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Daewoo TACUMA, Body Repair Manual, Page: 3 / 126

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Daewoo TACUMA Body Repair Manual Download Page 3

HOW TO USE THIS MANUAL

This manual covers the repairs of TACUMA/REZZO au-
tomobile which has been involved in accidents, and it de-
scribes the work related to the replacement of damaged
body parts.
Please read through these instructions and familiarize
yourself with them before actually using this manual.

NOTE: REFER TO TACUMA/REZZO

SERVICE MANUAL FOR SPECIFI-

CATIONS, WIRE HARNESS LOCA-

TIONS, SAFETY STAND SUPPORT

POINTS, ETC.

SPECIAL INFORMATION

WARNING: Indicates a strong possibility of personal in-
jury or equipment damage if instructions are not followed.

NOTE: Gives helpful information.

CAUTION: Detailed descriptions of standard workshop
procedures, safety principles and service operations are
not included. Please note that this manual does contain
warnings and cautions against some specific service
methods which could cause PERSONAL INJURY, or
could damage a vehicle or make it unsafe. Please un-
derstand that these warnings cannot cover all conceiv-
able ways in which service, whether or not recom-
mended by DAEWOO might be done or of the possible
hazardous consequences of each conceivable way, not
could DAEWOO investigate all such ways. Anyone us-
ing service procedures or tools, whether or not recom-
mended by DAEWOO, must satisfy himself thoroughly
that neither personal safety or tools, whether or not rec-
ommended by DAEWOO, must satisfy himself thor-
oughly that neither personal safety or vehicle safety will
be jeopardized.

All information contained in this manual is based on the
latest product information available at the time of print-
ing. We reserve the right to make changes at any time
without notice. No part of this publication may be repro-
duced, stored in retrieval system, or transmitted, in any
form by any means, electronic, mechanical, photocopy-
ing, recording, or otherwise, without the prior written
permission of the publisher. This includes text, figures
and tables.

DAEWOO MOTOR CO., LTD.

INCHON, KOREA

SERVICE NOTICE

Summary of Contents for TACUMA

Page 1: ...BODY REPAIR MANUAL TACUMA ...

Page 2: ...RAME REPAIR EQUIPMENT 1 2 3 4 5 6 7 8 9 10 11 BODY REPAIR MANUAL TACUMA FOREWORD This manual includes procedure for maintenance adjustment service operation and removal and in stallation of components All information illustrations and specifications con tained in this manual are based on the latest prod uct information available at the time of manual approval The right is reserved to make changes ...

Page 3: ...ehicle or make it unsafe Please un derstand that these warnings cannot cover all conceiv able ways in which service whether or not recom mended by DAEWOO might be done or of the possible hazardous consequences of each conceivable way not could DAEWOO investigate all such ways Anyone us ing service procedures or tools whether or not recom mended by DAEWOO must satisfy himself thoroughly that neithe...

Page 4: ...rd below the dashboard panel SRS harness is covered with a yellow corrugated tube Care should be taken not to damage the harness when repairing this area 3 Do not apply heat of more than 80 C 176 F when drying painted surfaces anywhere around the loca tions of SRS parts 4 If strong impact or high temperature needs to be applied to the areas around the locations of SRS parts remove the part before ...

Page 5: ...NTS GENERAL INSTRUCTION 1 2 IMPORTANT SAFETY NOTICE 1 2 BODY SAFETY 1 3 LOADS ON BODY PARTS 1 3 USE OF NEW HIGH QUALITY MATERIALS 1 3 CORROSION PROTECTION 1 3 SUMMARY 1 3 ZINC TREATED STEEL PLATE REPAIR 1 4 TECHNICAL ILLUSTRATION 1 6 BODY REPAIR PROCEDURES 1 14 ...

Page 6: ... leaks and repair as necessary Remove the fuel tank and or fuel lines if welding equipment is to be used near the fuel system Before welding sanding or cutting protect carpets and seats with fire proof covers Follow standard safety practices when using toxic or flammable liquids Use standard safety equipment when spraying paint welding cutting sanding or grinding Standard safety equipment includes...

Page 7: ...e this corrosion protection must be pre served or restored when repairs are carried out 7 SUMMARY All DAEWOO vehicles are built to the highest stan dards in terms of styling and material properties These high quality standards must be maintained when accident repairs are carried out Mistakes made when carrying out repair operations such as straightening welding sheet metal parts etc not only produ...

Page 8: ...aces thoroughly to pre vent rust 2 The electric continuity properties of zinc plated steel plate is different from ordinary steel plate When spot welding increase the current by 10 20 or increase the resistance welding time Increase the number of weld spots by 10 20 also NOTE The MIG welding procedures for zinc plated steel plate are the same as for ordinary steel plate CAUTION To prevent eye inju...

Page 9: ...GENERAL INFORMATION 1 5 BLANK ...

Page 10: ...1 6 GENERAL INFORMATION Fig 3 9 TECHNICAL ILLUSTRATION ...

Page 11: ...iller Inner 11 Rail Roof Side 12 Extension Side Inner Front 13 Panel Side Inner Rear 14 Bracket Trim Mounting Rear Upper 15 Reinforce D Filler Rear 16 Reinforce C Filler 17 Reinforce Retract Rear 18 Rear Seat Belt Upper 19 Patch Wheel House Inner 20 Patch Wheel House Inner 21 Front Door Hinge 22 Front Door Hinge Upper 23 Front Filler Upper 24 Rocker Front 25 Seat Belt Front 26 Rear Door Hinge 27 P...

Page 12: ...1 8 GENERAL INFORMATION Fig 4 ...

Page 13: ...al Outer Rear 30 Patch Reinf Longitudinal Outer 31 Reinf W Carrier Rear 32 Extension Front Longitudinal 33 Brace Front Longitudinal 34 Longitudinal Front Inner 35 Reinf Front Longitudinal Inner 36 Support Crossmember Radiator Inner 37 Longitudinal Front Inner 38 Reinf Stay Front Bumper 39 Support Crossmember Radiator Outer 40 Cap Brake Booster 41 Panel Dash Lower Inner 42 Panel Dash Lower 43 Cross...

Page 14: ...1 10 GENERAL INFORMATION Fig 5 ...

Page 15: ...uter 17 Crossmember Rear Floor Center 18 Panel Floor Side Rear 19 Longitudinal Rear 20 Reinf Rear Longitudinal Rear 21 Hanger Extension Pipe Rear Inner 22 Hanger Extension Pipe Rear Inner 23 Crossmember Rear Floor Center Side 24 Reinf Rear Longitudinal 25 Crossmember Rear Floor Rear 26 Crossmember Rear Floor Rear Side 27 Panel Rear Floor Rear Side 28 Crossmember Rear Floor Front 29 Support Rear Se...

Page 16: ...1 12 GENERAL INFORMATION Fig 6 ...

Page 17: ...e 4 Dash Panel Lower 5 Front Longitudinal 6 Brace Wheel House 7 Fender 8 Reinf Front Filler Lower 9 Side Body 10 Front Door 11 Rear Door 12 Floor Panel Side 13 Rear Frame 14 Front Floor 15 Rear Floor 16 Back Panel Lower 17 Tail Gate 18 Roof 19 Engine Hood 20 Dash Panel Upper ...

Page 18: ...nsions for correct position and preinstall the exte rior parts and check the clearances and level differences Perform a trial welding and the main welding Finish the welding areas and even out the flanges for a close fit Apply the sealer to the matching and over lapped surface Apply the undercoat to the required areas Apply the paint Apply the deadner to the designated areas Coating the anti rust ...

Page 19: ...PREPARATIONS OF BODYWORK 2 1 SECTION 2 PREPARATIONS OF BODYWORK CONTENTS GENERAL DESCRIPTION 2 2 CHECKPOINTS 2 3 CORRECTION OF THE DAMAGED AREA 2 4 MEASURING SYSTEMS WITHOUT SMALL DAMAGE 2 5 ...

Page 20: ...meeting the functions of the body as a whole Damage to the exterior of the body can be inspected visually but where there has been an external impact it is necessary to inspect the extent of the damage In some cases the deformation has spread beyond the actual areas which were in the collision and so this has to be inspected closely Unit mm Front wheel alignment 25 45 Manual steering 1 30 1 Power ...

Page 21: ...ering wheel Is there any deformation in the column and the column mounted parts 11 Is there any oil or water leakage and damage to the engine transmission or brakes 12 Is there any irregular noise in the gear changing operation engine and transmission rotation 13 Are there any traces of contact between the engine block and the center crossmember 14 Is there any damage to brake or fuel lines or wir...

Page 22: ...horizontal pinch welds for anchoring the car Fig 2 Apply load to the damaged section and pull it out until the section is almost restored to the original shape Underbody Clamp Specifications U type U Base Pro Tec etc Frame correctors C type Korek Auto pole etc Standard type Dataliner Car o liner Celette Flex o liner etc UNDERBODY CLAMPS STANDARD TYPE C TYPE U TYPE ...

Page 23: ... B POINTER C Adjust this to the diameter of the wheel disc Adjust this to the automobile ADJUST SCREW C ADJUST SCREW B POINTER A SET RING POINTER 4 HEIGHT FRAME FRAME A CLIP SET SCREW 4 MEASURING SYSTEMS WITHOUT SMALL DAMAGE Whenever possible make judgements and conclu sions based on measurement Measure the wheel alignment see pages 2 2 2 3 so as to prevent any future trouble like unsymmetrical we...

Page 24: ...OOLS 3 1 SECTION 3 WELDING AND TOOLS CONTENTS SPOT WELDING 3 2 General description 3 2 Welding conditions 3 2 Welding strength test 3 3 GAS WELDING 3 4 CARBON DIOXIDE ARC WELDER 3 5 MIG ARC WELDING REPAIR TOOLS 3 6 ...

Page 25: ...neration of distortion to the absolute minimum However please remember to remove all paint and other impurities from the surface of the material you intend to weld for reli able results 1 2 WELDING CONDITIONS When performing spot welding make absolutely sure that you conform to the conditions governed by the current conductivity time welding pressure holding time and shutdown time recommended for ...

Page 26: ...plate of the same thick ness and conduct a destruction test If holes appear in the steel plates this means that the welding is standard strength Drive a wedge between two panels near the nug get If the welded parts do not come apart and the diameter of the nugget appears more than 3 mm the welding should be satisfactory Fig 4 Stop inserting the wedge when the full size of the nugget appears WEDGE ...

Page 27: ...is not possible to perform spot welding because of space restrictions plug welding based on the arc welding method may be performed instead Here the welding sections must be close together 2 GAS WELDING Gas welding is indispensable for body repair because of the broad range of its applications from joining the body panels cutting the materials that construct the body and applying heat to reform pa...

Page 28: ... of applications including butt welding of thin plate fillet welding plug welding and MIG spot weld ing In terms of the weld strength it is also highly stable Welding the bending angle of a flange Melting the finger end of a flange Fig 6 WELDERS WELDING METHODS Fig 7 SINGLE PHASE 110V THREE PHASES 200 240V WELDING TORCH WELDING POWER SUPPLY BUILT IN WIRE FEED MECHANISM CARBON DIOXIDE OR ARGON CARB...

Page 29: ...s 5 Overalls with long sleeves 6 Dust proof mask 7 Protective apron 8 Welding gloves 9 Foot protectors 10 Safety shoes 11 Work gloves 12 Spattering guard Protective tools Vehicle body Plug hole drilling Processing tools 1 2 3 4 5 6 7 8 9 10 11 Heat resistant protective cover 12 PUNCH DRILLING BLADE DRILL SPOT CUTTER PRESSURE DRILL ...

Page 30: ... Work Tools equipment used Base metal fixing Fixing tools Skin panel shaping Shaping tools Body frame shaping SCREW CLAMP VISE GRIPS SQUILL VISE HAMMERS DOLLIES FILE FILE HOLDER SPOONS SNIPS SHEARS WELDER BODY JACK SLIDER HAMMER ...

Page 31: ...ools equipment used Measuring Measuring tools Edge preparation Flange tools Cutting tools Cleaning DISC SANDER Air type Electric type BELT SANDER Sanding tools AIR IMPACT CUTTER AIR JIGSAW HAND NIBBLER HANDSAW CHISEL RULES CONVEX RULES ...

Page 32: ...dure 4 3 2 FRONT WHEELHOUSE 4 6 General description 4 6 Repair procedure 4 7 3 FRONT LONGITUDINAL 4 11 General description 4 11 Repair procedure 4 11 4 SUPPORT CONTROL ARM 4 14 General description 4 14 Repair procedure 4 15 5 FRONT PILLAR 4 18 General description 4 18 Repair procedure 4 20 ...

Page 33: ... front wheelhouse and front longitudinal It forms the base for the headlamps and other parts and maintains the rigidity of the front section of the body Pay particular attention to twists and parallelism and check mounting of related parts when welding Fig 1 Front Welding Assembly ...

Page 34: ... the body level Jack up the body and place safety stands at the four designated places of the frame door open ing Fig 2 4 Cut and pry off the front panel Center punch around the spot weld imprints Use the special spot cutter to drill holes at the spot weld nuggets on the front wheel house and longitudinal NOTE When drilling holes be careful not to drill down to the front wheelhouse and longitudina...

Page 35: ...fety shoes Fig 4 NOTE Make sure that the right and left front panels are in line with each others 7 Measure the front compartment diagonally Measure the front compartment diagonally with a tracking gauge or convex rule as shown to check it for twisting or bending Temporarily assemble the fender head lamps and hood then check the clearances and level differences Fig 5 Fig 6 8 Perform the main weldi...

Page 36: ...re in a safe place and keep it away from sparks flames or cigarettes Fig 7 12 Coating the anti rust agents Coating the anti rust agents to the end of front panel side and the door hinge areas 13 Install the related parts Engine radiator and related parts Aircon condenser and related parts Head lamps and fenders Hood radiator grill and bumper Others Install in the reverse order in which they were r...

Page 37: ...nstructed as a unit with the locator shockabsorber Therefore replace ment of the component affects the front wheel alignment When assembling it either use a jig or follow dimen sions on the body repair chart for positioning It must be welded carefully Fig 9 Front Wheelhouse Welding Assembly ...

Page 38: ...rints Use the special spot cutter to drill holes at the spot weld nuggets on the brace wheelhouse Remove the MIG weld areas with a disc sander Fig 10 CAUTION To prevent eye injury wear goggles or safety glasses whenever sanding cutting or grind ing Using a chisel pry off the welded flange from the front body puller and wheelhouse 4 Peel off the undercoat and sealer Heat the undercoat and sealer at...

Page 39: ...sections for temporary instal lation CAUTION To prevent eye injury and burns when welding wear an approved welding helmet gloves and safety shoes 8 Measure the front compartment diagonally Measure the front compartment diagonally with a tracking gauge or convex rule to check it for twist ing or bending Temporarily assemble the fender and hood then check the clearances and level differences 9 Perfo...

Page 40: ...ce wheelhouse matching area as shown 11 Weld the brace wheelhouse Spot weld the brace wheelhouse as shown Make MIG or gas welds at the door hinge areas 3 7 6 6 6 2 2 1 2 2 5 12 3 7 5 7 3 3 11 6 1 1 11 4 2 2 WHEN REPLACING THE FRONT SIDE ONLY 3 3 5 2 5 3 2 6 1 12 1 7 5 11 3 SEALER TAPE Fig 16 12 Finish the welding areas Use a hammer and dolly to even out the rear wheelhouse and front longitudinal f...

Page 41: ...tes 16 Coating the anti rust agents Coating the anti rust agents to the end of front panel side and the door hinge areas 17 Install the related parts Wiring harness instrument panel and related parts Parts of the passenger compartment Parts to be installed when install the front panel Others Install in the reverse order in which they were re moved NOTE After install the all related parts rub in gr...

Page 42: ...ut the damage makes repair of the related parts difficult Do not pull out more than necessary NOTE Check the condition of the door and hinges 3 Peel off the undercoat and sealer Heat the undercoat and sealer at the welding ar eas of the damaged parts with a gas torch and peel off the undercoat and sealer with a steel spatula CAUTION Be careful not to burn the fittings inside the passenger compartm...

Page 43: ...ck that the both front longitudinal and wheelhouse are parallel Tack weld the clamped section for temporary in stallation 7 Perform the main welding Weld as much as possible with the jig still mounted Make MIG or gas welds at the butt joints at the front longitudinal carefully Fig 19 3 5 12 3 7 5 7 3 3 11 6 1 1 11 2 2 Spot weld the wheelhouse with the front longitu dinal flange areas and front pan...

Page 44: ...mable Store in a safe place and keep it away from sparks flames or cigarettes 12 Coating the anti rust agents Coating the anti rust agents to the end of front panel side and the front door hinge areas 13 Install the related parts Clean the passenger compartment Wiring harness instrument panel and related parts Parts of the passenger compartment Chassis components Engine radiator and related parts ...

Page 45: ...itudi nal and crossmember front floor panel It forms the base for the front suspension and is maintaining the rigidity of the front parts Pay particular attention to the posi tion and dimensions of the weld joints and weld care fully 2 2 2 3 4 Fig 22 Support Control Arm Welding Assembly 15 14 2 2 15 12 12 12 ...

Page 46: ...ed places of the frame door open ing If necessary place safety stands at the rear of frame 4 Peel off the undercoat sealer and deadner Heat the undercoat and sealer at the welding ar eas of the longitudinal cross member front floor panel and front floor panel with a gas torch and peel off the under with a steel spatula Peel off the deabner at the surface or front floor CAUTION Be careful not to bu...

Page 47: ...elding Plug weld the holes of support control arm with a MIG welder CAUTION To prevent eye injury and burns when welding wear an approved welding helmet gloves and safety shoes 9 Finish the welding areas Level the plug welded areas with a disc sander 10 Apply the sealer Apply the sealer to the inside of passenger com partment joint areas 11 Apply the undercoat Undercoat to the surface of front flo...

Page 48: ...nstall in the reverse order in which they were re moved NOTE After install the all related parts rub in grease to the moving parts and replenish cooling liquid break oil aircon gas and others 15 Check and adjust Measure the front wheel alignment Check clearances and level differences Check the hood locking and unlocking condition Adjust the head lamp aim Check all operation Check for gas oil and l...

Page 49: ...ield door hinges and floor frame and is important as a support for the front side of the cabin Connection of the front pillar determines the position of the windshield and front door Align the fender door and windshield while the front pillar is temporary mounted and check the clearances and level differences Fig 26 Front Pillar Welding Assembly ...

Page 50: ...do not pull out more than necessary CAUTION To prevent eye injury wear goggles or safety glasses whenever sanding cutting or grind ing Using a chisel pry off the welded flange from the front body pillar and wheelhouse Fig 27 3 Remove the brace wheelhouse Center punch around the spot weld imprints Use the special spot cutter to drill holes at the spot weld nuggets on the brace wheelhouse Remove the...

Page 51: ... prevent eye injury wear goggles or safety glasses whenever sanding cutting or grind ing 6 Mold damaged related parts Fill any holes drilled by welding CAUTION To prevent eye injury and burns when welding wear an approved welding helmet gloves and safety shoes Use a hammer and dolly to mold damaged areas of the remaining inner panel and even out the welding flanges 7 Set the new front pillar Align...

Page 52: ...condition Increase the number of spot by 20 for areas to be spot welded Fig 32 9 Finish the welding areas Level the gas or MIG welded areas with a disc sander then even out high areas with a hammer being care ful not to deform them CAUTION To prevent eye injury wear goggles or safety glasses whenever sanding cutting or grinding Use a hammer and dolly to even out the spot welded flanges for a close...

Page 53: ...hing when painting Paint is flammable Store in a safe place and keep it away from sparks flames or cigarettes 16 Coating the anti rust agents Coating the anti rust agents to the end of front panel side and the door hinge areas 17 Install the related parts Clean the passenger compartment Windshield cowl and wiper Wiring harness instrument panel and related parts Carpet trims and weatherstrip Door F...

Page 54: ...ECTION 5 ROOF BACK PANEL AND REAR FLOOR PANEL CONTENTS 1 ROOF 5 2 General description 5 2 Repair procedure 5 3 2 BACK PANEL 5 7 General description 5 7 Repair procedure 5 8 3 REAR FLOOR PANEL 5 11 General description 5 11 Repair procedure 5 12 ...

Page 55: ...highly noticeable in terms of the vehicle s outer appearance Before replac ing the roof make sure that the body is horizontal Before welding the roof panel adjust the frame door opening flanges so that they contact the roof panel Pay particular attention to twists and parallelism Fig 1 Roof Welding Diagram ...

Page 56: ... a chisel pry off the roof panel along the bold lines as shown Center punch around the spot weld imprints of the roof welded flange Drill holes using the spot cutter Using a chisel and a disc sander pry off the welded flange from the front rear body pillar and roof panel Level and finish the burrs of welded flanges with a disc sander CAUTION To prevent eye injury wear goggles or safety glasses whe...

Page 57: ...ody pillar inner for temporary instal lation Set the new roof panel and clamp again Temporarily set the windshield and rear glass and check the roof panel for proper installation Install the roof molding and check the clearance and outer appearance 8 Apply the sealer to the roof frames Dismantle the new roof panel again Apply the sealer to one groove of the rail wind shield header two grooves of t...

Page 58: ...e and keep it away from sparks flames or cigarettes 12 Apply the deadner Apply the deadner to the front inside of roof panel as shown 9 Perform the main welding and finish Spot weld the roof panel CAUTION To prevent eye injury and burns when welding wear an approved welding helmet gloves and safety shoes Perform a trial welding first and check the weld ing condition Increase the number of spot by ...

Page 59: ... wiper and related parts Wiring harness and headlining Pillar trims door weatherstrip and others Install in the reverse order in which they were re moved 14 Check and adjust Clean the passenger compartment Check the windshield and rear glass for water leaks Check the room lamp and other all operation ...

Page 60: ...side panel outer rear extension longitudinal and extension rear floor It forms the base for the rear combination lamps and other parts and maintains the rigidity of the rear body Pay particular attention to twists and parallelism and check mounting of related parts when welding Fig 8 Back Panel Welding Assembly ...

Page 61: ...ng the back panel Attach the car to the frame straightener by tight ening the underbody clamps located at the jack up designated points on the bottom of the frame door opening 3 Cut and pry off the rear panel Center punch around the spot weld imprints with the rear side outer and extension rear floor panel Use the special spot cutter to drill holes at the spot weld nuggets on the rear side outer a...

Page 62: ...nstal lation CAUTION To prevent eye injury and burns when welding wear an approved welding helmet gloves and safety shoes 7 Measure and check Measure the trunk compartment diagonally to check it for twisting or bending and its correct position with the rear bumper installed Temporarily assemble the rear combination lamps and trunk then check the clearances and level differences 8 Perform the main ...

Page 63: ... if inhaled or swal lowed Read the paint label before opening paint con tainer Avoid contact with skin Wear an approved res pirator gloves eye protection and appropriate clothing when painting Paint is flammable Store in a safe place and keep it away from sparks flames or cigarettes 13 Install the related parts Clean the trunk compartment Install in the reverse order in which they were re moved 14...

Page 64: ...ody and it is critical for the rigidity of the rear body During replace ment refer to the body dimension chart or body repair chart and determine the position to set the rear floor properly Be sure that the rear floor is not bent or deformed Weld securely to maintain the rigidity of the rear body Fig 14 Rear Floor Welding Assembly ...

Page 65: ...nk and off lines 2 Roughly pull out and straighten the damaged area Check the damage and roughly pull out and re pair the related back panel side panel wheel house inner rear longitudinal and other damaged parts with the frame straightener before remov ing the extension rear floor panel rear floor panel and back panel Attach the car to the frame straightener by tight ening the underbody clamps loc...

Page 66: ...evel and finish the burrs from the pried off spot welds with disc sander Sand off the paint and undercoat from both sides of the flange to be welded Fig 18 FORWARD REAR FLOOR NEW REAR FLOOR CROSS MEMBER REAR SEAT 4 0 m m Grind both sides of the welding section of the rear floor and extension rear floor with a disk sander to remove the paint and expose the steel plate CAUTION To prevent eye injury ...

Page 67: ...Level the MIG welded areas with a disc sander then even out high areas with a hammer being careful not to deform them CAUTION To prevent eye injury wear goggles or safety glasses whenever standing cutting or grind ing FORWARD REAR FLOOR CROSS MEMBER REAR SEAT NEW REAR FLOOR Fig 20 Use a hammer and dolly to even out the spot welded areas for a close fill the flange surface together 11 Apply the sea...

Page 68: ...ly the deadner Clean the passenger and trunk compartment Apply the deadner to the surface of rear floor and extension rear floor 15 Install the related parts Install in the reverse order in which they were re moved 16 Check and adjust Check clearances and level differences Check the trunk locking and unlocking condition Check all operation Check for water leaks in the trunk compartment NOTE Use sp...

Page 69: ...UTER 6 1 SECTION 6 FRAME DOOR OPENING DOOR AND SIDE PANEL OUTER CONTENTS 1 FRAME DOOR OPENING 6 2 General description 6 2 Repair procedure 6 3 2 DOOR 6 6 Repair procedure 6 6 3 SIDE PANEL OUTER 6 8 General description 6 8 Repair procedure 6 9 ...

Page 70: ...frame door area and side outer area It forms the base for the front rear doors and other parts and maintains the rigidity of the doors and roof The frame door opening area should depend ing on the degree of damage be repaired as much as possible rather than repalced Repair by pulling out Fig 1 Frame Door Opening Welding Assembly ...

Page 71: ...pillar front and rear Cut the damaged area with a hand saw along the bold line as shown NOTE Be careful not to cut the inner panel This could result in extensive repair If the damage involves part of the center pillar cut them as shown Center punch around the spot weld imprints on the welded flange Use the special spot cutter to drill holes at the spot weld nuggets NOTE When drilling holes be care...

Page 72: ...being careful not to deform them CAUTION To prevent eye injury wear goggles or safety glasses whenever sanding cutting or grind ing Use a hammer and dolly to even out the spot welded flanges for a close fit with the surface of the frame door opening panel Fill in deformations and level differences of the welded areas with solder or putty then finish 8 Apply the sealer Apply the sealer to the match...

Page 73: ...e and keep it away from sparks flames or cigarettes 11 Coating the anti rust agents Coating the anti rust agents to the inside of frame door opening areas sufficiently 12 Install the related parts Clean the passenger compartment Wiring harness and related parts Seat belt assembly and carpet Trims and weather strips Door and others Install in the reverse order in which they were re moved 13 Check a...

Page 74: ...eck any deformation 5 Remove the new door Remove the four bolts from door assembly 6 Apply the paint CAUTION Ventilate when spraying paint Most paint contains substances that are harmful if inhaled or swal lowed Read the paint label before opening paint con tainer Avoid contact with skin Wear an approved respi rator gloves eye protection and appropriate cloth ing when painting Paint is flammable S...

Page 75: ...nstall the related parts Handle linkage and lock set Glass and window lifter Solenoid valve and wiring harness Install door trim and others NOTE Before install the door trim and related parts rub in grease to the moving parts and check all op eration 11 Check and adjust Check clearance and level differences Check the door locking and unlocking condition Check for water leaks in the passenger compa...

Page 76: ...frame door area The side outer area is a conspicuous part of the outer appearance of the vehicle It is espe cially important for the body line continuing from door Therefore pay particular attention to it when conducting work This part must be aligned with the rear door trunk lid rear glass and other parts Fig 9 Side Panel Outer Welding Assembly ...

Page 77: ...door opening along the bold lines as shown with a handsaw and snips carefully Center punch around the spot weld imprints with the rear panel side panel inner and arch area Use the special spot cutter to drill holes at the spot weld nuggets on the rear side outer panel NOTE When drilling holes be careful not to drill down to the side panel inner and rear panel themselves Cut the panel from the body...

Page 78: ...as with a disc sander then even out high areas with a hammer being careful not to deform them CAUTION To prevent eye injury wear goggles or safety glasses whenever sanding cutting or grind ing Use a hammer and dolly to even out the spot welded flanges for a close fit with the surface of the side panel outer Fill in deformations and level differences of the welded areas with solder or putty then fi...

Page 79: ... Wiring harness and related parts Seat belt assembly and carpet Trims and weather strips Door and others Install in the reverse order in which they were re moved 14 Check and adjust Check clearances and level differences Check the door locking and unlocking condition Check for water leaks in the passenger compart ment ...

Page 80: ...FENDER HOOD AND TRUNK LID 7 1 SECTION 7 FENDER HOOD AND TRUNK LID CONTENTS 1 FENDER 7 2 Repair procedure 7 2 2 HOOD 7 4 Repair procedure 7 4 3 TRUNK LID 7 6 Repair procedure 7 6 ...

Page 81: ... paint CAUTION Ventilate when spraying paint Most paint contains substances that are harmful if inhaled or swal lowed Read the paint label before opening paint container Avoid contact with skin Wear an approved res pirator gloves eye protection and appropriate clothing when painting Paint is flammable Store in a safe place and keep it away from sparks flames or cigarettes Fig 1 5 Coating the anti ...

Page 82: ...e hood and check the front and rear clear ances and level differences of the hood and door Fig 4 8 Tighten fully After checking and adjusting the mounting posi tion tighten all bolts fully 9 Install the related parts Install in the reverse order in which they were re moved 10 Check clearance Check clearance of front bumper Fig 3 FENDER SECT AA FENDER DASH TOP REINF HOOD HINGE BRACE W HOUSE SECT BB...

Page 83: ...g 5 4 Apply the paint CAUTION Ventilate when spraying paint Most paint contains substances that are harmful if inhaled or swal lowed Read the paint label before opening paint con tainer Avoid contact with skin Wear an approved res pirator gloves eye protection and appropriate clothing when painting Paint is flammable Store in a safe place and keep it away from sparks flames or cigarettes 5 Preinst...

Page 84: ...king and adjusting the mounting posi tion tighten all bolts fully 7 Install the related parts Washer hose and nozzles Install in the reverse order in which they were re moved 8 Check and adjust Check clearances and level differences Check the hood locking and unlocking condition Check spray conditions of washer liquid and ad just washer spray nozzles on the hood panel ...

Page 85: ...s 4 Apply the paint CAUTION Ventilate when spraying paint Most paint contains substances that are harmful if inhaled or swal lowed Read the paint label before opening paint con tainer Avoid contact with skin Wear an approved res pirator gloves eye protection and appropriate clothing when painting Paint is flammable Store in a safe place and keep it away from sparks flames or cigarettes 5 Preinstal...

Page 86: ...nd adjusting the mounting posi tion tighten all bolts fully 7 Install the related parts Wiring harness and solenoid valve Lock set latches and linkages Install in the reverse order in which they were re moved 8 Check and adjust Clean the trunk compartment Check clearances and level differences Check the trunk lid locking and unlocking condi tion Check for water leaks in the trunk compartment ...

Page 87: ... 4 Rear Frame 8 5 Front Panel 8 6 Engine Room 8 7 Side Outer 8 10 2 BODY WELDING DIAGRAM 8 11 Front Panel Upper 8 11 Front Wheel House 8 12 Brace Wheel House 8 13 Dash Panel Upper 8 14 Dash Panel Lower 8 15 Roof 8 17 Body Side and Wheel House Inner 8 18 Rear Frame 8 19 Tail Gate 8 20 3 GAP CHART 8 21 ...

Page 88: ...8 2 BODY DIMENSION 1 BODY DRAWING Camber Caster 20 45 3 0 10 Front wheel alignment Camber 1 45 30 5 30 Rear wheel alignment Toe in 2 personload Toe in 2 personload Fig 1 ...

Page 89: ...BODY DIMENSION 8 3 Fig 2 1 1 UNDER BODY ...

Page 90: ...8 4 BODY DIMENSION Fig 3 1 2 FRONT FRAME ...

Page 91: ...BODY DIMENSION 8 5 Fig 4 1 3 REAR FRAME ...

Page 92: ...8 6 BODY DIMENSION Fig 5 1 4 FRONT PANEL ...

Page 93: ...BODY DIMENSION 8 7 Fig 6 1 5 ENGINE ROOM ...

Page 94: ...8 8 BODY DIMENSION Fig 7 ENGINE ROOM Continued ...

Page 95: ...BODY DIMENSION 8 9 Fig 8 ENGINE ROOM Continued ...

Page 96: ...8 10 BODY DIMENSION Fig 9 1 6 SIDE OUTER ...

Page 97: ...BODY DIMENSION 8 11 Fig 10 2 BODY WELDING DIAGRAM 2 1 FRONT PANEL UPPER ...

Page 98: ...8 12 BODY DIMENSION Fig 11 2 2 FRONT WHEEL HOUSE ...

Page 99: ...BODY DIMENSION 8 13 Fig 12 2 3 BRACE WHEEL HOUSE 6 5 3 3 1 1 1 1 4 4 2 7 7 7 8 16 5 5 1 3 6 4 2 1 2 2 6 5 3 3 1 1 7 8 22 17 3 3 5 2 ...

Page 100: ...8 14 BODY DIMENSION Fig 13 2 4 DASH PANEL UPPER ...

Page 101: ...BODY DIMENSION 8 15 Fig 14 2 5 DASH PANEL LOWER 4 8 8 4 5 5 5 5 19 19 5 5 5 5 7 7 10 4 10 16 11 11 3 2 5 8 8 4 4 10 4 3 3 ...

Page 102: ...8 16 BODY DIMENSION Fig 15 DASH PANEL LOWER Continued 1 2 2 4 5 2 2 1 Arc welding Arc welding ...

Page 103: ...BODY DIMENSION 8 17 Fig 16 2 6 ROