SIR system. Refer to SIR Disabling and Enabling .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Dimensions - Body (C 100/Long Body) Table 1: Table 2: Table 3:

Front Compartment Dimensions Body Dimensions (Long Body) Underbody Dimensions

Three Dimensional Distance -- X, Y, Z This universal measuring system is capable of simultaneously dimensioning the length, width, and height of a datum plane. Three dimensional distances are used for both underbody and upperbody measuring. X = Fore and aft measurements along the center line of the vehicle. An O plane is located forward of the master gage hole at the front of the vehicle. All measurements are made from this plane toward the rear of the vehicle. Y = Cross car dimensions. Positive values are measured from the center of the vehicle to the right side of the vehicle. Negative values are measured from the center of the vehicle to the left side. When values are not listed separately to change the side of the vehicle, you need only to change the Y dimensions to the opposite value, + or , from what is listed. Z = Vertical measurement from the datum plane below the rocker panel lower flange edge (O plane). All dimensions are symmetrical, unless otherwise noted. In order to properly repair the spaceframe, restore the vehicle to the XYZ dimensions, as originally built. Relational (linear) dimensions are for reference only. Use relational dimensions for diagnosis or inspection only. Relational dimensions are not as accurate as XYZ dimensions and measuring systems. The gage holes shown are the actual fixture locations that are used to build the vehicle.

Front Compartment

Front Compartment Dimensions Location

Description

Length = x

Width = y

Height = z

Point to Point

1

Hole

1187

2

Hole

1299

540

904

x

713

9080

x

3

Strut Attachment Hole

1698

648

934

x

4

Hood Hinge Hole

1919

760

987

x

5

Hood Hinge Hole

2003

773

996

x

6

Air Inlet Grille Attachment Hole

1776

600

977

x

7

Hole

1698

648

934

x

8

Air Inlet Grille Attachment Hole

1776

600

977

x

9

Hood Hinge Hole

1919

760

987

x

10

Hood Hinge Hole

2003

773

996

x

11

Hole

1299

713

908

x

12

Hole

1187

540

904

x

13

Hood Striker Attachment Hole

1071

0

903

x

14

Impact Bar Attachment Hole

1122

540

533

x

15

Impact Bar Attachment Hole

1122

423

531

x

16

Impact Bar Attachment Hole

1122

434

320

x

17

Impact Bar Attachment Hole

1122

554

324

x

18

Impact Bar Attachment Hole

1122

423

531

x

19

Impact Bar Attachment Hole

1122

540

533

x

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

20

Impact Bar Attachment Hole

1122

554

324

x

21

Impact Bar Attachment Hole

1122

534

320

x

14 to 19

x

x

x

x

1080

15 to 18

x

x

x

x

846

2 to 11

x

x

x

x

1426

4 to 11

x

x

x

x

1600

2 to 9

x

x

x

x

1600

16 to 21

x

x

x

x

868

All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless otherwise specified.

Body Side

Body Dimensions (Long Body)

Underbody

Location

Length

A-G

840 mm

A-I

1520 mm

B-F

1049 mm

B-E

1145 mm

B-C

392 mm

C-E

1059 mm

C-F

1108 mm

D-H

1956 mm

E-F

407 mm

F-H

1323 mm

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Location

Description

Length = x

Width = y

Height = z

Point to Point

A

Hole

1162

480

341

x

B

Hole

1261

474

287

x

C

Hole

2081

382

230

x

D

Hole

2192

600

193

x

F

Hole

3538

466

206

x

G

Hole

4955

475

404

x

H

Hole

4955

475

404

x

I

Hole

3538

466

206

x

J

Hole

2275

415

197

x

K

Hole

2192

600

193

x

L

Hole

2081

382

230

x

M

Hole

1261

474

287

x

N

Hole

1162

480

341

x

A to G

x

x

x

x

3794 mm

A to E

x

x

x

x

1124 mm

A to J

x

x

x

x

1435 mm

B to L

x

x

x

x

1187 mm

C to N

x

x

x

x

1266 mm

D to F

x

x

x

x

1353 mm

D to I

x

x

x

x

1717 mm

E to I

x

x

x

x

1540 mm

E to N

x

x

x

x

1126 mm

F to G

x

x

x

x

1431 mm

F to J

x

x

x

x

1540 mm

F to K

x

x

x

x

1717 mm

F to H

x

x

x

x

1712 mm

G to I

x

x

x

x

1712 mm

H to I

x

x

x

x

1431 mm

H to N

x

x

x

x

3794 mm

I to K

x

x

x

x

1353 mm

I to N

x

x

x

x

1124 mm

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Dimensions - Body (C 105/Short Body) Table 1: Table 2: Table 3:

Front Compartment Dimensions Body Dimensions (Short Body) Underbody Dimensions

Three Dimensional Distance -- X, Y, Z This universal measuring system is capable of simultaneously dimensioning the length, width, and height of a datum plane. Three dimensional distances are used for both underbody and upperbody measuring. X = Fore and aft measurements along the center line of the vehicle. An O plane is located forward of the master gage hole at the front of the vehicle. All measurements are made from this plane toward the rear of the vehicle. Y = Cross car dimensions. Positive values are measured from the center of the vehicle to the right side of the vehicle. Negative values are measured from the center of the vehicle to the left side. When values are not listed separately to change the side of the vehicle, you need only to change the Y dimensions to the opposite value, + or , from what is listed. Z = Vertical measurement from the datum plane below the rocker panel lower flange edge (O plane). All dimensions are symmetrical, unless otherwise noted. In order to properly repair the spaceframe, restore the vehicle to the XYZ dimensions, as originally built. Relational (linear) dimensions are for reference only. Use relational dimensions for diagnosis or inspection only. Relational dimensions are not as accurate as XYZ dimensions and measuring systems. The gage holes shown are the actual fixture locations that are used to build the vehicle.

Front Compartment

Front Compartment Dimensions Location

Description

Length = x

Width = y

Height = z

Point to Point

1

Hole

1170

488

904

x

2

Hole

1299

713

912

x

3

Strut Attachment Hole

1698

648

934

x

4

Hood Hinge Hole

1919

760

987

x

5

Hood Hinge Hole

2003

773

996

x

6

Air Inlet Grille Attachment Hole

1776

600

977

x

7

Hole

1698

648

934

x

8

Air Inlet Grille Attachment Hole

1776

600

977

x

9

Hood Hinge Hole

1919

760

987

x

10

Hood Hinge Hole

2003

773

996

x

11

Hole

1299

713

912

x

12

Hole

1170

488

904

x

13

Hood Striker Attachment Hole

1071

0

903

x

14

Impact Bar Attachment Hole

1122

540

533

x

15

Impact Bar Attachment Hole

1122

423

531

x

16

Impact Bar Attachment Hole

1122

434

320

x

17

Impact Bar Attachment Hole

1122

554

324

x

18

Impact Bar Attachment Hole

1122

423

531

x

19

Impact Bar Attachment Hole

1122

540

533

x

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

20

Impact Bar Attachment Hole

1122

554

324

x

21

Impact Bar Attachment Hole

1122

534

320

x

14 to 19

x

x

x

x

1080

15 to 18

x

x

x

x

846

2 to 11

x

x

x

x

1426

4 to 11

x

x

x

x

1600

2 to 9

x

x

x

x

1600

16 to 21

x

x

x

x

868

All dimensions are measured from a zero line, a center line, and a common datum. All dimensions are symmetrical unless otherwise specified.

Body Side

Body Dimensions (Short Body)

Underbody

Underbody Dimensions

Location

Length

A-G

840 mm

A-I

1520 mm

B-F

1049 mm

B-E

1145 mm

B-C

392 mm

C-E

1059 mm

C-F

1108 mm

D-H

1992 mm

E-F

407 mm

F-H

1331 mm

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Location

Description

Length = x

Width = y

Height = z

Point to Point

A

Hole

1162

480

341

x

B

Hole

1261

474

287

x

C

Hole

2081

382

230

x

D

Hole

2192

600

193

x

F

Hole

3538

466

206

x

G

Hole

4950

475

404

x

H

Hole

4950

475

404

x

I

Hole

3538

466

206

x

J

Hole

2275

415

197

x

K

Hole

2192

600

193

x

L

Hole

2081

382

230

x

M

Hole

1261

474

287

x

N

Hole

1162

480

341

x

A to G

x

x

x

x

3789 mm

A to E

x

x

x

x

1124 mm

A to J

x

x

x

x

1435 mm

B to j

x

x

x

x

1187 mm

C to N

x

x

x

x

1266 mm

D to F

x

x

x

x

1353 mm

D to I

x

x

x

x

1717 mm

E to I

x

x

x

x

1540 mm

E to N

x

x

x

x

1126 mm

F to G

x

x

x

x

1426 mm

F to J

x

x

x

x

1540 mm

F to K

x

x

x

x

1717 mm

F to H

x

x

x

x

1708 mm

G to I

x

x

x

x

1708 mm

H to I

x

x

x

x

1426 mm

H to N

x

x

x

x

3789 mm

I to K

x

x

x

x

1353 mm

J to N

x

x

x

x

1124 mm

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

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Frame and Underbody Engine Shield Replacement Engine Protection Shield Replacement Frame Replacement Fender Liner Replacement Rear Mud Flap Guard Replacement Muffler Replacement 2.4L Muffler Replacement 3.2L Muffler Replacement 2.0L Diesel Resonator Replacement 2.4L Resonator Replacement 3.2L Resonator Replacement 2.0L Diesel Fastener Tightening Specifications

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Engine Shield Replacement Removal Procedure

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the bolts and the engine shield.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the engine shield with the bolts. Tighten Tighten the engine shield bolts to 10 N·m (89 lb in). 2. Lower the vehicle.

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

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Engine Protection Shield Replacement Removal Procedure

1. 2. 3. 4.

Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the front wheel. Refer to Tire and Wheel Removal and Installation . Remove the nut and clips. Remove the engine protection shield.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the engine protection shield with the nut and clips. Tighten Tighten the engine front shield nut to 10 N·m (89 lb in). 2. Install the front wheel. Refer to Tire and Wheel Removal and Installation . 3. Lower the vehicle.

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Frame Replacement Removal Procedure

1. Raise and suitably support the vehicle and remove the wheels. Refer to Lifting and Jacking the Vehicle and Tire and Wheel Removal and Installation . 2. Remove the engine shield from the under body of the vehicle. Refer to Engine Shield Replacement .

3. Remove the front control arm ball joint to knuckle nut and pin. 4. Remove the front exhaust muffler and catalytic converter. Refer to Muffler Replacement and Resonator Replacement . 5. Incase of 4-wheel drive vehicle, Remove the propeller shaft.

6. Remove the outer tie rod to knuckle nut. Important: Do not allow the radiator to swing after removing the front suspension crossmember. The upper part of the radiator should be fixed using strings. 7. Remove the stabilizer shaft link to strut nut.

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8. Remove the power steering gear to front suspension crossmember bolts. 9. Support the front suspension crossmember by a jack stand.

10. Remove the front suspension crossmember to transmission rear mount bracket bolts.

11. Remove the transmission front mount to front suspension crossmember bolt and remove the mount.

12. Remove the front suspension crossmember to body bolts.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

13. Remove the front suspension crossmember support bracket to body bolts. 14. Lower the front suspension crossmember slowly with care. Rotate the stabilizer shaft and tie rod properly to have enough space during lowering the cradle.

15. Remove the stabilizer shaft clamp to front suspension crossmember bolts. 16. Remove the control arm to front suspension crossmember bolts and nuts. Refer to Lower Control Arm Replacement . .

Installation Procedure

1. Install the front control arm to front suspension crossmember bolts and nuts. Refer to Lower Control Arm Replacement . Notice: Refer to Fastener Notice in Cautions and Notices.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

2. Install the stabilizer shaft clamp to front suspension crossmember bolts. Tighten Tighten the stabilizer shaft clamp bolts to 50 N·m (37 lb ft).

3. Raise the front suspension crossmember slowly with care using a jack stand. Rotate the stabilizer shaft and tie rod properly to settle the front suspension crossmember in the correct position. 4. Install the front suspension crossmember support bracket and front suspension crossmember to body bolts. Tighten • Tighten the front suspension crossmember to body bolts to 155 N·m (114 lb ft). • Tighten the front suspension crossmember support bracket to body bolts to 50 N·m (37 lb ft).

5. Install the front suspension crossmember to transmission rear mount bolts. Tighten Tighten the front suspension crossmember to transmission rear mount bolts to 110 N·m (81 lb ft).

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

6. Install the transmission front mount and install the front suspension crossmember to transmission front mount bolt. Tighten • Tighten the transmission front mount to transmission bolts to 50 N·m (37 lb ft). • Tighten the front suspension crossmember to transmission front mount bolt to 110 N·m (81 lb ft).

7. Install the power steering gear to front suspension crossmember bolts. Tighten Tighten the power steering gear to front suspension crossmember bolts to 110 N·m (81 lb ft).

8. Install the stabilizer shaft link to strut nut. Tighten Tighten the stabilizer shaft link nut to 65 N·m (48 lb ft). 9. Install the tie rod to knuckle nut. Tighten Tighten the tie rod to knuckle nut to 50 N·m (37 lb ft).

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

10. Install the front exhaust muffler and catalystic converter. Refer to Muffler Replacement and Resonator Replacement . 11. Install the front control arm ball joint to knuckle nut and pin. Refer to Lower Control Arm Replacement .

12. 13. 14. 15.

Install the engine shield to the under body of the vehicle. Refer to Engine Shield Replacement . Install the wheels. Refer to Tire and Wheel Removal and Installation . Lower the vehicle. Check vehicle front end alignment. Refer to Measuring Wheel Alignment .

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Fender Liner Replacement Removal Procedure

1. 2. 3. 4. 5.

Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the front wheel. Refer to Tire and Wheel Removal and Installation . Remove the front mud guard. Refer to Guard Mud - Rear (One or Both) Replacement . Remove the engine protection shield. Refer to Engine Protection Shield Replacement . Remove the screws and the front fender liner.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the screws and the front fender liner. Tighten Tighten the front fender liner screws to 4 N·m (35 lb in). 2. 3. 4. 5.

Install the engine protection shield. Refer to Engine Protection Shield Replacement . Install the front mud guard. Refer to Guard Mud - Rear (One or Both) Replacement . Install the front wheel. Refer to Tire and Wheel Removal and Installation . Lower the vehicle.

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

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Rear Mud Flap Guard Replacement Removal Procedure

Remove the screw and the bolts and the mud guard.

Installation Procedure

Notice: Refer to Fastener Notice in Cautions and Notices. Install the mud guard with the bolts and the screw. Tighten Tighten the mud guard bolts to 2 N·m (18 lb in).

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Muffler Replacement (2.4L) Removal Procedure

1. Remove the nuts and the gaskets from both resonator pipe flanges-to-front muffler pipe flanges.

2. Detach both resonator assemblies from the rubber hangers. 3. Remove both resonators. 4. Check the rear resonator and the pipe for holes, damage, open seams and other deterioration which could permit exhaust fumes to seep into the passenger compartment or the trunk.

Installation Procedure

1. Secure both rear resonator assemblies to the rubber hangers. Notice: Refer to Fastener Notice in Cautions and Notices.

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2. Install the nuts and the gaskets to both rear resonator pipe flanges-to-front muffler pipe flanges. Tighten Tighten the front muffler-to-rear resonator nuts to 40 N·m (30 lb ft).

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Muffler Replacement (3.2L) Removal Procedure

1. Remove the nuts and the gaskets from the rear muffler pipe flange-to-front muffler pipe flange.

2. Detach the rear muffler assembly from the rubber hangers. 3. Remove the rear muffler. 4. Check the rear muffler and the pipe for holes, damage, open seams or other deterioration which could permit exhaust fumes to seep into the passenger compartment or the trunk.

Installation Procedure

1. Secure the rear muffler assembly to the rubber hangers. Notice: Refer to Fastener Notice in Cautions and Notices.

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2. Install the nuts and the gaskets to the rear muffler pipe flange-to-front muffler pipe flange. Tighten Tighten the front muffler-to-rear muffler nuts to 40 N·m (30 lb ft).

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Muffler Replacement (2.0L Diesel) Removal Procedure

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool. Notice: When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to prevent overheating of the floor pan and possible damage to the passenger compartment insulation and trim materials. 1. Remove the nuts and the gaskets from the both rear muffler pipe flange-to-front muffler pipe flange.

2. Detach the both rear muffler assembly from the rubber hangers. 3. Remove the both rear muffler. 4. Check the rear muffler and the pipe for holes, damage, open seams and other deterioration which could permit exhaust fumes to seep into the passenger compartment or the trunk.

Installation Procedure

1. Secure the both rear muffler assembly to the rubber hangers. Notice: Refer to Fastener Notice in Cautions and Notices.

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2. Install the nuts and the gaskets to the both rear muffler pipe flange-to-front muffler pipe flange. Tighten Tighten the front muffler-to-rear muffler nuts to 40 N·m (30 lb ft).

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Resonator Replacement (2.4L) Removal Procedure

1. Remove the nuts and the gasket from the front muffler pipe-to-underbody catalytic converter (UCC).

2. Remove the nuts and the gaskets from the both rear muffler pipe flange.

3. Disconnect the front muffler from the rubber hangers. 4. Remove the front muffler. 5. Check the UCC and the front muffler for holes, damage, open seams or other deterioration which could permit exhaust fumes to seep into the passenger compartment or the trunk.

Installation Procedure

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1. Secure the front muffler to the rubber hangers. Notice: Refer to Fastener Notice in Cautions and Notices.

2. Install the nuts and the gaskets to the both rear muffler pipe flange. Tighten Tighten the front muffler-to-rear muffler nuts to 40 N·m (30 lb ft).

3. Install the nuts and gasket to the front muffler pipe-to-UCC. Tighten Tighten the front muffler-to-underbody catalytic converter nuts to 30 N·m (22 lb ft).

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Resonator Replacement (3.2L) Removal Procedure

1. Remove the nuts and the gasket from the front muffler pipe-to-underbody catalytic converter (UCC).

2. Remove the nuts and the gaskets from the rear muffler pipe flange.

3. Disconnect the front muffler from the rubber hangers. 4. Remove the front muffler. 5. Check the UCC and the front muffler for holes, damage, open seams or other deterioration which could permit exhaust fumes to seep into the passenger compartment or the trunk.

Installation Procedure

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1. Secure the front muffler to the rubber hangers. Notice: Refer to Fastener Notice in Cautions and Notices.

2. Install the nuts and the gaskets to the rear muffler pipe flange. Tighten Tighten the front muffler-to-rear muffler nuts to 40 N·m (30 lb ft).

3. Install the nuts and gaskets to the front muffler pipe-to-UCC. Tighten Tighten the front muffler-to-underbody catalytic converter nuts to 30 N·m (22 lb ft).

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Resonator Replacement (2.0L Diesel) Removal Procedure

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool. Notice: When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to prevent overheating of the floor pan and possible damage to the passenger compartment insulation and trim materials. 1. Remove the nuts and the gasket from the front muffler pipe-to-DPF.

2. Remove the nuts and the gaskets from the both rear muffler pipe flange.

3. Remove the rubber hangers. 4. Remove the front muffler.

Installation Procedure

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1. Secure the front muffler to the rubber hangers. Notice: Refer to Fastener Notice in Cautions and Notices.

2. Install the nuts and the gaskets to the both rear muffler pipe flange. If damaged, replace the new gasket. Tighten Tighten the front muffler-to-rear muffler nuts to 40 N·m (30 lb ft).

3. Install the nuts and gasket to the front muffler pipe-to-DPF. If damaged, replace the new gasket. Tighten Tighten the front muffler-to-DPF nuts to 30 N·m (22 lb ft).

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Fastener Tightening Specifications Specification Application

Metric

English

Engine Protection Shield Nut

10 N·m

89 lb in

Engine Shield Bolts

2 N·m

18 lb in

Fender Liner Screws

4 N·m

35 lb in

Front Suspension Crossmember Support Bracket to Body Bolts

10 N·m

89 lb in

Front Suspension Crossmember to Body Bolts

155 N·m

114 lb ft

Front Suspension Crossmember to Transmission Front Mount Bolts

50 N·m

37 lb ft

Front Suspension Crossmember to Transmission Rear Mount Bolt

110 N·m

81 lb ft

Mud Guard Bolts

110 N·m

81 lb ft

Outer Tie Rod to Knuckle Nut

170 N·m

125 lb ft

Power Steering Gear to Front Suspension Crossmember Bolts

50 N·m

37 lb ft

Rear Support to Body Bolts

110 N·m

81 lb ft

Stabilizer Link Nuts

65 N·m

48 lb ft

Stabilizer Shaft Clamp to Front Suspension Crossmember Bolts

50 N·m

37 lb ft

Transmission Front Mount to Transmission Bolt

50 N·m

37 lb ft

Wheel Nuts

125 N·m

92 lb ft

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Paint and Coatings Clearcoat Repair without Repainting Environmental Fallout (Acid Rain) Paint Gauges Clearcoat Thickness Rail Dust Damage Repair Clearcoat Repair Specifications Basecoat / Clearcoat Paint systems Anti-Corrosion Treatment and Repair Paint Identification

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Clearcoat Repair without Repainting Service Precautions • Avoid washing vehicles in direct sunlight. • Avoid using strong soaps or chemical detergents. • Use brushless type automatic car wash equipment. • Avoid using products containing acids, unless specified in order to correct a condition such as rail dust. • Do not use brushes or brooms in order to remove snow or ice from vehicles in storage or on lots. • Cleaning agents and water should be dried promptly and not allowed to dry on the surface. Drying with a soft chamois is recommended. • Standing rinse water should be dried promptly and not allowed to dry on the surface. Drying with a soft chamois is recommended. • Do not polish vehicles unless a surface condition exists that can only be corrected by polishing. Refer to Clearcoat Repair Specifications - 3M Products . • If a surface condition does exist, the repair approach should be one of less is best, the very least it takes to correct the condition. • Avoid removing too much clear coat whenever possible, use paint gauges before, during and after polishing. Refer to Paint Gages . • Use only the products recommended in this procedure (or their equivalent). Refer to Clearcoat Repair Specifications - 3M Products . • Ensure that any power polishing equipment does not exceed the requirements in the polish manufacturers recommendations. The final process step typically uses an orbital type polisher with speeds of 1,500-2,000 RPM. Refer to Clearcoat Repair Specifications - 3M Products . • Do not use wax or silicone type products in order to hide swirl marks, this damage will reappear later and cause customer dissatisfaction. • Specific conditions on the paint (environmental damage, rail dust, etc.) may be corrected by:

- Refer to Environmental Fallout (Acid Rain) . - Refer to Rail Dust Damage Repair . Repair Procedure Notice: Removing more than 0.5 mils of the clearcoat can result in early paint failure. The clearcoat contains ultraviolet screeners. Do not finesse sand more than what is required to remove the defect. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Thoroughly wash the repair area with Liquid Wash and Wax GM P/N 1052870 or the equivalent. Readings of the paint film build should be taken prior to the operation. Refer to Paint Gages . Apply a small amount of the appropriate material to repair area and smear evenly with the pad. Refer to Clearcoat Repair Specifications - 3M Products . With the polisher running at approximately 1,500-2,000 RPM, polish the repair area. Keep the pad flat against the panel while applying heavier pressure for 46 seconds. Then, polish with lighter pressure for 6-8 seconds. Feature lines and panel edges should be hand-rubbed in order to avoid burn-through. Inspect the repair area frequently. Add more of the appropriate material as needed. Always blend or feather the outer edges of the repaired area. After buffing, inspect the repaired area. If swirls are still visible, repeat the buffing procedure. Clean the repaired area using a clean soft, non-scratching cloth with a 50/50 mixture of Isopropyl Alcohol and water. If sanding is required, refer to Clearcoat Repair Specifications - 3M Products .

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Environmental Fallout (Acid Rain) Since the severity of the condition varies from area to area, proper diagnosis of the damage extent is critical to the success of repairs. Perform diagnosis under high intensity fluorescent lighting, on horizontal surfaces, hood, roof panel, rear compartment lid after the surfaces have been properly cleaned. There are 3 basic types of acid rain damage: Surface Level Contamination: May be repaired by simply washing the vehicle, cleaning the surface with a silicone, wax and grease remover, neutralizing acidic residue and finesse polishing. Refer to Surface Level Contamination Repair. Clearcoat Etching: Slight etching still noticeable after the above washing and finesse polishing procedure. Refer to Slight Clearcoat Damage - Wet Sanding, Finesse Polishing. Basecoat Etching: Severe etching beyond the clearcoat into the basecoat.

Slight Clearcoat Damage - Wet Sanding, Finesse Polishing Notice: Removing more than 0.5 mils of the clearcoat can result in early paint failure. The clearcoat contains ultraviolet screeners. Do not finesse sand more than what is required to remove the defect. Important: Always refer to manufacture's packaged instructions for the detailed procedures of materials used for compounding or polishing. 1. Select a small test area on the damaged panel. 2. Readings of the paint film build should be taken prior to the operation. Refer to Paint Gages . 3. Wet sand the damaged area using an ultra-fine sandpaper and rubber sponge sanding block. Refer to the manufacturer's instructions for detailed procedures for the materials used in the repairs. During the wet sand process: • Use ample amounts of water.

• Work slowly in order to prevent removing too much clearcoat. 4. Remove the excess water with a rubber squeegee and inspect the area. If wet sanding has repaired the damage, continue the sanding procedure on the entire panel. 5. Apply a finesse-type polish with a foam pad. Remove any swirl marks with a dual action orbital polisher and foam pad. Refer to Clearcoat Repair Specifications 3M Products . If, during the repair, you suspect or observe that etching has penetrated into the basecoat, too much clearcoat has been removed during sanding or base color is transferred to pad during polishing, the affected areas may require clearcoat/basecoat application or refinishing. 6. Polish the entire vehicle after all damage has been repaired.

Surface Level Contamination Repair Notice: Removing more than 0.5 mils of the clearcoat can result in early paint failure. The clearcoat contains ultraviolet screeners. Do not finesse sand more than what is required to remove the defect. Important: Always refer to manufacture's packaged instructions for the detailed procedures of materials used for compounding or polishing. 1. 2. 3. 4.

Thoroughly wash the repaired area with Liquid Wash and Wax GM P/N 1052870. Dry the area thoroughly. Clean the affected area with silicone, wax and grease remover. Neutralize left over acidic residue by cleaning damaged areas with mixture of baking soda and water, 1 tablespoon of baking soda per 1 liter or 1 quart of water. Rinse thoroughly and dry the panel completely. 5. Apply finesse-type polish with a foam panel. If damage has been repaired, remove any swirl marks with dual action orbital polisher and foam pad. Refer to Clearcoat Repair Specifications - 3M Products . 6. If some damage remains, refer to Slight Clearcoat Damage--Wet Sanding, Finesse Polishing.

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Paint Gauges Paint thickness gauges measure the total thickness of the vehicle finish. It is important to accurately measure the thickness of the finish on each vehicle as the thickness of the finish will vary on each vehicle. Use a paint gauge before the sanding process in order to accurately measure how much finish there is to remove before, during, and after the sanding process. Paint gauges range from magnetic pull type to sophisticated electronic types, and are available from a variety of sources. The older magnetic type gauges, at best have a 5 percent accuracy range and are not sensitive enough to detect removal of 0.02 mm 0.5 mil (0.0005 in) clearcoat. The newer type magnetic gauges have improved accuracy ranges. Most gauges are confined to checking either ferrous metal, steel, non-ferrous metal, or aluminum panel. At this time, there are no viable gauges for reading film thickness on composite (SCM doors, RIM fenders) panels. The more sophisticated (ETG) electronic paint thickness gauges digital type gauges are able to read film thickness on both ferrous and non-ferrous metal panel. Digital ETG gauges may have an accuracy range of 1 percent and include thickness standards for recalibration. The following paint thickness gauges are available. Call 1-800-GM-TOOLS for information: Paint Thickness Gages z z z z z

147-5437-ETG Standard model 147-5437-ETG-P Standard model with print option 147-5437-N-ETG-N Non-ferrous model for aluminum panels 147-5437-NP-ETG-NP Non-ferrous model with print option 147-54437-SD-ETG Steel and aluminum gauge

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Clearcoat Thickness The clearcoat on the vehicle is typically 0.059-0.078 mm (1.5-2 mils [0.0015-0.0020 in]) thick. The clearcoat contains ultraviolet screeners. Removing more than 0.5 mils (0.019 in) of the clearcoat may result in early paint failure.

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Rail Dust Damage Repair Caution: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. Important: If rail dust has penetrated into the basecoat, the panel requires refinishing. Ensure all the rail dust has been removed prior to refinishing or the rust spots will return. Rail dust damage comes from the tiny iron particles produced from the friction between the train wheels and the track. It can also be deposited on vehicles if stored near any operation producing iron dust, i.e., steel ore yards. This dust can either lay on top of, or embed into the paint surface. It is usually diagnosed as bumps in the paint surface or rust colored spots in the paint. 1. 2. 3. 4. 5.

Move the vehicle to a cool shaded area and ensure the vehicle surfaces are cool during the removal process. Thoroughly wash the repair area with Liquid Wash and Wax GM P/N 1052870 or the equivalent. Wipe the area dry. Clean the affected area with silicone, wax and grease remover. Perform the removal process according to the manufacturer's directions of the type of repair material used, Gel Type Oxalic Acid or Clay Type Non-Acid Based. If, upon inspection, some particles are still present, the process may be repeated. If the damage has been repaired, complete the repair to the entire panel. 6. Polish the entire panel after the removal process. Refer to Clearcoat Repair Specifications - 3M Products . If small pits remain in the clearcoat after all of the damage has been repaired, refer to Clearcoat Repair without Repainting .

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Clearcoat Repair Specifications - 3M Products Paint Condition

New vehicle prep or fine wheel marks

Wet Sanding

Scratch Refinement

Compounding

Rotary Polisher

Dual Action Orbital Polisher • Perfect-It 3000 Swirl Mark Remover P/N 06064

--

--

--

--

• Perfect-It Foam Polishing Pad P/N 05725/38

Hand Glazing/ Polishing

• Perfect-It Wax P/N 39026/39526 • Detail Cloth P/N 06016

• Hookit DA 6-inch Backup Pad P/N 05776

Swirl marks, water spotting, or light oxidation

• Perfect-It 3000 Swirl Mark Remover P/N 06064 --

--

--

• Hookit SBS/Perfect-it Backup Pad P/N 05717/18 • Perfect-It III Cleaning Clay P/N 38070

Overspray or medium oxidation

--

--

• Perfect-It 3000 Rubbing Compound P/N 06060/62 • Superbuff III Buff Pad P/N 05703/04

Heavy oxidation or minor acid rain pitting

Micro Fine 2000

--

• Perfect-It 3000 Rubbing Compound P/N 06060/62 • Superbuff III Buff Pad P/N 05703/04

Dust nibs, minor scratches, or Micro Fine 1500 or major acid rain 2000 pitting

Orange peel, paint runs or sags

• Perfect-It Foam Polishing Pad P/N 05725/38

• Trizact Hookit II Foam Disc 6 in 3000 P/N 02075 • Hookit II Soft Interface Pad 6 in P/N 05274 • Hookit II Painters Disc Pad 6 in P/N 05251

• Hookit II Film Disc 6 in P1200 P/N 00868

• Trizact Hookit II Foam Disc 6 in 3000 P/N 02075

• Hookit II Film Disc 6 in P1500 P/N 000850

• Hookit II Soft Interface Pad 6 in P/N 05274

• Hookit II Painters Disc Pad P/N 05251

• Hookit II Painters Disc Pad 6 in P/N 05251

• Perfect-It 3000 Rubbing Compound P/N 06060/62 • Superbuff III Buff Pad P/N 05703/04

• Perfect-It 3000 Rubbing Compound P/N 06060/62 • Superbuff III Buff Pad P/N 05703/04

• Perfect-It 3000 Swirl Mark Remover P/N 06064 • Perfect-It Foam Polishing Pad P/N 05725/38 • Hookit SBS/Perfect-it Backup Pad P/N 05717/18 • Perfect-It 3000 Swirl Mark Remover P/N 06064 • Perfect-It Foam Polishing Pad P/N 05725/38 • Hookit SBS/Perfect-It Backup Pad P/N 05717/18 • Perfect-It 3000 Swirl Mark Remover P/N 06064 • Perfect-It Foam Polishing Pad P/N 05725/38 • Hookit SBS/Perfect-It Backup Pad P/N 05717/18 • Perfect-It 3000 Swirl Mark Remover P/N 06064 • Perfect-It Foam Polishing Pad P/N 05725/38 • Hookit SBS/Perfect-It Backup Pad P/N 05717/18

• Perfect-It 3000 Swirl Mark Remover P/N 06064 • Perfect-It Foam Polishing Pad P/N 05725/38 • Hookit DA 6-inch Backup Pad P/N 05776 • Perfect-It 3000 Swirl Mark Remover P/N 06064 • Perfect-It Foam Polishing Pad P/N 05725/38 • Hookit DA 6-inch Backup Pad P/N 05776 • Perfect-It 3000 Swirl Mark Remover P/N 06064 • Perfect-It Foam Polishing Pad P/N 05725/38 • Hookit DA 6 in Backup Pad P/N 05776 • Perfect-It 3000 Swirl Mark Remover P/N 06064 • Perfect-It Foam Polishing Pad P/N 05725/38 • Hookit DA 6 in Backup Pad P/N 05776 • Perfect-It 3000 Swirl Mark Remover P/N 06064 • Perfect-It Foam Polishing Pad P/N 05725/38 • Hookit DA 6 in Backup Pad P/N 05776

• Perfect-It 3000 Swirl Mark Remover P/N 06066 • Perfect-It III Foam DA Pad P/N 05729 • Detail Cloth P/N 06016 • Perfect-It Wax P/N 39026/39526 • Perfect-It 3000 Swirl Mark Remover P/N 06066 • Perfect-It III Foam DA Pad P/N 05729 • Detail Cloth P/N 06016 • Perfect-It Wax P/N 39026/39526 • Perfect-It 3000 Swirl Mark Remover P/N 06066 • Perfect-It III Foam DA Pad P/N 05729 • Detail Cloth P/N 06016 • Perfect-It Wax P/N 39026/39526 • Perfect-It 3000 Swirl Mark Remover P/N 06066 • Perfect-It III Foam DA Pad P/N 05729 • Detail Cloth P/N 06016 • Perfect-It Wax P/N 39026/39526 • Perfect-It 3000 Swirl Mark Remover P/N 06066 • Perfect-It III Foam DA Pad P/N 05729 • Detail Cloth P/N 06016 • Perfect-It Wax P/N 39026/39526

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Basecoat/Clearcoat Paint Systems Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. All paint finish repairs of rigid exterior surfaces must meet GM standards. Refer to the latest revision of the GM Approved Refinish Materials book GM P/N GM4901MD to identify the paint systems you may use that have been engineered to meet GM standards. The GM Approved Refinish Materials book supplies all approved products, including volatile organic compound (VOC) compliant regulations recommended by the individual manufacturer, and detailed procedures for materials used in their paint system. The booklet is now located on the Goodwrench website www.gmgoodwrench.com.

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Anti-Corrosion Treatment and Repair Caution: When applying sound deadeners, or anti-corrosion materials due care and preventative measures must be exercised to prevent any material from being sprayed into door and quarter panel mechanisms such as door locks, window run channels, window regulators and seat belt retractors, as well as any moving or rotating mechanical or suspension parts on the underbody, particularly the parking brake cable. After material application, be sure that all body drain holes are open. Improper application may increase chance of corrosion damage or limit the operation of moving parts, resulting in personal injury. Any procedure that disturbs these special treatments, such as panel replacement or collision damage repair operations, may leave the metal unprotected and result in corrosion. Proper recoating of these surfaces with service-type anti-corrosion material is essential. After repair and/or replacement parts are installed, all accessible bare metal surfaces must be treated with metal conditioner and reprimed. Refer to the GM Approved Refinish Materials book GM P/N GM4901M-D which identifies the paint systems you may use. Anti-corrosion compounds are light-bodied materials designed to penetrate between metal-to-metal surfaces, such as pinch-weld joints, hem flanges, and integral panel attaching points where metal surfaces are difficult to coat with conventional undercoating materials, and are inaccessible for painting. The materials that are suitable for interior and exterior are listed in the chart below. Conventional undercoating is recommended in order to coat large areas, such as replacement door and quarter outer panels, floor pan sections, lids, hoods, fenders, etc. During undercoating operations, care should be taken to prevent the material from being sprayed into door and quarter panel hardware mechanisms, such as door locks, window run channels, window regulators, and seat belt retractors. On the underbody, the material should not be applied to any moving or rotating part, energy absorbing bumper components, or shock absorbers. After undercoating, ensure that all body drain holes are open. Interior Protectant The following products are available from GM Dealer Equipment. For technical information, call 187-Permatex (1-877-376-2839): Permatex Part Number

Description

310-JDI-UCA1

Permatex Canister and Wand Assembly

310-81881

Permatex Amber Rust Proofing (24 oz) (Qty of 12)

310-81882

Permatex Amber Rust Proofing (1 gal)

Exterior Protectants The following product is available from *ECP, Inc. Contact them at 1-800-323-3521 or www.ecpinc.net. Part Number

Description

178660

Nox Rust X-121B (12 cans per case)

The following products are available from your local *3M® distributor, or call 1-800-521-8180, ext. 779-5165. 3M® Part Number

Description

08804

Water-Based Undercoat

08801

No Clean-Up Applicator Gun

05917

Weld-Thru Coating

08891

Rust Fighter-I

The following product is available from *Transtar Autobody Technologies. Contact the company at 1-800-824-2843 or www.tat-co.com Part Number

Description

4353

Weld-Through Primer

*We believe these sources and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products from these firms, or for any such items which may be available from other sources. These sealers are intended to prevent water and dust from entering the vehicle and also are anti-corrosion barriers. Sealers are applied to such areas as rear compartment lid hem flanges, wheelhouse, quarter outer, floor, cowl, roof, and various other panel to panel attaching points. The originally sealed joints are obvious and any damage to these sealed locations should be corrected by resealing. Attaching points of new replacement panels should be resealed. Replacement lids and doors will also require sealing in the hem flange areas. Flanged joints, overlap joints, and seams should be sealed using a quality sealer of medium-bodied consistency. The sealer used must retain its flexible characteristics after curing and be paintable. Open joints which require bridging of the sealer in order to close a gap should be sealed using a heavy-bodied caulking material. Follow the label directions for the material selected. Color application may be required in order to restore repaired areas such as hood, fenders, doors, quarters, lid, roof, engine compartment, underbody, and inner panels to original appearance. When this is necessary, conventional refinishing preparation, undercoat buildup, and color application techniques should be followed. Deadener materials, spray-on type, are used on various metal panels in order to provide corrosion resistance and joint sealing. They control the general noise level inside the passenger area of the vehicle. When deadeners are disturbed because of damage, are removed during repair operations, or a new replacement panel is installed, the deadener material must be replaced by a service equivalent material. The application pattern and location of deadener materials can be determined by observing the original production installation. Cleaning of the interior and underbody panel surfaces is necessary when original galvanized or other anti-corrosion materials have been burned off during welding or heating operations. Removal of the residue from burning will require additional care in such areas as interior surfaces of box-type construction and when configurations of the metal panels limit access to interior surfaces.

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Paint Identification Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important Always refer to the GM Approved Refinish Materials book GM P/N 4901M-D. This book identifies the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: z z z z

A cathodic immersion primer A primer/surfacer A basecoat A clear top coat (clearcoat)

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Plastic Panel Information and Repair Flexible Plastic Part Repair Materials Rigid Plastic Part Repair Materials General Plastic Repair How to Identify Plastic Parts Plastic Identification and Refinishing Systems

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Flexible Plastic Part Repair Materials Product - 88861039, *88861040, High Strength Plastic Repair 50 ml Components - 12 cartridges with 2 mixers each Structural and Cosmetic Recommended Repair Material Product

Work Time Handling 70°F Strength at 70°F

Components

Recommended Repair Material

12 cartridges with 2 mixers each

Structural and cosmetic bonding and repairing of all flexible plastics. Requires GM P/N 12378462 on TPO plastics. Will also bond e-coated/primed metals.

88861039 *88861040 High

90 seconds

10 minutes

Strength Plastic Repair 50 ml * TPO, TEO, (Polyolefin Plastics) require the application of polyolefin adhesive primer before the GM P/N 88861039 repair compound is applied. Working Time Adhesive Sandability at Part Paintability at Adhesive Full Cure at 70°F 70°F 70°F Product Program 88861039 *88861040 High

20 minutes

30 minutes

24 hours

Bumper covers, emblems, door trims, exterior and interior repairs*

Strength Plastic Repair 50 ml * TPO, TEO, (Polyolefin Plastics) require the application of polyolefin adhesive primer before the GM P/N 88861039 repair compound is applied.

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Rigid Plastic Part Repair Materials Thermoset Plastic Type

Type of Repair

Recommended Repair Material

Availability

Sheet metal compound (SMC), RIM rigid plastic parts

Cosmetic filling

GM Goodwrench® Structural Bonding Epoxy (GM P/N 12345726 or equivalent)

GM Dealer/Retailer

Sikkens Polystop LP™ or equivalent polyester repair putty

Refer to a local paint supplier

Most rigid plastic parts

Cosmetic repair, adhesive bonding

GM Goodwrench® Structural Bonding Epoxy (GM P/N 12345726 or equivalent)

GM Dealer/Retailer

Lord Fusor® SMC Body Panel Repair Adhesive or equivalent

Refer to local paint supplier

GM Goodwrench® Structural Bonding Epoxy (GM P/N 12345726 or equivalent)

GM Dealer/Retailer

Dynatron Dyna-Weld Plio Grip® or equivalent (OE structural adhesive)

Refer to local paint supplier

GM Goodwrench® Structural Bonding Epoxy (GM P/N 12345726 or equivalent)

GM Dealer/Retailer

Ashland Pliogrip® 7773B-3-minute

Supplied by Crest Industries

Ashland Pliogrip® 7779B-10-minute

1-800-822-4100

Ashland Pliogrip® 7770B-35-minute

fax 1-800-344-4461

Most rigid plastic parts Most rigid plastic parts

Adhesive bonding Adhesive structural* bonding Adhesive bonding

Most rigid plastic parts Structural bonding

GM Goodwrench® SRIM™ repair kit (GM P/N 12378523) or SRIM most rigid plastic parts

Cosmetic repair, adhesive bonding

SIA™ Adhesives, INC. SRIM™ repair kit P/N 30208030001 adhesive 200ML TUBES P/N 30208020001 50ML TUBES P/N 30208010001

* Structural adhesive bonding may require the use of a pneumatic applicator, A8-37479-1A, or equivalent, to speed the application of the GM P/N 12345726 epoxy.

SIA Adhesives, INC. customer service 1-330-374-2468 Kent-Moore 1-800-GM-TOOLS

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General Plastic Repair Caution: In order to reduce the risk of personal injury when exposed to toxic fumes while grinding, cutting, or applying repair material on any type of sheet molded compound or RIM rigid plastic, observe the following guidelines: • Work in a properly ventilated area

• • • • •

Apply protective cream to any exposed skin Remove any mixture that comes into contact with skin Wash skin with cold water to remove glass and resin dust Use a sander with a vacuum attachment Follow the repair material manufacturer's instructions

Also, always wear the following: • An approved respirator, or air supplied respirator

• • • •

Eye protection Rubber gloves Earplugs Protective clothing

The following procedures should be followed when repairing all types of thermoset plastic: • Follow the manufacturer's application and curing recommendations. • Do not intermix systems. Use the supplies and the repair materials from the same manufacturer. • Clean the inner and outer surfaces of the repair area with a soap impregnated scouring pad in order to remove any dirt or mold release agent. • Clean the area with a wax and grease remover, using only enough of the remover to dampen a cloth. Allow the panel to dry thoroughly. • Remove the surface finish from the area to be repaired. Adhesives are designed to adhere to the plastic substrate, not the finish. • Prime a metal surface before applying the repair material. • Inspect the rear side of the work area before making repairs in order to avoid possible damage to wires, motors, etc.

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How to Identify Plastic Parts

Plastic parts can be identified by the SAE code, which is usually found on the rear of the part, and/or by the characteristics of the plastic. Knowing the type of plastic aids in selecting the proper repair materials and in selecting the proper repair procedure. Look for the SAE code stamped into the part. Code Found

Match the code to those in the plastic identification chart to determine whether the plastic is thermoplastic or thermoset plastic, and whether the plastic is rigid or flexible. Refer to Plastic Identification and Refinishing Systems . No Code Found

Caution: Do NOT use a plastic burn test to distinguish the type of plastic. The burn test produces vapors which are harmful. Perform one or both of the following tests to determine if the part is thermoplastic polyolefin or thermoset non-polyolefin. Float Test

1. Cut a shaving of plastic from the back of the part. The shaving should be free of mold release agents and paint. 2. Place the shaving in a container of water. - Thermoplastic polyolefin floats.

- Thermoset non-polyolefin sinks. Abrasion Test

• Sand a spot near the damaged area with Grade 36 Roloc Disc. • Thermoplastic polyolefin material melts or frays when sanded. • Thermoset non-polyolefin material sands cleanly. Thermoplastic and thermoset plastics can be either rigid or flexible. Thermoplastic plastic parts are best repaired with a hot iron plastic material-feed welder, but are usually replaced. Thermoset plastic can be repaired with epoxy or other more rigid 2 package repair material.

• For rigid thermoset repair materials, refer to Repair Materials - Rigid Plastic Part . • For flexible thermoset repair materials, refer to Repair Materials - Flexible Plastic Part . • For general repair instructions, refer to General Plastic Repair Instructions .

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Plastic Identification and Refinishing Systems Identifying Symbol - Old Symbol in ( )s

Chemical Composition or Plastic Family Name

ABS

Acrylonitrile/ Butadiene-Styrene

Armrest Support, Console, IPC, Steering Column Bracket/Jacket, Trim Molding

ABS, Absafil, Magnum, Cycolac, Dyel, Kralastic, Lustran

Thermoplastic

ABS + PC

Acrylonitrile/ Butadiene-Styrene + Polycarbonate

Instrument Panel, IPC

Bayblend, Cycoloy, KHA, Pulse

Rigid

ABS/PVC

ABS/Vinyl (Soft)

Head Rest Cover, Instrument Panel Pad, Trim Molding/Panel

ABS Vinyl

Flexible, Vinyl

EPDM

Ethylene Propylene Diene Monomer

Body Panel, Bumper Impact Strip

EPDM, Nordel

Rigid

EVA (EVAC)

Ethylene/Vinyl Acetate

Head Rest Cover, Misc Soft Trim

Elvax, Microthane

Flexible

PA

Polyamide

Headlamp Bezels, Quarter Panel Extensions, Exterior Finish Trim Panels

Nylon, Capron, Zytel, Rilsan, Minion, Vydyne, Welland

Rigid

PA, PAG, PAGG

Polyamide

Exterior Finish Trim Panel, Headlamp Bezel, Quarter Panel Extension

PA + PPE

Polymide + Polypheneylene Ether

Exterior Trim, Fender

GTX

Rigid, Thermoset

PBT + TEEE (PBTP + EEBC)

Polybutylene, Terephthalate + Ether, Ester Block Compound

Fascia, Rocker Panel Molding

Bexloy M

Rigid

PC

Polycarbonate

Interior Rigid/Hard Trim Panel, Valance Panel

Calibre, Lexan, Merlon, Makrolon

Rigid, Thermoset

PC + PETP

Polycarbonate + Polybutylene, Terephthalate

Bumper Fascia

Macroblend, Valox, Xenoy

Flexible, Thermoset

PE

Polyethylene

Fuel Tank Shield, Inner Fender Panel, Interior Trim Panel, Seat Belt Cover, Spoiler, Valance

Alathon, Dylan, Foriflex, Hifax, Hosalen, Marlex, Paxon

Rigid, Thermoplastic

PF

Phenol Formaldehyde

Ashtray

Amberol, Bakelite, Durez, Genal, Phenolic, Plyophen, Resinox

Rigid, Thermoset

PP

Polypropylene

Bumper Fascia, Cowl Panel, Deflector Panel, Door Panel, Inner Fender, Interior Molding, Kick Panel, Load Floor, Radiator Shroud, Wheel Cover

Azdel, Daplen, Escorene, Marlex, Novolen, Oleflo, Profax, Tenite

Flexible, Thermoplastic

PPE (PPO)

Polyphenylene Ether

Bezels, Chromed Plastic, Headlamp Door, Ornaments

Noryl, Oleflo, Prevex

Rigid, Thermoset Flexible, Soft

Typical Area(s) Where Part is Used

Examples of Common/Trade Names

Type of Plastic

Capron, Minlon, Nylon, Rilsan, Rigid, Thermoset Vydyne, Wellamid, Zytel

PS

Polystyrene

Dash Panel, Door Panel

Durathon, Dylan, Lustrex, Polystyrol, Styron

PUR

Polyurethane, Thermoset (Unsaturated)

Bumper Fascia, Filler Panel, Front/Rear Body Panel, Pickup Box

Bayflex, Castethane, RIM, RRIM, SRIM

Thermoset

PVC

Polyvinyl Chloride (Vinyl)

Interior Soft Trim, I/P Skins, Roof Cover

Geon, Pliovic, Unichem, Vinoflex, Vinyl, Vinylite

Flexible, Vinyl

SAN (SA)

Styrene Acrylonitrite

Center Console, Glove Box Door, Interior Trim Panel

Foracryl, Lustran, Tyril

Rigid

TEO (EP, EPM, TPO)

Ethylene/Propylene (Rubber)

Air Dam, Bumper Fascia, Valance Panel

EPI, EPII, TPO, TPR (Thermoplastic Rubber)

Flexible, Thermoplastic

TPO

Thermal Plastic Oletin

Bumper Covers

TPO

Flexible Thermoplastic

TPU (TPUR)

Polyurethane, Polyolefin

Bumper Fascia, Gravel Deflector, Soft Filler Panel, Window Molding

Estane, Pellethane, Roylar, Toxin

Flexible, Thermoplastic

UP

Polyester/Thermoset

Air Scoop, Air Spoiler, Fascia Extension, Hood, Instrument Housing, Rear Compartment Lid, Roof, Ventilation Grid

Fiberglass, Premi-glass, Selectron, SMC, Vibrinmat

Rigid, Thermoset

For symbols not listed in this table, contact the Society of Automotive Engineers, 400 Commonwealth Drive, Warrendale, PA 15096-0001.

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Body Systems Fixed and Movable Windows Mirrors Vehicle Access Wipers and Washers

Section04

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Fixed and Movable Windows Windshield Replacement Front Side Door Window Replacement Rear Side Door Window Replacement Quarter Window Replacement (Long Body C/100) Quarter Window Replacement (Short Body C/105) Liftgate Window Replacement Liftgate Window Strut Replacement Liftgate Window Latch Replacement Front Side Door Window Channel Replacement Rear Side Door Window Channel Replacement Door Window Regulator Replacement Door Window Guide Replacement (Rear C 105/Short Body) Door Window Guide Replacement (Front) Door Window Guide Replacement (Rear C 100/Long Body) Outer Belt Sealing Strip Replacement (C 105/Short Body) Outer Belt Sealing Strip Replacement (C 100/Long Body) Front Side Door Window Weatherstrip Replacement Rear Side Door Window Weatherstrip Replacement Adhesive Installation of Stationary Windows (Windshield) Full-Cut Method Description Adhesive Service Kit Description Stationary Window Description Power Windows Description and Operation Rear Window Defogger Description and Operation Fastener Tightening Specifications Special Tools

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Windshield Replacement Tools Required • J 24402-A Glass Sealant Cold Knife Remover • J 39032 Stationary Glass Removal Tool • Urethane Adhesive Kit GM P/N 12346392 or Equivalent • Isopropyl Alcohol or Equivalent • Cartridge-type Caulking Gun • Commercial-type Utility Knife • Razor Blade Scraper • Suction Cups • Plastic Paddle

Removal Procedure Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 1. 2. 3. 4. 5.

Open the hood. Remove the windshield wiper arms and blades. Refer to Wiper Arm Replacement . Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement . Remove the interior windshield pillar garnish moldings. Refer to Windshield Garnish Molding Replacement . Remove the rearview mirror. Refer to Rearview Mirror Replacement . Caution: Refer to Defroster Outlet Caution in Cautions and Notices.

6. Cover the following parts to protect from broken glass: • Upper dash pad

• Defroster outlets and A/C outlets • Seats and carpeting Caution: Refer to Glass and Sheet Metal Handling Caution in Cautions and Notices.

7. Using a utility knife, carefully cut the exposed reveal molding (1) from the sides and the top edge of the windshield to access the urethane adhesive bead.

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Important: Keep the cutting edge of the tool against the window. 8. Remove the window from the urethane adhesive. • Leave a base of urethane approximately 2 mm (0.078 in) on the pinch-weld flange.

• The only suitable lubrication is clear water. • Use J 24402-A , J 39032 , or equivalent to remove the window.

Important: Keep the cutting edge of the knife/tool against the window. Do this from inside the vehicle. 9. If necessary, use a long utility knife or similar tool to remove the bottom corners of the windshield from the urethane adhesive.

10. With the aid of an assistant (2), remove the windshield (1) from the vehicle.

Installation Procedure

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1. 2. 3. 4. 5. 6. 7.

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

With the aid of an assistant (2) install the windshield (1) into the opening. Refer to Adhesive Installation of Stationary Windows . Install the rearview mirror. Refer to Rearview Mirror Replacement . Install the interior windshield pillar garnish moldings. Refer to Windshield Garnish Molding Replacement . Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement . Install the windshield wipers arms and blades. Refer to Wiper Arm Replacement . Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. Close the hood.

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Front Side Door Window Replacement Removal Procedure

1. 2. 3. 4.

Remove the front door trim. Refer to Front Side Door Trim Panel Replacement . Remove the front side door window frame rear applique. Refer to Front Door Frame Applique Replacement . Remove the screws that secure the glass to the window regulator. Remove the glass from the door.

Installation Procedure

1. Install the glass in the door and position the glass within the window regulator. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the glass to the window regulator with the screws. Tighten Tighten the glass screws to 3 N·m (27 lb in). 3. Install the front side door window frame rear applique. Refer to Front Door Frame Applique Replacement . 4. Install the front door trim. Refer to Front Side Door Trim Panel Replacement .

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

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Rear Side Door Window Replacement Removal Procedure

1. 2. 3. 4.

Remove the rear door trim. Refer to Rear Door Trim Panel Replacement . Remove the rear side door window frame rear applique. Refer to Rear Door Frame Applique Replacement . Remove the screws that secure the glass to the window regulator. Remove the glass from the door.

Installation Procedure

1. Install the glass in the door and position the glass within the window regulator. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the glass screws. Tighten Tighten the glass screws to 1.3 N·m (12 lb in). 3. Install the rear side door window frame rear applique. Refer to Rear Door Frame Applique Replacement . 4. Install the rear door trim. Refer to Rear Door Trim Panel Replacement .

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Quarter Window Replacement (Long Body C/100) Removal Procedure

1. Remove the quarter window garnish molding. Refer to Body Side Window Rear Garnish Molding Replacement . 2. Remove the nuts and the outer window.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the outer window with the nuts. Tighten Tighten the outer window nuts to 6 N·m (53 lb in). 2. Install the quarter window garnish molding. Refer to Body Side Window Rear Garnish Molding Replacement .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Quarter Window Replacement (Short Body C/105) Removal Procedure 1. Disconnect the negative battery cable, if equipped with glass breakage detector. Refer to Battery Negative Cable Disconnection and Connection .

2. Remove the quarter window garnish molding. Refer to Body Side Window Rear Garnish Molding Replacement . 3. Disconnect the glass breakage detector connector (1), if equipped. 4. Remove the nuts and the outer window.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the outer window with the nuts. Tighten Tighten the outer window nuts to 6 N·m (53 lb in). 2. Connect the glass breakage detector connector (1), if equipped. 3. Install the quarter window garnish molding. Refer to Body Side Window Rear Garnish Molding Replacement . 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Liftgate Window Replacement Removal Procedure

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 2. Open the liftgate. 3. Disconnect the rear window defogger electrical connector.

4. Remove the liftgate upper garnish molding. Refer to Liftgate Garnish Molding Replacement . 5. Remove the liftgate window strut. Refer to Liftgate Window Replacement . 6. With the aid of an assistant, remove the bolts and liftgate glass from the vehicle.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the liftgate glass with the bolts. Tighten Tighten the liftgate glass bolts to 6 N·m (53 lb in).

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2. Install the liftgate window strut. Refer to Liftgate Window Replacement . 3. Install the liftgate window upper garnish molding. Refer to Liftgate Garnish Molding Replacement .

4. Connect the rear window defogger electrical connector. 5. Close the liftgate. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

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Liftgate Window Strut Replacement Removal Procedure

1. 2. 3. 4. 5.

Raise and support the liftgate window in the open position. Lift up and partially remove the spring clips on the strut using a small flat-bladed tool. Remove the upper end of the strut from the ball joint. Remove the lower end of the strut from the ball joint. Remove the strut from the liftgate window.

Installation Procedure

1. Position the strut to the liftgate window. 2. Install the upper end of the strut to the ball joint. Press in to place until fully seated. 3. Install the lower end of the strut to the ball joint. Press in to place until fully seated. 4. Install the support from the liftgate window. 5. Close the liftgate window.

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Liftgate Window Latch Replacement Removal Procedure

1. Remove the liftgate lower trim. Refer to Liftgate Trim Panel Replacement . 2. Remove the bolts and the liftgate window latch. 3. Disconnect the electrical connector.

Installation Procedure

1. Connect the electrical connector. 2. Install the liftgate window latch with the bolts. 3. Install the liftgate lower trim. Refer to Liftgate Trim Panel Replacement .

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Front Side Door Window Channel Replacement Removal Procedure

1. 2. 3. 4.

Remove the outside rearview mirror. Refer to Mirror Replacement . Remove the front door glass. Refer to Front Side Door Window Replacement . Remove the front window applique. Refer to Front Door Frame Applique Replacement . Remove the channel.

Installation Procedure

1. 2. 3. 4.

Install the channel. Install the front door glass. Refer to Front Side Door Window Replacement . Install the front window applique. Refer to Front Door Frame Applique Replacement . Install the outside rearview mirror. Refer to Mirror Replacement .

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

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Rear Side Door Window Channel Replacement Removal Procedure

1. Remove the rear door glass. Refer to Rear Side Door Window Replacement . 2. Remove the rear window applique. Refer to Rear Door Frame Applique Replacement . 3. Remove the rear door channel.

Installation Procedure

1. Install the rear door channel. 2. Install the rear Window applique. Refer to Rear Door Frame Applique Replacement . 3. Install the rear door glass. Refer to Rear Side Door Window Replacement .

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Door Window Regulator Replacement Removal Procedure

1. 2. 3. 4.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the door glass. Refer to Front Side Door Window Replacement or Rear Side Door Window Replacement . Disconnect the electrical connector. Remove the nuts and the window regulator.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the window regulator with the nuts. Tighten Tighten the window regulator nuts to 10 N·m (89 lb in). 2. Connect the electrical connector. 3. Install the door glass. Refer to Front Side Door Window Replacement or Rear Side Door Window Replacement . 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Door Window Guide Replacement (Rear C 105/Short Body) Removal Procedure

1. 2. 3. 4. 5.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the rear door glass. Refer to Rear Side Door Window Replacement . Remove the power window regulator. Refer to Door Window Regulator Replacement . Remove the rear door upper trim. Remove the bolt and the rear window guide.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the rear window guide with the bolt. Tighten Tighten the rear window guide bolt to 10 N·m (89 lb in) 2. 3. 4. 5.

Install the rear door upper trim. Install the power window regulator. Refer to Door Window Regulator Replacement . Install the rear door glass. Refer to Rear Side Door Window Replacement . Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Door Window Guide Replacement (Front) Removal Procedure

1. 2. 3. 4.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the front door glass. Refer to Front Side Door Window Replacement . Remove the power window regulator. Refer to Door Window Regulator Replacement . Remove the bolts and the front window guide.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the front window guide with the bolts. Tighten Tighten the front window guide bolts to 10 N·m (89 lb in). 2. Install the power window regulator. Refer to Door Window Regulator Replacement . 3. Install the front door glass. Refer to Front Side Door Window Replacement . 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Door Window Guide Replacement (Rear C 100/Long Body) Removal Procedure

1. 2. 3. 4. 5.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the rear door glass. Refer to Rear Side Door Window Replacement . Remove the power window regulator. Refer to Door Window Regulator Replacement . Remove the rear door upper trim. Remove the bolt and the nut, rear window guide.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the rear window guide with the bolt and the nut. Tighten Tighten the rear windowguide bolt and nut to 10 N·m (89 lb in) 2. 3. 4. 5.

Install the rear door upper trim. Install the power window regulator. Refer to Door Window Regulator Replacement . Install the rear door glass. Refer to Rear Side Door Window Replacement . Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Outer Belt Sealing Strip Replacement (C 105/Short Body) Removal Procedure

1. 2. 3. 4.

Lower the window completely. Remove the window outer sealing strip screws. Remove the outside rearview mirror. Refer to Mirror Replacement . Lift the window outer sealing strip off the door.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Press the outside channel molding onto the door. 2. Install the window outer sealing strip screws. Tighten Tighten the window outer sealing strip screws to 1.3 N·m (12 lb in). 3. Install the outside rearview mirror. Refer to Mirror Replacement . 4. Raise the window.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Outer Belt Sealing Strip Replacement (C 100/Long Body) Removal Procedure

1. 2. 3. 4.

Lower the window completely. Remove the window outer sealing strip screw. Remove the outside rearview mirror. Refer to Mirror Replacement . Lift the window outer sealing strip off the door.

Installation Procedure

1. Press the outside channel molding onto the door. Notice: Refer to Fastener Notice in the Preface section. 2. Install the window outer sealing strip screw. Tighten Tighten the window outer sealing strip screw to 1.3 N·m (12 lb in). 3. Install the outside rearview mirror. Refer to Mirror Replacement . 4. Raise the window.

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Front Side Door Window Weatherstrip Replacement Removal Procedure

1. Remove the outside rearview mirror. Refer to Mirror Replacement . 2. Remove the front door window weatherstrip.

Installation Procedure

1. Install the front door window weatherstrip. 2. Install the outside rearview mirror. Refer to Mirror Replacement .

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

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Rear Side Door Window Weatherstrip Replacement Removal Procedure

1. Open Door. 2. Remove the rear door window weatherstrip.

Installation Procedure

1. Install the rear door window weatherstrip. 2. Close Door.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Adhesive Installation of Stationary Windows (Windshield) Caution: Refer to Glass and Sheet Metal Handling Caution in the Preface section. Important: Remove all but approximately 2 mm (3/64 in) of the existing bead of urethane adhesive from the pinch-weld flange. 1. Remove all mounds or loose pieces of urethane adhesive from the pinch-weld area. 2. If the original window is being reused, remove all but a thin film of the existing urethane adhesive from the window surface by using a clean utility knife or razor blade scraper. 3. Inspect the following components for the causes of a broken window: • The flange of the window opening

• The window reveal molding 4. Inspect for any of the following problems in order to help prevent future breakage of the window: • High weld

• Solder spots • Hardened sealer • Any other obstruction or irregularity in the pinch-weld flange Important: If corrosion of the pinch-weld flange is present or if sheet metal repairs or replacements are required, the pinch-weld flange must be refinished in order to restore the bonding area strength. If paint repairs are required, mask the flange bonding area prior to applying the color coat in order to provide a clean primer only surface. Materials such as BASF DE15®, DuPont 2610®, Sherwin-Williams PSE 4600 and NP70® and Martin-Semour 5120 and 5130® PPG DP90LF SPIES/HECKER 3688/8590 - 3688/5150 - 4070/5090 STANDOX 11158/13320 - 14653/14980 products are approved for this application. 5. After repairing the opening as indicated, perform the following steps: 5.1. Remove all traces of broken glass from the outer cowl panel, seats, floor and defroster ducts. 5.2. Clean around the edge of the inside surface of the window with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth. Caution: Refer to Window Retention Caution in the Preface section. 6. Verify all primers and urethane adhesive are within expiration dates.

Caution: Failure to prep the area prior to the application of primer may cause insufficient bonding of urethane adhesive. Insufficient bonding of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury. Important: Do not apply the black #3 primer to the existing bead (1) of the urethane adhesive on the pinch-weld flange. Apply the primer only to nicks, scratches or the primed surfaces. 7. Shake the pinch-weld primer black #3 for at least 1 minute. 8. Use a new dauber in order to apply the primer to the surface of the pinch-weld flange (2). 9. Allow the pinch-weld primer to dry for approximately 10 minutes.

10. Install the new windshield acoustic strip (1) to the windshield (2), if equipped or damaged. The acoustic strip aids in reducing noise.

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11. With the aid of an assistant (2), dry fit the window (1) to the opening in order to determine the correct position.

12. If equipped, ensure that the windshield locator pins are positioned into the locator slots on the upper pinch-weld flange.

13. Using masking tape in order to mark the locations (1) of the window (2) in the opening. 14. Cut the masking tape in the center and remove the window from the opening.

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Important: Use care when applying glass prep clear #1 on the window. This primer dries almost instantly, and may stain the viewing area of the window if not applied evenly. 15. Use a new dauber in order to apply glass prep clear #1 to the area approximately 18 mm (0.71 in) around the entire perimeter of the window inner surface. Immediately wipe the glass primed area using a clean, lint-free cloth.

16. Apply a second coat of the glass prep clear #1 to the same area of the glass.

Important: The glass primer black #2 is effective up to 8 hours after applying it to the glass. The primed surface of the glass must be kept clean. 17. Shake the glass primer black #2 for at least 1 minute. 18. Use a new dauber in order to apply the glass primer black #2 to the same areas (2) that glass prep clear #1 was applied. 19. Allow the glass primer to dry for approximately 10 minutes.

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20. Cut the applicator nozzle in order to provide a minimum urethane bead of 8 mm (0.31 in) wide and 14 mm (0.55 in) high.

21. Use a cartridge-type caulking gun in order to apply a smooth, continuous bead of urethane adhesive.

22. Use the edge of the window or the inside edge of the reveal molding as a guide for the nozzle in order to apply the urethane adhesive (1) to the inner surface of the window (3).

23. With the aid of an assistant (2), place the window (1) in the opening.

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24. Align the masking tape (1) lines on the window (2) and the body.

Important: To prevent damage to the window due to objects impacting an exposed edge, upon installation, the window must rest 1 mm (0.040 in) below the surface of the sheet metal. 25. Press firmly around the entire periphery of the windshield in order to wet-out the urethane bead. 26. Tape the window to the body in order to minimize movement until the urethane adhesive cures.

27. Clean any excess urethane adhesive from the body.

Important: Do not direct a hard stream of high pressure water to the freshly applied urethane adhesive.

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28. 29. 30. 31.

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Use a soft spray of warm water in order to immediately water test the window. Inspect the window for leaks. If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the leak point. Retest the window for leaks. Caution: Insufficient curing of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury. • For the moisture-curing type of urethane adhesive, allow a minimum of 6 hours at 21°C (70°F) or greater and with at least 30 percent relative humidity. Allow at least 24 hours for the complete curing of the urethane adhesive.

• For the chemical-curing type of urethane adhesive, allow a minimum of 1 hour . Do NOT physically disturb the repair area until after these minimum times have elapsed. 32. Maintain the following conditions in order to properly cure the urethane adhesive: • Partially lower a door window in order to prevent pressure buildups when closing doors before the urethane adhesive cures.

• Do not drive the vehicle until the urethane adhesive is cured. Refer to the above curing times. • Do not use compressed air in order to dry the urethane adhesive. 33. Complete the window installation.

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Full-Cut Method Description Important: • If corrosion of the pinch-weld flange is present, or if sheet metal repairs or replacements are required, refinish the pinch-weld flange in order to present a clean, primer-only surface.

• If paint repairs are required, mask the flange bonding area, prior to applying the color coat, in order to provide a clean, primer-only surface. • Appropriate materials for these primer applications are typically 2 component catalyzed products. Use materials such as BASF DE15®, DuPont 2610®, Sherwin-

Williams PSE 4600 and NP70® and Martin-Semour 5120 ,5130® , PPG DP90LF SPIES/HECKER 3688/8590 - 3688/5150 - 4070/5090 STANDOX 11158/13320 - 14653/14980 products are approved for this application. Follow the manufacturer's directions for the mix, the application, and the drying times.

• After repairing the opening as indicated, shake the pinch-weld primer black #3 well. Using a new dauber, apply the primer to the primed surface of the flange in the bonding area. Allow the primer to dry for 10 minutes.

Use only the full cut method, also known in the field as full strip method, when installing windows. This method includes the following: • The replacement of a majority of the urethane adhesive bead. Remove all but approximately 2 mm (3/64 in) of the existing bead of urethane adhesive from the pinch-weld flange. • Apply pinch-weld primer to any exposed painted areas on the pinch-weld flange. No mounds or loose pieces of urethane adhesive should remain on the pinch-weld flange. Do not remove all traces of urethane adhesive.

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Adhesive Service Kit Description The GM of Canada Adhesive Caulking Kit, P/N 10952983, contains the following items: • Four different primers • A tube of urethane adhesive with a nozzle • Four daubers • Instructions with warnings Use the urethane adhesive caulking kit for replacement of any urethane adhesive-installed window using the full cut method. In the United States or Canada, you may use any of the following equivalent urethane adhesive systems which meet GM Specification GM 3651G: • Dow Automotive - Essex 400HV. One part and requires associated primers. • Dow Automotive - Essex U216. Two part and requires associated primers. Call Dow Automotive at 1-800-453-3779 for more information. • 3M™ "Fast Cure" Auto Glass Urethane. One part and requires associated primers. Call 3M™ at 1-877-666-2277 for more information. Use these materials based on specific manufacturer. Do NOT intermix primers or adhesives from one manufacturer to another. Always follow the system manufacturer's instructions for application, handling, and curing.

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Stationary Window Description Most stationary windows, specifically windshields, are retained to the body with urethane adhesive which adheres the window to the body, increasing structural integrity. The reinstallation of the windows with urethane adhesive requires complete replacement of the urethane adhesive bead, and is known as the full cut method.

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Power Windows Description and Operation The power windows are controlled by electrical switches on the door panels and are operated by a motor at each window regulator. Each door has a switch to control its window, and the driver's side door has 4 switches to control all of the door windows on the vehicle. Press the switch to lower the window and pull up on the switch to raise the window. The window will stop movement when the switch is released or when the window is completely open or closed. The driver side window opens automatically. By pressing and releasing the switch, the window will lower and will stop only when the switch is activated again, or when the window is completely open. The driver side door control also contains a window lock button. When depressed this button will prevent the operation of the windows on the front passenger door or the rear door.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Rear Window Defogger Description and Operation Rear Window Defogger System Components The rear window defogger system consist of the following components: • HVAC control module • Body control module (BCM) • DEFOG relay • Rear window defogger grid

Rear Window Defogger Operation When you turn the ignition to the ON position, ignition voltage is supplied to the DEFOG relay coil. Battery positive voltage is supplied at all times to the DEFOG relay switched input. When the rear window defogger switch is depressed, the HVAC control module illuminates the rear window defogger indicator and sends a class 2 message to the BCM. The BCM energizes the DEFOG relay by grounding the control circuit of the relay. This allows battery positive voltage from the relay switched input through the switch contacts and out the relay switched output to the rear window defogger. When you turn ON the ignition and press the rear window defogger switch for the first time, the defogger cycle lasts 10 minutes. Further operation results in 5 minute defogger cycles.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Fastener Tightening Specifications Specification Application

Metric

English

Front Door Glass Screws

3 N·m

27 lb in

Liftgate Glass Bolts

6 N·m

53 lb in

Outer Window Nuts

6 N·m

53 lb in

Outside Rearview Mirror Assembly Screws

10 N·m

88 lb in

Rear Door Glass Screws

1.3 N·m

12 lb in

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Special Tools Illustration

Tool Number/ Description

J-9886-01 Door Handle Clip Remover

J-24402-A Glass Sealant Cold Knife Remover

J-33431-C Signal Generator and Instrument Panel Tester

J-34946 Window Pin Remover

J-39032 Stationary Glass Removal Tool

J-39040 Quarter Window Remover

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Mirrors Outside Rear view Mirror Replacement Outside Rear View Mirror Glass Replacement Inside Rear View Mirror Replacement Rear View Mirror Support Installation Fastener Tightening Specifications

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Outside Rearview Mirror Replacement Removal Procedure

1. 2. 3. 4.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the outside rearview mirror cover. Remove the bolts and the outside rearview mirror assembly from the door. Disconnect the mirror electrical connector if the mirror is electronically controlled.

Installation Procedure

1. Connect the mirror electrical connector if the mirror is electrically controlled. Notice: Refer to Fastener Notice in the Preface section. 2. Install the outside rearview mirror assembly to the door with the screws. Tighten Tighten the outside rearview mirror assembly screws to 10 N·m (85 lb in). 3. Install the outside rearview mirror cover. 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Outside Rear View Mirror Glass Replacement Removal Procedure

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 2. Adjust the mirror glass so it is in the fully upward position. 3. Wrap the end of a flat-blade tool with tape or a clean shop rag. Important: The heater element is fitted to the rear of the mirror glass and is susceptible to damage during mirror glass removal. Extreme care must be taken while removing the mirror glass. 4. 5. 6. 7.

Insert the flat-blade tool into the slot on the inside of the mirror glass. Gently lever the mirror glass away from the motor assembly. Remove the outside rearview mirror glass. Disconnect the heating mirror connector.

Installation Procedure

1. Connector the heating mirror connector. 2. Support the mirror housing and push the mirror glass squarely onto the motor assembly until it is. 3. Connector the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Inside Rearview Mirror Replacement Removal Procedure 1. Open the door.

2. Using a small flat-bladed tool, remove the rearview mirror from the rearview mirror support and slide it back.

Installation Procedure

1. Install the rearview mirror into the rearview mirror support. Ensure that the mirror is fully seated. 2. Close the door.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Rearview Mirror Support Installation

The inside rearview mirror is attached to a support which is secured to the windshield glass. The support is installed by the glass supplier using a plastic-polyvinyl butyl adhesive. Service replacement windshield glass has the mirror support bonded to the glass assembly. In order to install a detached mirror support or to install a new part, the following items will be needed: • Loctite® Minute-Bond Adhesive • Original or replacement mirror support • Wax marking pencil or crayon • Rubbing alcohol • Clean paper towel • Fine grit sandpaper (grit #320 or #360) • Two mm allen wrench

Installation Procedure 1. Measure the distance from the headliner to the bottom of the location where the mirror support will be mounted on the windshield.

2. Mark this position on the outside of the glass with a wax pencil or crayon. Draw a large diameter circle around the mirror support location on the outside of the glass. 3. Clean the inside surface of the glass with a domestic scouring cleanser, a glass cleaning solution, or a polishing compound and paper towels. Rub the glass until the area is completely dry. When the area is dry, clean the area with an alcohol-saturated paper towel in order to remove any traces of the scouring powder or the glass cleaning solution. 4. If the mirror support is new, clean the bonding surface with fine grit sandpaper #320 or #360. If the original mirror support is being used, all traces of factory installed adhesive must be removed prior to reinstallation. 5. Wipe the sanded mirror support with a clean paper towel saturated with rubbing alcohol. Allow the support to dry. 6. Follow the adhesive kit manufacturer’s directions for adhesive application and mirror support preparation before installing the mirror support to the glass. 7. Position the mirror support to its premarked position. Use steady pressure and press the support against the glass for 30 to 60 seconds. 8. After 5 minutes, remove the excess adhesive with an alcohol-moistened towel or a glass-cleaning solution. Notice: Refer to Fastener Notice in Cautions and Notices. 9. Install the inside rearview mirror to the mirror support with the mounting screw. Tighten Tighten the rearview mirror mounting bolt to 1.2 N·m (11 lb in).

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Fastener Tightening Specifications Specification Application

Metric

English

Inside Rearview Mirror Mounting Screw

10 N·m

85 lb in

Outside Rearview Mirror Assembly Screws

1.2 N·m

11 lb in

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Vehicle Access Door Lock Cylinder Replacement Front Side Door Outside Handle Replacement (C100/Long Body) Front Side Door Outside Handle Replacement (C105/Short Body) Liftgate Outside Handle Replacement (C100/Long Body) Liftgate Outside Handle Replacement (C105/Short Body) Liftgate Latch Replacement Rear Side Door Outside Handle Replacement (C100/Long Body) Rear Side Door Outside Handle Replacement (C105/Short Body) Front Side Door Lock Replacement (C100/Long Body) Front Side Door Lock Replacement (C105/Short Body) Rear Door Lock Replacement Door Lock Striker Adjustment Door Striker Replacement Liftgate Lock Striker Replacement Fastener Tightening Specifications

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Door Lock Cylinder Replacement Removal Procedure

1. Remove the door water deflector. Refer to Door Water Deflector Replacement . 2. Disconnect the outside door handle lock rod. 3. Remove the retaining clip and the lock cylinder.

Installation Procedure

1. Install the lock cylinder with the retaining clip. 2. Connect the outside door handle lock rod. 3. Install the door water deflector. Refer to Door Water Deflector Replacement .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Front Side Door Outside Handle Replacement (C100/Long Body) Removal Procedure

1. 2. 3. 4.

Remove the door water deflector. Refer to Door Water Deflector Replacement . Remove the outside door handle screw cap. Remove the outside door handle screw through the door shut face. Remove the outside door handle by sliding rearward and pulling away from the door.

5. Remove the gasket, if necessary.

Installation Procedure

1. Install the gasket, if necessary.

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2. Install the handle by placing into position and sliding rearward ensuring to engage the outside door handle cap. 3. Install the outside door handle cap. Notice: Refer to Fastener Notice in the Preface section. 4. Install the outside door handle screw through door shut face. Tighten Tighten the outside door handle screws to 4.5 N·m (40 lb in). 5. Install the outside door handle screw cap. 6. Install the door water deflector. Refer to Door Water Deflector Replacement .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Front Side Door Outside Handle Replacement (C105/Short Body) Removal Procedure

1. 2. 3. 4.

Remove the door water deflector. Refer to Door Water Deflector Replacement . Disconnect the outside door handle and lock rods. Remove the bolt that secures the outside door handle cover. Remove the screw that secures the outside door handle support.

5. Remove the outside door handle cover. 6. Slide the outside door handle knob backward and pull it outward. 7. Remove the outside door handle support.

Installation Procedure

1. Install the outside door handle support. 2. Install the outside door handle knob. 3. Install the outside door handle cover. Notice: Refer to Fastener Notice in the Preface section.

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4. Install the screw that will secure the outside door handle support. Tighten Tighten the door handle support screw to 4.5 N·m (40 lb in). 5. Install the bolt that secures the outside door handle cover. Tighten Tighten the outside door handle cover bolt to 4.5 N·m (40 lb in). 6. Connect the outside door handle and lock rods. 7. Install the door water deflector. Refer to Door Water Deflector Replacement .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Liftgate Outside Handle Replacement (C100/Long Body) Removal Procedure

1. 2. 3. 4.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the liftgate lower trim. Refer to Liftgate Trim Panel Replacement . Disconnect the electrical connector. Remove the nuts and the liftgate outside handle.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the liftgate outside handle with the nuts. Tighten Tighten the liftgate outside handle nut to 3 N·m (27 lb in). 2. Connect the electrical connector. 3. Remove the liftgate lower trim. Refer to Liftgate Trim Panel Replacement . 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Liftgate Outside Handle Replacement (C105/Short Body) Removal Procedure

1. 2. 3. 4.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the liftgate lower trim. Refer to Liftgate Trim Panel Replacement . Disconnect the electrical connector. Remove the nuts and the liftgate outside handle.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the liftgate outside handle with the nuts. Tighten Tighten the liftgate outside handle nut to 3 N·m (27 lb in). 2. Connect the electrical connector. 3. Install the liftgate lower trim. Refer to Liftgate Trim Panel Replacement . 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Liftgate Latch Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

2. Remove the liftgate trim panel. Refer to Liftgate Trim Panel Replacement . 3. Disconnect the electrical connector. 4. Remove the bolts and the liftgate latch.

Installation Procedure

1. Connect the electrical connector. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the liftgate latch with the bolts. Tighten Tighten the liftgate latch bolts to 10 N·m (89 lb in). 3. Install the liftgate trim panel. Refer to Liftgate Trim Panel Replacement . 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Rear Side Door Outside Handle Replacement (C100/Long Body) Removal Procedure

1. 2. 3. 4.

Remove the door water deflector. Refer to Door Water Deflector Replacement . Remove the outside door handle screws. Remove the outside door handle screw through the door shut face. Remove the outside door handle by sliding rearward and pulling away from the door.

5. Remove the gasket, if necessary.

Installation Procedure

1. Install the gasket, if necessary.

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2. Install the handle by placing into position and sliding rearward ensuring to engage the outside door handle. Notice: Refer to Fastener Notice in the Preface section. 3. Install the outside door handle screws. Tighten Tighten the outside door handle screws to 4.5 N·m (40 lb in). 4. Install the door water deflector. Refer to Door Water Deflector Replacement .

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Rear Side Door Outside Handle Replacement (C105/Short Body) Removal Procedure

1. 2. 3. 4. 5.

Remove the door water deflector. Refer to Door Water Deflector Replacement . Remove the rear door lock. Refer to Rear Door Lock Replacement . Remove the outside door handle cover bolt. Remove the outside door handle support screw . Remove the outside door handle cover.

6. Slide the outside door handle knob backward and pull it outward. 7. Remove the outside door handle support.

Installation Procedure

1. Install the outside door handle support. 2. Install the outside door handle knob.

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3. Install the outside door handle cover. Notice: Refer to Fastener Notice in the Preface section. 4. Install the outside door handle screw. Tighten Tighten the outside door handle screw to 4.5 N·m (40 lb in). 5. Install the outside door handle cover bolt. Tighten Tighten the outside door handle cover bolt to 4.5 N·m (40 lb in) 6. Install the rear door lock. Refer to Rear Door Lock Replacement . 7. Install the door water deflector. Refer to Door Water Deflector Replacement .

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Front Side Door Lock Replacement (C100/Long Body) Removal Procedure

1. 2. 3. 4. 5.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the water deflector. Refer to Door Water Deflector Replacement . Remove the screws and the front door lock. Disconnect the lock rods. Disconnect the electrical connector.

Installation Procedure

1. Connect the electrical connector. 2. Connect the lock rods. Notice: Refer to Fastener Notice in the Preface section. 3. Install the front door lock with the screws. Tighten Tighten the front door lock bolt to 8 N·m (71 lb in). 4. Install the water deflector. Refer to Door Water Deflector Replacement . 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Front Side Door Lock Replacement (C105/Short Body) Removal Procedure

1. 2. 3. 4. 5.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the water deflector. Refer to Door Water Deflector Replacement . Remove the screws and the front door lock. Disconnect the lock rods. Disconnect the electrical connector.

Installation Procedure

1. Connect the electrical connector. 2. Connect the lock rods. Notice: Refer to Fastener Notice in the Preface section. 3. Install the front door lock with the screws. Tighten Tighten the front door lock bolt to 8 N·m (71 lb in). 4. Install the water deflector. Refer to Door Water Deflector Replacement . 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Rear Door Lock Replacement Removal Procedure

1. 2. 3. 4. 5.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the water deflector. Refer to Door Water Deflector Replacement . Remove the screws and the front door lock. Disconnect the lock rods. Disconnect the electrical connector.

Installation Procedure

1. Connect the electrical connector. 2. Connect the lock rods. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the front door lock with the screws. Tighten Tighten the front door lock bolt to 10 N·m (89 lb in). 4. Install the water deflector. Refer to Door Water Deflector Replacement . 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Door Lock Striker Adjustment The door striker consists of a striker with 2 screws that are threaded into a tapped, floating cage plate located in the appropriate body pillar. This floating cage plate allows the striker to be easily adjusted in and out or up and down. The door is secured in the closed position when the door lock fork snaps over and engages the striker. Important: The door striker is an important attaching part that can affect the performance of vital components and systems. It can cause major repair expenses. If replacement becomes necessary, the door lock striker must be replaced by one with the same part number or with an equivalent. Do not use a replacement part of lesser quality or of a substitute design. The specified torque values must be used during reassembly to ensure the proper retention of the part.

Up/Down or In/Out Adjustment

An adjustment of the striker in the up and down or in and out directions may be necessary for a number of reasons: • Vehicle frame damage as the result of a collision • Installation of new door weatherstrip • Customer complaints of excessive windnoise • Difficulty in opening or closing the door To adjust the door striker in an up and down or in and out direction, perform the following procedure: 1. 2. 3. 4.

The door must be properly aligned. Loosen the striker screws. The floating cage plate can be moved slightly using the ends of the striker screws. Move the floating cage plate to the desired position. If proper adjustment requires that the floating cage plate be moved more than is possible, use an electric hand drill and a 3/8-inch rotary file bit with a flat head to enlarge the body opening in the direction required. Important: It is important to use a flat-tipped drill bit to prevent damage to the tapped floating cage plate. The striker screws and the tapped floating cage plate are important attaching parts that could affect the performance of vital components and systems. Notice: Refer to Fastener Notice in the Preface section.

5. Tighten the door striker screws to the correct position. Tighten Tighten the door striker screws to 24 N·m (18 lb ft).

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Door Striker Replacement Removal Procedure

1. Open the door. 2. Remove the screws and the door striker. Front door shown, rear door similar.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the screws and the door striker. Tighten Tighten the door striker screws to 24 N·m (18 lb ft). 2. Close the door.

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Liftgate Lock Striker Replacement Removal Procedure

1. 2. 3. 4.

Open the liftgate. Remove the floor panel rear extension. Remove the bolts securing the latch striker. Pull the lock striker out.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the latch striker with the bolts. Tighten Tighten the liftgate latch striker bolt to 10 N·m (89 lb in). 2. Install the floor panel rear extension. 3. Close the liftgate.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Fastener Tightening Specifications Specification Application

Metric

English

Door Lock Bolts

8 N·m

71 lb in

Door Striker Screws

24 N·m

18 lb in

Liftgate Handle Nut

4.5 N·m

40 lb in

Liftgate Lock Striker Bolts

3 N·m

27 lb in

Outside Door Handle Screws

10 N·m

89 lb in

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Wipers and Washers Windshield Wiper and Washer Switch Replacement Windshield Washer Nozzle Replacement Rear Window Washer Nozzle Replacement Windshield Washer Hose Replacement Windshield Washer Solvent Container Replacement Washer Pump Replacement Air Inlet Grille Panel Replacement Windshield Wiper Arm Replacement Rear Window Wiper Arm Replacement Windshield Wiper Blade Replacement Wiper Blade Element Replacement Rear Window Wiper Motor Replacement Windshield Wiper System Module Replacement Rear Wiper Park Replacement Fastener Tightening Specifications

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Windshield Wiper and Washer Switch Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices.

1. 2. 3. 4.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the steering column cover. Refer to Steering Column Trim Covers Replacement . Remove the wiper switch by pushing in on the tabs on the top and the bottom of the switch housing. Disconnect the electrical connectors from the wiper switch. Disconnect the cruise control connector, if equipped.

Installation Procedure

1. 2. 3. 4.

Connect the electrical connector to the wiper switch. Connect the cruise control connector, if equipped. Install the wiper switch by snapping it into the switch housing. Install the steering column cover. Refer to Steering Column Trim Covers Replacement . Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Windshield Washer Nozzle Replacement Removal Procedure

Important: The left-hand drive is shown. The right-hand drive is similar. 1. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement . 2. Depress the washer nozzle tabs to disengage the nozzle from the air inlet grille. 3. Remove the nozzle.

Installation Procedure

1. Push the washer nozzles into the air inlet grille panel until the tabs engage with the panel. 2. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .

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Rear Window Washer Nozzle Replacement Removal Procedure

1. Remove the liftgate upper applique. Refer to Liftgate Upper Applique Replacement . 2. Remove the rear wiper nozzle.

Installation Procedure

1. Install the rear wiper nozzle. 2. Install the liftgate upper applique. Refer to Liftgate Upper Applique Replacement .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Windshield Washer Hose Replacement Removal Procedure Important: The left-hand drive is shown. The right-hand drive is similar. 1. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement .

2. Separate the front washer nozzle hose from the front washer solvent container hose that runs along the upper motor compartment rail. 3. Remove the front washer nozzle hose.

Installation Procedure

1. Connect the front nozzle hose to the front washer solvent container hose that runs along the upper motor compartment rail. 2. Position the washer hoses into the vehicle. 3. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement .

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Windshield Washer Solvent Container Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in the Preface section.

1. 2. 3. 4. 5. 6. 7.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the front right wheel. Refer to Tire and Wheel Removal and Installation . Remove the front fender liner. Refer to Fender Liner Replacement . Remove the front fascia bumper. Refer to Front Bumper Fascia Replacement . Disconnect the washer hose from the washer pump. Disconnect the electrical connectors. Remove the bolts and the reservoir.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the reservoir with the bolts. Tighten Tighten the washer fluid reservoir bolts to 10 N·m (89 lb in). 2. 3. 4. 5. 6. 7.

Connect the electrical connector. Connect the washer hose to the washer pump. Install the front fascia bumper. Refer to Front Bumper Fascia Replacement . Install the front fender liner. Refer to Fender Liner Replacement . Install the front right wheel. Refer to Tire and Wheel Removal and Installation . Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Washer Pump Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices.

1. 2. 3. 4. 5. 6. 7.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the right front wheel. Refer to Tire and Wheel Removal and Installation . Remove the front fender liner. Refer to Fender Liner Replacement . Remove the front bumper. Refer to Front Bumper Fascia Replacement . Disconnect the electrical connector. Disconnect the washer hose from the washer pump. Remove the washer pump.

Installation Procedure

1. 2. 3. 4. 5. 6. 7.

Install the washer pump. Connect the washer hose to the washer pump. Connect the electrical connector. Install the front bumper. Refer to Front Bumper Fascia Replacement . Install the front fender liner. Refer to Fender Liner Replacement . Install the right front wheel. Refer to Tire and Wheel Removal and Installation . Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Air Inlet Grille Panel Replacement Removal Procedure 1. Raise the hood. 2. Remove the wiper arms. Refer to Wiper Arm Replacement .

3. Remove the air inlet grille panel sealing strip.

4. Remove the air inlet grille panel retaining clips, and the two-piece grille.

Installation Procedure

1. Install the two-piece grille with the air inlet grille panel retaining clips.

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2. Install the air inlet grille panel sealing strip. 3. Install the wiper arms. Refer to Wiper Arm Replacement . 4. Lower the hood.

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Windshield Wiper Arm Replacement Removal Procedure

Important: The left-hand drive is shown. The right-hand drive is similar. 1. Open the hood. 2. Remove the nuts to access wiper arm nut from the wiper arm. 3. Lift wiper arm assembly away from windshield and remove wiper arm from pivot shaft.

Installation Procedure

1. Install the wiper arm. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Secure the wiper arm with the nut. Tighten Tighten the wiper arm nut to 22 N·m (16 lb ft). 3. Operate the windshield wipers and inspect for proper operation. 4. Close the hood.

CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

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Rear Window Wiper Arm Replacement Removal Procedure

1. Remove the rear wiper arm finish cap to expose the wiper arm nut. 2. Remove the rear wiper arm nut. 3. Lift the rear wiper arm assembly away from the rear window and remove the wiper from pivot shaft.

Installation Procedure

1. Position wiper blade assembly on the blackout strip as shown. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the rear wiper arm nut. Tighten Tighten the nut to 22 N·m (16 lb ft). 3. Install the rear wiper arm finish cap. 4. Operate the windshield wipers and inspect for proper operation.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Windshield Wiper Blade Replacement Removal Procedure 1. Move the wiper arm to the service up position

2. Depress the wiper blade attachment clip and slide blade out of wiper arm hook.

Installation Procedure Important: Passenger and driver side wiper blades are different lengths. Ensure that the longer blade is installed on the driver side.

1. Install the hook of the wiper arm through the opening in the wiper blade. 2. Press the wiper blade pivot into the wiper arm hook until the pivot locks into the hook. 3. Operate the windshield wipers and inspect for proper operation.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Wiper Blade Element Replacement Removal Procedure

1. Lift the wiper arm up to the service position. 2. Remove the wiper blade element by squeezing the metal tabs and pulling on the end of the insert at the heel claw.

Installation Procedure

Important: Passenger and driver side wiper blades are different lengths. Ensure that the longer blade is installed on the driver side. Important: Do not remove the retainer clips from the new wiper blade element until installed. 1. Slide the wiper blade element into the wiper blade, starting with the heel claw, so that the claw engages in the groove of the wiper blade element. 2. Guide the wiper blade element through the wiper blade claw sets.

Notice: If the metal clip on the wiper blade insert is not completely engaged to the heel claw, the wiper blade insert will not be sufficiently retained and may result in windshield damage. 3. Push the wiper blade insert so that the metal tabs fully engage into the heel claw.

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Rear Window Wiper Motor Replacement Removal Procedure

1. 2. 3. 4. 5.

Remove the rear wiper arm. Refer to Rear Window Wiper Arm Replacement . Remove the liftgate lower trim. Refer to Liftgate Trim Panel Replacement . Remove the rear wiper motor bolts. Remove the motor By sliding the pivot shaft out of the rear window grommet. Disconnect the electrical connector.

Installation Procedure

1. Connect the electrical connector. 2. Install the rear wiper motor through the rear window grommet. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the wiper motor bolts. Tighten Tighten the bolts to 8 N·m (11 lb ft). 4. Install the liftgate trim panel. Refer to Liftgate Trim Panel Replacement . 5. Install the rear wiper arm. Refer to Rear Window Wiper Arm Replacement .

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Windshield Wiper System Module Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in the Preface section.

Important: The left-hand drive model is shown. The right-hand drive is similar. 1. 2. 3. 4. 5.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement . Remove the wiper motor bolts. Pry the wiper arm linkage off the motor driveshaft. Disconnect the wiper module electrical connector at the motor.

6. Remove the bolts and the wiper motor.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the wiper motor with the bolts. Tighten Tighten the wiper motor bolts to 4 N·m (35 lb in). 2. Connect the electrical connector.

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3. Press the wiper arm linkage onto the motor driveshaft. 4. Install the wiper arm linkage to the motor driveshaft with the bolts. Tighten Tighten the wiper arm linkage nut to 10 N·m (89 lb ft). 5. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement . 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Rear Wiper Park Replacement Removal Procedure

1. Remove the liftgate lower applique. Refer to Liftgate Applique Replacement . 2. Remove the bolt and rear wiper arm park.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the rear wiper arm park with the bolt. Tighten Tighten the rear wiper arm park bolt to 3 N·m (27 lb in). 2. Install the liftgate lower applique. Refer to Liftgate Applique Replacement .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Fastener Tightening Specifications Specification Application

Metric

English

Washer Fluid Reservoir Bolts

10 N·m

89 lb in

Wiper Arm Linkage Nut

15 N·m

11 lb ft

Wiper Arm Nut

22 N·m

16 lb ft

Wiper Motor Bolts

10 N·m

89 lb in

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Wiper/Washer System Description and Operation Windshield Wiper System The windshield wiper system consists of a wiper motor, a linkage, a wiper arm, a blade and a wiper/washer switch. The windshield wiper circuit incorporates a selfparking device which consists of a worm gear and a cam plate in order to keep the circuit engaged temporarily when the switch is turned off. The wiper system is driven by a permanent magnet-type motor. The windshield wiper motor is mounted on the dash panel and is directly connected to the windshield wiper linkage. The windshield wiper motor has two speeds, LO and HI, and also has intermittent wiper capability. The wiper switch is an integral part of the wiper/washer switch. Windshield wiper operation is actuated through the lever on the right side of the steering column.

Windshield Washer System The windshield washer system is equipped with a washer fluid reservoir, a washer fluid pump, hoses, nozzles, and a wiper/washer switch. The windshield washer reservoir is mounted behind the front right wheel well splash shield. Attached to the reservoir is a washer pump, which pumps fluid through the hoses to the two nozzles mounted on the hood. The washer switch is an integral part of the wiper/ washer switch. Windshield washer operation is actuated through the lever on the right side of the steering column.

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Roof Power Sunroof Calibrations Sunroof Replacement Sunroof Switch Replacement (C 100/Long Body) Sunroof Switch Replacement (C 105/Short Body) Sunroof Description and Operation Fasteners Tightening Specifications

Section05

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Power Sunroof Calibration Condition Some customers may comment that the sunroof may not close completely or after reaching closed position does not stop and continues to operate until the vent position is reached.

Re-Calibration Description Sunroof Control Unit (SCU) has been designed to memorize closing and opening steps. However, the above condition may occur due to a loss of the memorized positioning data. The memorized positioning data can be lost when the operating current increases unusually over the specification operating current, 3.5-4.0 ampere because the foreign material is on sunroof guide rail or an object blocks the sunroof closing during operation.

SCU Re-Calibration Procedures 1. Press the switch rearward direction until the sunroof tilted open. Release the switch when the sunroof has fully opened. Important: If the sunroof opens slightly and stops, release then press the switch and hold it and repeat these steps until the sunroof opens fully. 2. If the sunroof is stopped when close movement, press the switch forward direction until the sunroof close fully. 3. Press the switch rearward direction until the sunroof open for 15 seconds. 4. Confirm the re-calibration procedures by performing sunroof opening and closing operation.

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Sunroof Replacement Removal Procedure

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 2. Remove the headliner. Refer to Headlining Trim Panel Replacement . 3. Remove the drain hoses.

4. Disconnect the electrical connectors. 5. Remove the screws and the motor.

6. Remove the motor control module. 7. Remove the bolts and the housing from the vehicle.

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8. 9. 10. 11.

Remove the rubber end caps. Remove the drain nozzles. Remove the shade stops. Remove the glass stops.

12. 13. 14. 15.

Remove the shade. Remove the glass and the frame from the housing. Remove the plastic trim. Remove the screws and the glass from the frame.

Installation Procedure

1. Install the glass to the frame with the screws.

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2. 3. 4. 5. 6. 7. 8.

Install the plastic trim. Install the glass and the frame to the housing. Install the shade. Install the glass stops. Install the shade stops. Install the drain nozzles. Install the rubber end caps. Notice: Refer to Fastener Notice in Cautions and Notices.

9. Install the housing to the roof of the vehicle with the bolts. Tighten Tighten the sunroof housing bolts to 10 N·m (89 lb in).

10. Install the motor control module. 11. Install the motor with the screws. Tighten Tighten the sunroof motor screws to 3 N·m (27 lb in). 12. Connect the electrical connectors.

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13. Install the drain hoses. 14. Install the headliner. Refer to Headlining Trim Panel Replacement . 15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Sunroof Switch Replacement (C 100/Long Body) Removal Procedure

1. 2. 3. 4. 5.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Pry off the map lamp lens by inserting a taped flat-bladed tool into the recess along the edge of the lens. Remove the screws and the map lamp housing from the headliner. Disconnect the electrical connector. Remove the power sunroof control switch.

Installation Procedure

1. Install the replacement bulb. 2. Connect the electrical connector. Notice: Refer to Fastener Notice in the Preface section. 3. Install the map lamp housing to the headliner with the screws. Tighten Tighten the map lamp housing screw 2 N·m (18 lb in). 4. Press the map lamp lens onto the housing. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Sunroof Switch Replacement (C 105/Short Body) Removal Procedure

1. 2. 3. 4. 5.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Pry off the map lamp lens by inserting a taped flat-bladed tool into the recess along the edge of the lens. Remove the screws and the map lamp housing from the headliner. Disconnect the electrical connector. Remove the power sunroof control switch.

Installation Procedure

1. Install the power sunroof control switch. Notice: Refer to Fastener Notice in the Preface section. 2. Connect the electrical connector. 3. Install the map lamp housing to the headliner with the screws. Tighten Tighten the map lamp housing screw 2 N·m (18 lb in). 4. Press the map lamp lens onto the housing. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Sunroof Description and Operation Power Sunroof/Sunroof Control Switch The sunroof has the following characteristics: • Intended to provide light and air through the roof the vehicle • Built into the roof • Made of glass • Equipped with a sunshade that opens and closes manually • Powered by an electric motor • Controlled by a switch built into the map lamp assembly. The sunroof control switch is located on the center of the map lamp assembly. To operate the sunroof, the ignition must be ON. Tilting the Sunroof, Open and Closed To tilt open the rear end of the sunroof, press the switch rearward direction until the sunroof tilts open. To close the sunroof from a tilted-open position, press the switch forward direction until the sunroof tilts closed. Sliding the Sunroof, Open and Closed To slide open the sunroof, press the switch rearward direction until the sunroof slides. If the sun shade is closed, the sunroof will pull the sunshade open when the sunroof slides open. To close the sunroof from a slid-open position, press the switch forward direction until the sunroof slides closed.

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Fastener Tightening Specifications Specification Application

Metric

English

Front Console Screws

2 N·m

18 lb in

Map Lamp Housing Screws

2 N·m

18 lb in

Sunroof Housing Bolts

10 N·m

89 lb in

Sunroof Motor Screws

3 N·m

27 lb in

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Seats Power seats Seat Hardware Trim and Upholstery Seat Heating and Cooling

Section06

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Power Seats Front Seat Adjuster Replacement Power Seats System Description and Operation Fastener Tightening Specifications

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Front Seat Adjuster Replacement Removal Procedure

1. 2. 3. 4.

Remove the driver seat. Refer to Bucket Seat Replacement . Remove the front seat cushion. Refer to Front Seat Cushion Replacement . Disconnect the electrical connector. Remove the bolts the screws, and the slide assembly.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the slide assembly with the bolts and the screws. Tighten • Tighten the slide assembly bolts to 25 N·m (18 lb ft). • Tighten the slide assembly screws to 10 N·m (89 lb in). 2. Connect the electrical connector. 3. Install the front seat cushion. Refer to Front Seat Cushion Replacement . 4. Install the driver seat. Refer to Bucket Seat Replacement .

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Power Seats System Description and Operation Seats Do not attempt to change the designed seat position by altering the designed seat adjuster-to-floor pan anchor provisions or the seat adjuster-to-seat frame anchor provisions. Changing the seat position could affect the performance of the seat system. This vehicle is equipped with front seats with adjustable head restraints, and a 3-passenger rear bench seat with an optional split folding rear seat. The front seats also have a recline, a height, and a lumbar adjustment. A power driver seat is optional. Seat cushions and seatbacks have formed foam pads, which fit the contours of the full panel seatback frame assembly and the designed contour of the seat cushion frame.

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Fastener Tightening Specifications Specification Application

Metric

English

3rd Rear Seat Bolts

45 N·m

33 lb ft

Front Seat Cover Screws

12 N·m

9 lb ft

Front Seat Cushion Bolts

12 N·m

9 lb ft

Front Seat to Floor Bolts

45 N·m

33 lb ft

Front Seat Trim Screws

12 N·m

9 lb ft

Front Seatback Bolts

45 N·m

33 lb ft

Heating Mat Switch

2 N·m

18 lb in

Rear Console Deposit Box Screws

2 N·m

18 lb in

Rear Seat to Floor Bolts

45 N·m

33 lb ft

Rear Seat Trim Screws

12 N·m

9 lb ft

Rear Seatback Bolts

12 N·m

9 lb ft

Slide Assembly Bolts

25 N·m

18 lb ft

Slide Assembly Screws

10 N·m

89 lb in

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Seat Hardware Trim and Upholstery Bucket Seat Replacement Front Seat Trim Panel Replacement Front Seat Adjuster Replacement Two-Way Manual Seat Adjuster Handle Replacement Front Seat Head Restraint Replacement Front Seat Cushion Replacement Front Seat Back Replacement Front Seat Recliner Knob Replacement Lumber Support Knob Replacement Rear Seat Replacement Rear Seat Cushion Trim Cover Replacement Rear Seat Back Replacement Rear Number 2 Folding Seat Replacement Fasteners Tightening Specifications

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Bucket Seat Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Disconnect the negative battery cable. 2. Remove the plastic caps and the bolts securing the rear portion of the front seat to the floor.

3. Disconnect the electrical connectors. 4. Remove the seat.

Installation Procedure

1. Install the seat. 2. Connect the electrical connectors. Notice: Refer to Fastener Notice in Cautions and Notices.

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3. Install the bolts into the rear portion of the front seat. Tighten Tighten the front seat-to-floor bolts to 45 N·m (33 lb ft). 4. Install the plastic caps. 5. Connect the negative battery cable.

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Front Seat Trim Panel Replacement Removal Procedure

1. Remove the front seat from the vehicle. Refer to Bucket Seat Replacement . 2. Remove the screw and the recliner lever. 3. Remove the screws and the front seat trim.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the front seat trim with the screws. Tighten Tighten the front seat trim screws to 12 N·m (9 lb ft). 2. Install the recliner lever. 3. Install the front seat in the vehicle. Refer to Bucket Seat Replacement .

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Front Seat Adjuster Replacement Removal Procedure

1. 2. 3. 4.

Remove the seatback. Refer to Seat Back Replacement - Front . Remove the seat trim. Refer to Front Seat Trim Panel Replacement . Remove the seat cushion bolts. Remove the seat track from the seat cushion.

Installation Procedure

1. Install the cushion onto the seat track. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the seat track to the seat cushion with the seat cushion bolts. Tighten Tighten the front seat cushion bolts to 12 N·m (9 lb ft). 3. Install the seat trim. Refer to Front Seat Trim Panel Replacement . 4. Install the seatback. Refer to Seat Back Replacement - Front .

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Two-Way Manual Seat Adjuster Handle Replacement Removal Procedure

Remove the height adjustment lever.

Installation Procedure

Install the height adjustment lever.

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Front Seat Head Restraint Replacement Removal Procedure

1. Press in the hand into the restraint adjust button and remove the head restraint from the seatback.

2. Insert the head back side of the seat and press the sleeve. 3. Remove the head restraint.

Installation Procedure

1. Install the guide sleeves into the seatback and press them down to engage the guide sleeve retaining latches. 2. Install the front seatback cover. 3. Install the head restraint into the guide sleeves.

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Front Seat Cushion Replacement Removal Procedure

1. 2. 3. 4.

Remove the front seat from the vehicle. Refer to Bucket Seat Replacement . Remove the seat trims. Remove the seat cushion bolts. Remove the cushion from the seat track.

Installation Procedure

1. Install the cushion onto the seat track. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the seat cushion with the bolts. Tighten Tighten the front seat cushion bolts to 12 N·m (9 lb ft). 3. Install the seat trims. 4. Install the front seat in the vehicle. Refer to Bucket Seat Replacement .

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Front Seat Back Replacement Removal Procedure

1. Remove the front seat from the vehicle. Refer to Bucket Seat Replacement . 2. Remove the back panel.

3. Remove the each seat trim. 4. Disconnect the electrical connectors. 5. Remove the bolts and the seatback.

Installation Procedure

1. Install the seatback onto the seat cushion. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the front seatback bolts. Tighten

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Tighten the front seatback bolts to 45 N·m (33 lb ft). 3. Connect the electrical connectors.

4. Install the seat trims to its original position. 5. Install the back panel onto the seat. 6. Install the front seat in the vehicle. Refer to Bucket Seat Replacement .

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Front Seat Recliner Knob Replacement Removal Procedure

Remove the seat recliner lever.

Installation Procedure

Install the seat recliner lever.

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Lumbar Support Knob Replacement Removal Procedure

Remove the lumbar support knob.

Installation Procedure

Install the lumbar support knob.

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Rear Seat Replacement Removal Procedure

1. Remove the bolts securing the rear portion of the rear seat to the floor.

2. Remove the seat.

Installation Procedure

1. Install the rear seat cushion by inserting the metal loops into the rear retaining brackets and pressing the front of the seat cushion down. Notice: Refer to Fastener Notice in Cautions and Notices.

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2. Install the bolts into the rear portion of the rear seat. Tighten Tighten the rear seat-to-floor bolts to 45 N·m (33 lb ft).

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Rear Seat Cushion Trim Cover Replacement Removal Procedure

1. Remove the rear seat from the vehicle. Refer to Rear Seat Replacement . 2. Remove the screws and the rear seat trim.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the rear seat trim with the screws. Tighten Tighten the rear seat trim screws to 12 N·m (9 lb ft). 2. Install the rear seat from the vehicle. Refer to Rear Seat Replacement .

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Rear Seat Back Replacement Removal Procedure

1. 2. 3. 4.

Remove the rear seat from the vehicle. Refer to Rear Seat Replacement . Remove the rear seat trim. Refer to Rear Seat Cushion Trim Cover Replacement . Remove the bolts both sides of the rear seat. Remove the rear seatback.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the rear seatback with the bolts. Tighten Tighten the rear seatback bolts to 12 N·m (9 lb ft). 2. Install the rear seat trim. Refer to Rear Seat Cushion Trim Cover Replacement . 3. Install the rear seat in the vehicle. Refer to Rear Seat Replacement .

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Rear Number 2 Folding Seat Replacement Removal Procedure

1. Remove the bolts securing the rear portion of the 3rd rear seat to the floor. 2. Remove the 3rd rear seat.

Installation Procedure

1. Install the 3rd rear seat. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts into the rear portion of the 3rd rear seat. Tighten Tighten the rear seat-to-floor bolts to 45 N·m (33 lb ft).

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Fastener Tightening Specifications Specification Application

Metric

English

3rd Rear Seat Bolts

45 N·m

33 lb ft

Front Seat Cover Screws

12 N·m

9 lb ft

Front Seat Cushion Bolts

12 N·m

9 lb ft

Front Seat to Floor Bolts

45 N·m

33 lb ft

Front Seat Trim Screws

12 N·m

9 lb ft

Front Seatback Bolts

45 N·m

33 lb ft

Heating Mat Switch

2 N·m

18 lb in

Rear Console Deposit Box Screws

2 N·m

18 lb in

Rear Seat to Floor Bolts

45 N·m

33 lb ft

Rear Seat Trim Screws

12 N·m

9 lb ft

Rear Seatback Bolts

12 N·m

9 lb ft

Slide Assembly Bolts

25 N·m

18 lb ft

Slide Assembly Screws

10 N·m

89 lb in

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Seat Heating and Cooling Heated Seat Switch Replacement Driver Seat and Passenger Seat Cushion Heater Replacement

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Heated Seat Switch Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Disconnect the negative battery cable. 2. Remove the screws and the rear console box.

3. Remove the rear console cover and disconnect the connector.

4. Remove the screws and heating mat switch.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

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1. Install the heating mat switch with the screws. Tighten Tighten the heating mat switch screws to 2 N·m (18 lb in). 2. Connect the connector and install the rear console cover. Notice: Refer to Fastener Notice in Cautions and Notices.

3. Install the rear console box with the screws. Tighten Tighten the rear console deposit box screws to 2 N·m (18 lb in). 4. Connect the negative battery cable.

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Driver Seat and Passenger Seat Cushion Heater Replacement Removal Procedure Caution: If the seat cushion or seatback foam is damaged when you remove the seat heater element, replace the seat cushion or seatback in order to prevent personal injury. Caution: Refer to Battery Disconnect Caution in the Preface section.

1. 2. 3. 4. 5.

Disconnect the negative battery cable. Disconnect the airbag and heating mat wiring harness. Remove the seatback and/or cushion. Refer to Front Seat Cushion Replacement . Remove the seat cover from the seatback and/or the cushion. Peel the heating mat off of the cushion.

Installation Procedure

1. 2. 3. 4. 5.

Install the heating mat. Install the seat cover onto the seatback and/or the cushion. Install the seatback and/or the seat cushion. Refer to Front Seat Cushion Replacement . Connect the airbag and heating mat wiring harness. Connect the negative battery cable.

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Steering Steering Wheel and Column Description and Operation Intermediate Steering Shaft Replacement Steering Column Trim Covers Replacement (C100/Long Body) Steering Column Trim Covers Replacement (C105/Short Body) Turn Signal Multifunction Switch Replacement (C105/Short Body) Turn Signal Multifunction Switch Replacement (C100/Long Body) Steering Wheel Replacement (C100/Long Body) Steering Wheel Replacement (C105/Short Body) Steering Column Replacement Fasteners Tightening Specifications Steering Wheel and Column Description and Operation Special Tools

Section07

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Steering Wheel and Column Description and Operation In addition to the steering function, the steering column provides safety and security. The energy-absorbing column is designed to compress in a front-end collision to lessen the chance of driver injury. The ignition switch and the lock are mounted on the column, allowing the ignition and steering operations to be locked to inhibit theft of the car. The column levers trigger the turn signals, the headlight beams, and the windshield washer and wipers. A tilt steering column uses a spherical joint to allow the steering wheel to tilt up and down. This enables the driver to adjust the steering wheel to a comfortable position.

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Intermediate Steering Shaft Replacement Removal Procedure Notice: Refer to Steering Column in Lock Position Notice in Cautions and Notices. Important: The left-hand drive model is shown. The right-hand drive model is similar. 1. Turn the steering wheel to the straight-ahead position and LOCK the steering column. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 3. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

4. Place a match mark on the stub shaft housing that lines up with the groove of the intermediate shaft. This mark is for proper alignment during installation. 5. Remove the lower pinch bolt from the universal joint on the steering gear.

6. Remove the upper pinch bolt from the universal joint on the intermediate shaft. 7. Remove the intermediate shaft and dash seal.

Installation Procedure

Important: Ensure the steering wheel is in the straight-ahead position. 1. Install the intermediate shaft and dash seal into the vehicle. 2. Attach the universal joint of the intermediate shaft onto the steering column. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the pinch bolt into the universal joint on the intermediate shaft. Tighten Tighten the intermediate shaft pinch bolt to 34 N·m (25 lb ft).

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Important: Align the marks on the intermediate shaft and on the stub shaft. 4. Attach the intermediate shaft onto the steering gear stub shaft. Important: When installing the lower intermediate shaft pinch bolt, ensure the bolt goes through the universal joint on the side of the stub shaft with the notch. If you have trouble seating the universal joint completely down onto the stub shaft, have an assistant unlock the steering column and rotate the steering wheel slightly while you push down on the universal joint. 5. Install the bolt into the lower universal joint on the intermediate shaft. Tighten Tighten the intermediate shaft pinch bolt to 34 N·m (25 lb ft). 6. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation . 7. Lower the vehicle.

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Steering Column Trim Covers Replacement (C100/Long Body) Removal Procedure

1. Remove the lower steering column cover screw. 2. Turn the steering wheel in order to expose the upper steering column cover screws. Remove the upper steering column cover screws and remove the upper steering column cover.

3. Remove the lower steering column cover from the cluster bezel.

Installation Procedure

1. Install the lower steering column cover to the cluster bezel. 2. Install the upper steering column cover. Notice: Refer to Fastener Notice in Cautions and Notices.

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3. Install the upper and lower steering column cover screws. Tighten Tighten the upper and lower steering column cover screws to 1.5 N·m (13 lb in).

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Steering Column Trim Covers Replacement (C105/Short Body) Removal Procedure

1. 2. 3. 4.

Remove the lower steering column cover panel screw. Turn the steering wheel in order to expose the upper steering column cover panel screws. Remove the upper steering column cover panel screws. Remove the upper steering column cover panel.

5. Remove the lower steering column cover panel from the cluster bezel.

Installation Procedure

1. Install the lower steering column cover panel to the cluster bezel. 2. Install the upper steering column cover panel.

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3. Turn the steering wheel in order to expose the upper steering column cover panel screw holes. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the upper and the lower steering column cover panel screws. Tighten Tighten the steering column cover panel screws to 1.5 N·m (13 lb in).

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Turn Signal Multifunction Switch Replacement (C105/Short Body) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 2. Remove the steering column covers. Refer to Steering Column Trim Covers Replacement .

3. Remove the turn signal switch by pushing in on the tabs on the top and the bottom of the switch housing. 4. Disconnect the electrical connectors from the turn signal switch.

Installation Procedure

1. 2. 3. 4.

Connect the electrical connectors to the turn signal switch. Install the turn signal switch by snapping the switch into the housing. Install the steering column covers. Refer to Steering Column Trim Covers Replacement . Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Turn Signal Multifunction Switch Replacement (C100/Long Body) Removal Procedure

1. 2. 3. 4.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the steering column covers. Refer to Steering Column Trim Covers Replacement . Remove the turn signal switch by pushing in on the tabs on the top and the bottom of the switch housing. Disconnect the electrical connections from the turn signal switch.

Installation Procedure

1. 2. 3. 4.

Connect the electrical connections to the turn signal switch. Install the turn signal switch by snapping the switch into the switch housing. Install the steering column cover. Refer to Steering Column Trim Covers Replacement . Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Steering Wheel Replacement (C100/Long Body) Tools Required KM-210-A Steering Wheel Puller

Removal Procedure 1. Turn the steering wheel to the straight-ahead position. Caution: The sensing and the diagnosis module (SDM) can maintain sufficient voltage to deploy the airbags and pretensioners for up to 1 minute after the ignition has been turned OFF and the fuse has been removed. If the airbags and pretensioners are not disconnected, do not begin service until one minute has been passed after disconnecting power to the SDM. Failure to do so may cause personal injury. 2. Disconnect the negative battery cable and let the vehicle sit for 1 minute. Refer to Battery Negative Cable Disconnection and Connection . 3. Remove the supplemental inflatable restraints (SIR) module. Refer to Inflatable Restraint Steering Wheel Module Replacement .

4. Remove the steering wheel nut. 5. Use paint in order to place match marks on the steering column shaft and on the steering wheel.

6. Remove the steering wheel using the KM-210-A .

Installation Procedure

1. Align the match marks on the steering wheel and the steering column shaft. Turn the signal canceling cam on the wheel to the left. 2. Install the steering wheel. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the steering wheel nut. Tighten Tighten the steering wheel nut to 41 N·m (30 lb ft). 4. Install the SIR module. Refer to Refer to Inflatable Restraint Steering Wheel Module Replacement . 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Steering Wheel Replacement (C105/Short Body) Tools Required KM-210-A Steering Wheel Puller

Removal Procedure 1. Turn the steering wheel to the straight-ahead position. Caution: The sensing and the diagnosis module (SDM) can maintain sufficient voltage to deploy the airbags and pretensioners for up to 1 minute after the ignition has been turned OFF and the fuse has been removed. If the airbags and pretensioners are not disconnected, do not begin service until one minute has been passed after disconnecting power to the SDM. Failure to do so may cause personal injury. 2. Disconnect the negative battery cable and let the vehicle sit for 1 minute. Refer to Battery Negative Cable Disconnection and Connection . 3. Remove the SIR module. Refer to Inflatable Restraint Steering Wheel Module Replacement .

4. Remove the steering wheel nut. 5. Use paint in order to place match marks on the steering column shaft and on the steering wheel.

6. Remove the steering wheel using the KM-210-A .

Installation Procedure

1. Align the match marks on the steering wheel and the steering column shaft. Turn the signal canceling cam on the wheel to the left. 2. Install the steering wheel. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the steering wheel nut. Tighten Tighten the steering wheel nut to 41 N·m (30 lb ft). 4. Install the SIR module. Refer to Refer to Inflatable Restraint Steering Wheel Module Replacement . 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Steering Column Replacement Important: Remove the steering column only if: • The steering column requires replacement.

• The steering and the ignition lock housing require replacement. • Another operation requires the removal of the steering column. Removal Procedure Notice: Refer to Steering Column in Lock Position Notice in the Preface section. Important: Ensure the front wheels are in the straight-ahead position. 1. Adjust the steering wheel to the straight-ahead position. Caution: The sensing and the diagnosis module (SDM) can maintain sufficient voltage to deploy the airbags and pretensioners for up to 1 minute after the ignition has been turned OFF and the fuse has been removed. If the airbags and pretensioners are not disconnected, do not begin service until one minute has been passed after disconnecting power to the SDM. Failure to do so may cause personal injury. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Disconnect the negative battery cable and let the vehicle sit for 1 minute. Refer to Battery Negative Cable Disconnection and Connection . Remove the inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering Wheel Module Replacement . Remove the steering wheel. Refer to Steering Wheel Replacement . Remove the steering column trim covers. Refer to Steering Column Trim Covers Replacement . Remove the turn signal and headlamp switch. Refer to Turn Signal Multifunction Switch Replacement . Remove the windshield wiper and washer switch. Refer to Windshield Wiper and Washer Switch Replacement . Remove the coil. Refer to Inflatable Restraint Steering Wheel Module Coil Replacement . Remove the driver knee bolster. Refer to Knee Bolster Replacement . Remove the ignition switch. Refer to Ignition and Start Switch Replacement . Remove the key hole lamp. Refer to Ignition Lock Cylinder Bulb Replacement . Remove the immobilizer module, if equipped. Refer to Theft Deterrent Module Replacement . Remove the key cylinder. Refer to Ignition Switch Lock Cylinder Replacement . Remove the SSPS control module, if equipped. Refer to Power Steering Control Module Replacement .

15. 16. 17. 18.

Use paint in order place match marks on the intermediate steering shaft and on the lower portion of the steering column shaft. Remove the steering shaft universal joint pinch bolt. Remove the intermediate shaft from the steering column shaft. Remove the steering angle sensor, if equipped. Refer to Steering Wheel Position Sensor Replacement .

19. Remove the steering column assembly lower bracket bolt.

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20. Remove the steering column assembly upper bracket bolts. Notice: Once the steering column is removed from the vehicle, the column is extremely susceptible to damage. Dropping the column assembly on the end could collapse the steering shaft or loosen the plastic injections, which maintain column rigidity. Leaning on the column assembly could cause the jacket to bend or deform. Any of the above damage could impair the columns collapsible design. Do NOT hammer on the end of the shaft, because hammering could loosen the plastic injections, which maintain column rigidity. If you need to remove the steering wheel, refer to the Steering Wheel Replacement procedure in this section. 21. Remove the steering column assembly from the vehicle.

Installation Procedure 1. 2. 3. 4.

Verify the front tires are in the straight-ahead position. If you are replacing the steering column, copy the match marks from the old column to the new column. Position the steering column in the vehicle. Install the steering angle sensor, if equipped. Refer to Steering Wheel Position Sensor Replacement .

Important: Provide support for the steering column assembly until the mounting bolts are fastened. Do not let the steering column assembly hang unsupported. 5. Align the match marks and carefully guide the steering shaft into the universal joint of the intermediate shaft. Notice: Refer to Fastener Notice in the Preface section. 6. Install the pinch bolt into the universal joint on the intermediate shaft. Tighten Tighten the intermediate shaft pinch bolt to 34 N·m (25 lb ft).

7. Install the steering column assembly lower bracket bolt. Tighten Tighten the steering column assembly lower bracket bolt to 25 N·m (18 lb ft).

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8. Install the upper bracket bolts. Tighten Tighten the steering column assembly upper bracket bolts to 22 N·m (16 lb ft). 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

Install the SSPS control module, if equipped. Refer to Power Steering Control Module Replacement . Install the key cylinder. Refer to Ignition Switch Lock Cylinder Replacement . Install the immobilizer module, if equipped. Refer to Theft Deterrent Module Replacement . Install the key hole lamp. Refer to Ignition Lock Cylinder Bulb Replacement . Install the ignition switch. Refer to Ignition and Start Switch Replacement . Install the driver knee bolster. Refer to Knee Bolster Replacement . Install the coil. Refer to Inflatable Restraint Steering Wheel Module Coil Replacement . Install the windshield wiper and washer switch. Refer to Windshield Wiper and Washer Switch Replacement . Install the turn signal and headlamp switch. Refer to Turn Signal Multifunction Switch Replacement . Install the steering column trim covers. Refer to Steering Column Trim Covers Replacement . Install the steering wheel. Refer to Steering Wheel Replacement . Install the inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering Wheel Module Replacement . Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Fastener Tightening Specifications Specification Application

Metric

English

Steering Column Assembly Lower Bracket Bolt

25 N·m

18 lb ft

Steering Column Assembly Upper Bracket Bolts

22 N·m

16 lb ft

Steering Shaft Universal Joint Pinch Bolt

34 N·m

25 lb ft

Steering Wheel Nut

41 N·m

30 lb ft

Upper and Lower Steering Column Cover Panel Screws

1.5 N·m

13 lb in

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Steering Wheel and Column Description and Operation In addition to the steering function, the steering column provides safety and security. The energy-absorbing column is designed to compress in a front-end collision to lessen the chance of driver injury. The ignition switch and the lock are mounted on the column, allowing the ignition and steering operations to be locked to inhibit theft of the car. The column levers trigger the turn signals, the headlight beams, and the windshield washer and wipers. A tilt steering column uses a spherical joint to allow the steering wheel to tilt up and down. This enables the driver to adjust the steering wheel to a comfortable position.

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Special Tools Illustration

Tool Number/ Description

KM-210-A Steering Wheel Puller

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Air Inlet Grille Panel Replacement Removal Procedure 1. Raise the hood. 2. Remove the wiper arms. Refer to Wiper Arm Replacement .

3. Remove the air inlet grille panel sealing strip.

4. Remove the air inlet grille panel retaining clips, and the two-piece grille.

Installation Procedure

1. Install the two-piece grille with the air inlet grille panel retaining clips.

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2. Install the air inlet grille panel sealing strip. 3. Install the wiper arms. Refer to Wiper Arm Replacement . 4. Lower the hood.

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Battery Negative Cable Disconnection and Connection Removal Procedure Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. 1. 2. 3. 4. 5. 6.

Record all preset and theft codes, (if equipped), from the radio. Turn the ignition switch to the OFF position. Verify that all the electrical components are OFF such as interior lights, all doors are closed, the underhood lamp , etc. Loosen the clamping bolt from the battery negative cable. Remove the battery negative cable from the battery. Position the battery negative cable away from any body ground.

Installation Procedure 1. Verify that all the electrical components are OFF such as interior lights, all doors are closed, the underhood lamp , etc. 2. Clean corrosion from the negative battery cable using a metal brush. 3. Install the battery negative cable to the battery. Notice: Refer to Fastener Notice in the Preface section. 4. Install the clamping bolt to the negative cable. Tighten Tighten the battery negative cable to 4.5 N·m (40 lb in). 5. Reset the radio stations and the clock.

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Battery Negative Cable Disconnection and Connection Removal Procedure Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. 1. 2. 3. 4. 5. 6.

Record all preset and theft codes, (if equipped), from the radio. Turn the ignition switch to the OFF position. Verify that all the electrical components are OFF such as interior lights, all doors are closed, the underhood lamp , etc. Loosen the clamping bolt from the battery negative cable. Remove the battery negative cable from the battery. Position the battery negative cable away from any body ground.

Installation Procedure 1. Verify that all the electrical components are OFF such as interior lights, all doors are closed, the underhood lamp , etc. 2. Clean corrosion from the negative battery cable using a metal brush. 3. Install the battery negative cable to the battery. Notice: Refer to Fastener Notice in the Preface section. 4. Install the clamping bolt to the negative cable. Tighten Tighten the battery negative cable to 4.5 N·m (40 lb in). 5. Reset the radio stations and the clock.

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Air Inlet Grille Panel Replacement Removal Procedure 1. Raise the hood. 2. Remove the wiper arms. Refer to Wiper Arm Replacement .

3. Remove the air inlet grille panel sealing strip.

4. Remove the air inlet grille panel retaining clips, and the two-piece grille.

Installation Procedure

1. Install the two-piece grille with the air inlet grille panel retaining clips.

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2. Install the air inlet grille panel sealing strip. 3. Install the wiper arms. Refer to Wiper Arm Replacement . 4. Lower the hood.

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Battery Negative Cable Disconnection and Connection Removal Procedure Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. 1. 2. 3. 4. 5. 6.

Record all preset and theft codes, (if equipped), from the radio. Turn the ignition switch to the OFF position. Verify that all the electrical components are OFF such as interior lights, all doors are closed, the underhood lamp , etc. Loosen the clamping bolt from the battery negative cable. Remove the battery negative cable from the battery. Position the battery negative cable away from any body ground.

Installation Procedure 1. Verify that all the electrical components are OFF such as interior lights, all doors are closed, the underhood lamp , etc. 2. Clean corrosion from the negative battery cable using a metal brush. 3. Install the battery negative cable to the battery. Notice: Refer to Fastener Notice in the Preface section. 4. Install the clamping bolt to the negative cable. Tighten Tighten the battery negative cable to 4.5 N·m (40 lb in). 5. Reset the radio stations and the clock.

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Battery Negative Cable Disconnection and Connection Removal Procedure Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. 1. 2. 3. 4. 5. 6.

Record all preset and theft codes, (if equipped), from the radio. Turn the ignition switch to the OFF position. Verify that all the electrical components are OFF such as interior lights, all doors are closed, the underhood lamp , etc. Loosen the clamping bolt from the battery negative cable. Remove the battery negative cable from the battery. Position the battery negative cable away from any body ground.

Installation Procedure 1. Verify that all the electrical components are OFF such as interior lights, all doors are closed, the underhood lamp , etc. 2. Clean corrosion from the negative battery cable using a metal brush. 3. Install the battery negative cable to the battery. Notice: Refer to Fastener Notice in the Preface section. 4. Install the clamping bolt to the negative cable. Tighten Tighten the battery negative cable to 4.5 N·m (40 lb in). 5. Reset the radio stations and the clock.

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Dome Lamp Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

2. 3. 4. 5.

Pry off the dome lamp lens by inserting a screwdriver into the recess along the edge of the lens. Remove the screws and the dome lamp housing from the headliner. Disconnect the electrical connector. Remove the bulb.

Installation Procedure

1. Install the replacement bulb. 2. Connect the electrical connector. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the dome lamp housing to the headliner with the screws. Tighten Tighten the dome lamp housing screw to 2 N·m (18 lb in). 4. Press the dome lamp lens onto the housing. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection

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Exterior Windnoise Caution: An assistant should drive the vehicle while the technician checks for the location of the reported condition. Otherwise, personal injury could result. Exterior windnoise is louder when the vehicle is driven with one or more windows down. Exterior windnoise occurs when air passes over the body panels, the seams, or the openings. Use the following items during the test drive in order to aid in the detection of leaks: • Mechanic's stethoscope or heater hose • Masking tape-51 mm (2 in) width • Strip caulk • A water soluble marking pencil 1. While driving, determine the location of the exterior windnoise by lowering one window at a time. If the location corresponds with the condition in step 2, pull over and make a temporary repair with 51 mm (2 in) wide masking tape. 2. Tape over the gaps and the moldings one at a time. Test between each taping. Taping over the gaps and moldings will correct the condition. 3. Temporarily repair the condition with masking tape. Adjust the tape when needed. 4. Continue testing in order to determine if the noise has been eliminated or other leak areas exist. 5. When all the reported leak conditions are located, make permanent repairs using the proper alignment techniques and the sealing materials.

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Fender Liner Replacement Removal Procedure

1. 2. 3. 4. 5.

Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the front wheel. Refer to Tire and Wheel Removal and Installation . Remove the front mud guard. Refer to Guard Mud - Rear (One or Both) Replacement . Remove the engine protection shield. Refer to Engine Protection Shield Replacement . Remove the screws and the front fender liner.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the screws and the front fender liner. Tighten Tighten the front fender liner screws to 4 N·m (35 lb in). 2. 3. 4. 5.

Install the engine protection shield. Refer to Engine Protection Shield Replacement . Install the front mud guard. Refer to Guard Mud - Rear (One or Both) Replacement . Install the front wheel. Refer to Tire and Wheel Removal and Installation . Lower the vehicle.

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Front Fender Wheel Opening Molding Replacement Removal Procedure

1. Remove the front mud guards. 2. Remove the screws and front fender wheel opening molding.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the front fender wheel opening molding with the screws. Tighten Tighten the front fender wheel opening molding screws to 4 N·m (35 lb in). 2. Install the front mud guard.

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Headlamp Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 2. Remove the radiator grille upper cover.

3. Remove the bolts and the headlamp assembly.

4. Disconnect the headlamp assembly electrical connectors.

5. Remove the cap that conceals the headlamp bulb. 6. Disconnect the headlamp bulb electrical connectors. 7. Remove the headlamp bulbs.

Installation Procedure

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1. Install the headlamp bulbs. 2. Connect the headlamp bulb electrical connectors. 3. Install the cap that conceals the headlamp bulbs.

4. Connect the headlamp assembly electrical connectors. Notice: Refer to Fastener Notice in Cautions and Notices.

5. Install the headlamp assembly with the bolts. Tighten Tighten the headlamp assembly bolts to 7 N·m (62 lb in). 6. Install the radiator grille upper cover. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Heater and Air Conditioning Control Replacement (C105/Short Body) Removal Procedure Caution: Refer to Battery Disconnect Caution in the Preface section.

Important: The left-hand drive is shown. The right-hand drive is similar. 1. 2. 3. 4. 5. 6. 7.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the instrument panel accessory bezel. Refer to Instrument Panel Accessory Bezel Replacement . Remove the control assembly retaining screws. Pull out the unit to gain access to the rear. Disconnect the electrical connectors. Remove the air inlet tube. Remove the automatic temperature control assembly.

Installation Procedure

1. Connect the air inlet tube. 2. Connect the electrical connectors. Notice: Refer to Fastener Notice in the Preface section. 3. Position the automatic temperature control assembly and install the retaining screws. Tighten Tighten the control assembly retaining screws to 2.5 N·m (22 lb in). 4. Install the instrument panel accessory bezel. Refer to Instrument Panel Accessory Bezel Replacement . 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Heater and Air Conditioning Control Replacement (C100/Long Body) Removal Procedure Caution: Refer to Battery Disconnect Caution in the Preface section.

Important: The left-hand drive is shown. The right-hand drive is similar. 1. 2. 3. 4. 5. 6. 7.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the instrument panel accessory bezel. Refer to Instrument Panel Accessory Bezel Replacement . Remove the control assembly retaining screws. Pull out the unit to gain access to the rear. Disconnect the electrical connectors. Remove the air inlet tube. Remove the automatic temperature control assembly.

Installation Procedure

1. Connect the air inlet tube. 2. Connect the electrical connectors. Notice: Refer to Fastener Notice in the Preface section. 3. Position the automatic temperature control assembly and install the retaining screws. Tighten Tighten the control assembly retaining screws to 2.5 N·m (22 lb in). 4. Install the instrument panel accessory bezel. Refer to Instrument Panel Accessory Bezel Replacement . 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Inflatable Restraint Steering Wheel Module Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disable the supplemental inflatable restraints (SIR). Refer to SIR Disabling and Enabling . 2. Position the steering wheel straight ahead.

Caution: The sensing and the diagnosis module (SDM) can maintain sufficient voltage to deploy the airbags and pretensioners for up to 1 minute after the ignition has been turned OFF and the fuse has been removed. If the airbags and pretensioners are not disconnected, do not begin service until one minute has been passed after disconnecting power to the SDM. Failure to do so may cause personal injury. 3. Insert a small flat-bladed screwdriver in the horizontal position into the hole on the side of the steering wheel.

4. Push the pin of the air bag module bracket to release the lock securing the air bag module to the steering wheel. 5. Remove the connector from the driver air bag module. Caution: When you are carrying an undeployed inflator module: • Do not carry the inflator module by the wires or connector on the inflator module

• Make sure the bag opening points away from you When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 6. Remove the driver air bag module.

Installation Procedure

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1. 2. 3. 4.

Install the connector to the driver air bag module. Align the retaining pins on the driver air bag module with the steering wheel. Push the driver air bag module to secure. Enable the SIR. Refer to SIR Disabling and Enabling .

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Instrument Cluster Replacement (C100/Long Body) Removal Procedure

1. Remove the instrument cluster trim panel. Important: Perform the SPO reprogramming when instrument cluster replaced. 2. Remove the screws and the instrument cluster.

Installation Procedure Notice: Refer to Fastener Notice in the Preface section.

1. Install the instrument cluster with the screws. Tighten Tighten the instrument cluster screws to 2 N·m (18 lb in). 2. Install the instrument cluster trim panel.

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Instrument Cluster Replacement (C105/Short Body) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 2. Remove the steering column cover. Refer to Steering Column Trim Covers Replacement .

3. Remove the instrument cluster trim panel. Important: Perform the SPO reprogramming when instrument cluster replaced. 4. Remove the screws and the instrument cluster. 5. Disconnect the electrical connectors.

Installation Procedure 1. Connect the electrical connectors. Notice: Refer to Fastener Notice in the Preface section.

2. Install the instrument cluster with the screws. Tighten Tighten the instrument cluster screws to 2 N·m (18 lb in). 3. Install the instrument cluster trim panel. 4. Install the steering column cover. Refer to Steering Column Trim Covers Replacement . 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Lifting and Jacking the Vehicle Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Caution: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure: • Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure.

• • • •

The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.

Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Vehicle Lifting Points

(1) Frame Contact Lift - Front (2) Frame Contact Lift - Rear

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Lower Control Arm Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

3. Remove the cotter pin and the nut that retains the control arm ball joint to the knuckle. 4. Separate the ball joint from the knuckle assembly.

5. Remove the control arm to cradle bolts and nuts. 6. Remove the control arm.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the control arm to cradle front bolt and nut. Tighten Tighten the front bolt and nut to 120 N·m (89 lb ft). 2. Install the control arm to cradle rear bolts and nuts.

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2. Install the control arm to cradle rear bolts and nuts. Tighten Tighten the rear bolts and nuts to 70 N·m (52 lb ft).

3. Install the control arm ball joint to the knuckle. 4. Install the nut to the ball joint stud. Tighten Tighten the control arm ball joint nut to 10 N·m (89 lb in). 5. Install the cotter pin. 6. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation . 7. Lower the vehicle.

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Radio Replacement Removal Procedure

1. Disconnect the negative battery cable. 2. Remove the I/P center trim panel.

3. Remove the screws and the audio system. 4. Disconnect the audio system electrical connectors.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Connect the audio system electrical connectors. 2. Install the audio system with the screws. Tighten Tighten the audio system screws to 4 N·m (35 lb in).

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3. Install the I/P center trim panel. 4. Connect the negative battery cable.

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CHEVROLET CAPTIVA BODY REPAIR MANUAL 2007 TO MODEL INDEX

Repairs and Inspections Required After a Collision Caution: Proper operation of the SIR sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment in a collision or deployment for conditions less severe than intended. • If any supplemental inflatable restraints (SIR) components are damaged, they must be replaced. If SIR components mounting points are damaged, they must be repaired or replaced. • Never use SIR parts from another vehicle. This does not include remanufactured parts purchased from an authorized source. • Do not attempt to service the sensing and diagnostic module (SDM), the steering wheel module coil, or other air bag modules. These items must be replaced if they are defective. • Verify the part number of replaced air bag modules. Some inflator modules look identical but contain different internal components.

Accident with Deployment Component Replacements All SIR components must be replaced after a frontal crash involving air bag deployment. After deployment, a powdery residue may be on the surface of the air bag. The powder consists primarily of cornstarch, used to lubricate the bag as it inflates, and by-products of the chemical reaction. The sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium bicarbonate, also known as baking soda. Therefore, it is unlikely that sodium hydroxide will be present after deployment. Replace the following SIR components. Caution: Safety precautions must be followed when handling a deployed inflator module (air bag). After deployment, the inflator module (air bag) surface may contain a small amount of sodium hydroxide, a by-product of the deployment reaction, that is irritating to the skin and eyes. Most of the powder on the inflator module (air bag) is harmless. as a precaution, wear gloves and safety glasses when handling a deployed inflator module (air bag), and wash your hands with mild soap and water afterwards. • The SDM • Air bag modules (as needed) and pretensioners • SIR wiring • Clock spring

Accident without Deployment Component Inspection The following inspections must be performed after any crash, whether the air bag has deployed or not: • The steering column must be dimensionally inspected. • Inspect the knee bolsters and mounting points for distortion, bending and cracking or other damages. • Inspect the instrument panel (I/P) and steering column reinforcement plate for distortion, bending and cracking or other damage. • Inspect the I/P braces for distortion, bending and cracking or other damage. • Inspect the seat belt and mounting points. Refer to Seat Belt System Description and Operation .

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Rocker Panel Molding Replacement Removal Procedure

1. Remove the front mud guards. 2. Remove the clips and the rocker panel molding.

Installation Procedure

1. Install the rocker panel molding with the clips. 2. Install the front mud guards.

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Seat Belt Retractor Replacement - No. 1 Rear Removal Procedure

1. Remove the bolt (1) and the seat belt anchor on the wheelhouse trim panel. 2. Remove the quarter window trim panel. 3. Remove the wheelhouse trim panel.

4. Remove the bolt (1) and the seat belt anchor (2).

5. Remove the bolt (1) and the seat belt retractor (2).

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

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1. Install the seat belt retractor (2) with the bolt (1). Tighten Tighten the seat belt retractor bolt to 38 N·m (28 lb ft). Notice: Refer to Fastener Notice in Cautions and Notices.

2. Install the seat belt anchor (2) with the bolt (1). Tighten Tighten the seat belt anchor bolt to 38 N·m (28 lb ft). 3. Install the wheelhouse trim panel. 4. Install the quarter window trim panel.

5. Install the seat belt anchor with the bolt (1). Tighten Tighten the seat belt anchor bolt to 38 N·m (28 lb ft).

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Seat Belt Retractor Replacement - No. 2 Rear Removal Procedure

1. Remove the bolt (1) and the seat belt anchor (2) on the floor. 2. Remove the quarter window trim panel. 3. Remove the wheelhouse trim panel.

4. Remove the bolt (1) and the seat belt anchor (2).

5. Remove the bolt (1) and the seat belt retractor (2).

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

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1. Install the seat belt retractor (2) with the bolt (1). Tighten Tighten the seat belt retractor bolt to 38 N·m (28 lb ft). Notice: Refer to Fastener Notice in Cautions and Notices.

2. Install the seat belt anchor (2) with the bolt (1). Tighten Tighten the seat belt anchor bolt to 38 N·m (28 lb ft). 3. Install the wheelhouse trim panel. 4. Install the quarter window trim panel.

5. Install the seat belt anchor with the bolt (1)to the floor. Tighten Tighten the seat belt anchor bolt to 38 N·m (28 lb ft).

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SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views . There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. Condition

Action

If the vehicle was involved in an accident with an air bag deployment.

Disconnect the negative battery cable(s) *. Refer to Repairs and Inspections Required After a Collision .

When performing SIR diagnostics.

Follow the appropriate SIR service manual diagnostic procedure(s) *

When removing or replacing an SIR component or a component attached to an SIR component.

Disconnect the negative battery cable(s) *

If the vehicle is suspected of having shorted electrical wires.

Disconnect the negative battery cable(s) *

When performing electrical diagnosis on components other than the SIR system.

Remove the SIR/Airbag fuse(s) when indicated by the diagnostic procedure to disable the SIR system

* DTCs will be lost when the negative battery cable is disconnected. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply.

General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity:

• Do not expose inflator modules to temperatures above 65°C (150°F). • Verify the correct replacement part number. Do not substitute a component from a different vehicle. • Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater:

• • • • • •

Inflatable restraint sensing and diagnostic module (SDM) Any Inflatable restraint air bag module Inflatable restraint steering wheel module coil Any Inflatable restraint sensor Inflatable restraint seat belt pretensioners Inflatable restraint Passenger Presence System (PPS) module or sensor

Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics or Electrical Center Identification Views . 4. Wait 1 minute before working on the system.

Enabling Procedure - Air Bag Fuse 1. 2. 3. 4.

Place the ignition in the OFF position. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics or Electrical Center Identification Views . Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle .

Disabling Procedure - Negative Battery Cable 1. 2. 3. 4.

Turn the steering wheel so that the vehicles wheels are pointing straight ahead. Place the ignition in the OFF position. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnect/Connect Procedure . Wait 1 minute before working on system.

Enabling Procedure - Negative Battery Cable 1. 2. 3. 4.

Place the ignition in the OFF position. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnect/Connect Procedure . Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle .

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Tail Lamp Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

2. Disconnect the electrical connectors. 3. Remove the nuts and the lamp assembly. 4. Remove any inoperative bulb.

Installation Procedure

1. Install the replacement bulbs. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the lamp assembly with the nuts. Tighten Tighten the rear combination lamp assembly nuts to 2.5 N·m (22 lb in). 3. Connect the electrical connectors. 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Tire and Wheel Removal and Installation Removal Procedure

1. 2. 3. 4. 5.

Remove the wheel cover, if equipped. Use paint or a felt tipped pen in order to mark the relationship of the wheel to the hub. Loosen the wheel nuts. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the wheel nuts. Caution: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident. Notice: Removing the wheel may be difficult because of foreign materials or a tight fit between the wheel and the hub/rotor. Slightly tap the tire side wall with a rubber mallet in order to remove the wheel. Failure to follow these instructions may result in damage to the wheel.

6. If the tire and wheel assembly is difficult to remove, perform the following steps: 6.1. Install the wheel nuts. 6.2. Loosen each wheel nut 2 revolutions. 6.3. Lower the vehicle. 6.4. Rock the vehicle from side to side. 6.5. Start the engine. 6.6. Drive the vehicle forward slightly. 6.7. Apply the brakes quickly and firmly. 6.8. Drive the vehicle backward slightly. 6.9. Apply the brakes quickly and firmly. 6.10. Remove the wheel nuts. 6.11. Repeat this procedure if necessary. 7. Remove the tire and wheel assembly from the vehicle.

Installation Procedure Caution: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. 1. Remove any corrosion or foreign material from the wheel and the hub. Clean the following surfaces: • The hub mounting surface.

• • • •

The brake rotor mounting surface. The wheel mounting surface. The threads on the studs. The threads on the wheel nuts.

2. Verify the nuts turn freely on the stud. 3. Replace any nut that does not turn freely on the stud. 4. If a NEW nut does not turn freely on the stud, replace the 5 studs on the hub. Refer to Wheel Stud Replacement in order to replace the front wheel studs. Refer to Wheel Stud Replacement in order to replace the rear wheel studs.

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5. Align the match marks and install the tire and wheel assembly to the hub. Caution: Never use oil or grease on studs or nuts. Tighten the wheel nuts with your fingers until they are snug. Then, tighten the nuts (in the sequence shown) to the fastener tightening specification shown in Specifications in this Section. Improperly tightened wheel nuts could eventually allow the wheel to come off while the vehicle is moving, possibly causing loss of control, personal injury, and property damage. Notice: Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. 6. Install the wheel nuts in the sequence shown. Do not tighten the wheel nuts. 7. Lower the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 8. Tighten the wheel nuts in the sequence shown. Tighten Tighten the wheel nuts to 125 N·m (92 lb ft). 9. Install the wheel cover, if equipped.

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Water Hose Test

1. Place another person inside the vehicle in order to detect the location of the leak. 2. Use a water hose without a nozzle.

3. Begin spraying the water at the base of the suspected leak area. Continue spraying the water upward until the leak is found.

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Dome Lamp Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

2. 3. 4. 5.

Pry off the dome lamp lens by inserting a screwdriver into the recess along the edge of the lens. Remove the screws and the dome lamp housing from the headliner. Disconnect the electrical connector. Remove the bulb.

Installation Procedure

1. Install the replacement bulb. 2. Connect the electrical connector. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the dome lamp housing to the headliner with the screws. Tighten Tighten the dome lamp housing screw to 2 N·m (18 lb in). 4. Press the dome lamp lens onto the housing. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection

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Exterior Windnoise Caution: An assistant should drive the vehicle while the technician checks for the location of the reported condition. Otherwise, personal injury could result. Exterior windnoise is louder when the vehicle is driven with one or more windows down. Exterior windnoise occurs when air passes over the body panels, the seams, or the openings. Use the following items during the test drive in order to aid in the detection of leaks: • Mechanic's stethoscope or heater hose • Masking tape-51 mm (2 in) width • Strip caulk • A water soluble marking pencil 1. While driving, determine the location of the exterior windnoise by lowering one window at a time. If the location corresponds with the condition in step 2, pull over and make a temporary repair with 51 mm (2 in) wide masking tape. 2. Tape over the gaps and the moldings one at a time. Test between each taping. Taping over the gaps and moldings will correct the condition. 3. Temporarily repair the condition with masking tape. Adjust the tape when needed. 4. Continue testing in order to determine if the noise has been eliminated or other leak areas exist. 5. When all the reported leak conditions are located, make permanent repairs using the proper alignment techniques and the sealing materials.

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Fender Liner Replacement Removal Procedure

1. 2. 3. 4. 5.

Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the front wheel. Refer to Tire and Wheel Removal and Installation . Remove the front mud guard. Refer to Guard Mud - Rear (One or Both) Replacement . Remove the engine protection shield. Refer to Engine Protection Shield Replacement . Remove the screws and the front fender liner.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the screws and the front fender liner. Tighten Tighten the front fender liner screws to 4 N·m (35 lb in). 2. 3. 4. 5.

Install the engine protection shield. Refer to Engine Protection Shield Replacement . Install the front mud guard. Refer to Guard Mud - Rear (One or Both) Replacement . Install the front wheel. Refer to Tire and Wheel Removal and Installation . Lower the vehicle.

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Front Fender Wheel Opening Molding Replacement Removal Procedure

1. Remove the front mud guards. 2. Remove the screws and front fender wheel opening molding.

Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the front fender wheel opening molding with the screws. Tighten Tighten the front fender wheel opening molding screws to 4 N·m (35 lb in). 2. Install the front mud guard.

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Headlamp Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 2. Remove the radiator grille upper cover.

3. Remove the bolts and the headlamp assembly.

4. Disconnect the headlamp assembly electrical connectors.

5. Remove the cap that conceals the headlamp bulb. 6. Disconnect the headlamp bulb electrical connectors. 7. Remove the headlamp bulbs.

Installation Procedure

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1. Install the headlamp bulbs. 2. Connect the headlamp bulb electrical connectors. 3. Install the cap that conceals the headlamp bulbs.

4. Connect the headlamp assembly electrical connectors. Notice: Refer to Fastener Notice in Cautions and Notices.

5. Install the headlamp assembly with the bolts. Tighten Tighten the headlamp assembly bolts to 7 N·m (62 lb in). 6. Install the radiator grille upper cover. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Heater and Air Conditioning Control Replacement (C105/Short Body) Removal Procedure Caution: Refer to Battery Disconnect Caution in the Preface section.

Important: The left-hand drive is shown. The right-hand drive is similar. 1. 2. 3. 4. 5. 6. 7.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the instrument panel accessory bezel. Refer to Instrument Panel Accessory Bezel Replacement . Remove the control assembly retaining screws. Pull out the unit to gain access to the rear. Disconnect the electrical connectors. Remove the air inlet tube. Remove the automatic temperature control assembly.

Installation Procedure

1. Connect the air inlet tube. 2. Connect the electrical connectors. Notice: Refer to Fastener Notice in the Preface section. 3. Position the automatic temperature control assembly and install the retaining screws. Tighten Tighten the control assembly retaining screws to 2.5 N·m (22 lb in). 4. Install the instrument panel accessory bezel. Refer to Instrument Panel Accessory Bezel Replacement . 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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Heater and Air Conditioning Control Replacement (C100/Long Body) Removal Procedure Caution: Refer to Battery Disconnect Caution in the Preface section.

Important: The left-hand drive is shown. The right-hand drive is similar. 1. 2. 3. 4. 5. 6. 7.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the instrument panel accessory bezel. Refer to Instrument Panel Accessory Bezel Replacement . Remove the control assembly retaining screws. Pull out the unit to gain access to the rear. Disconnect the electrical connectors. Remove the air inlet tube. Remove the automatic temperature control assembly.

Installation Procedure

1. Connect the air inlet tube. 2. Connect the electrical connectors. Notice: Refer to Fastener Notice in the Preface section. 3. Position the automatic temperature control assembly and install the retaining screws. Tighten Tighten the control assembly retaining screws to 2.5 N·m (22 lb in). 4. Install the instrument panel accessory bezel. Refer to Instrument Panel Accessory Bezel Replacement . 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .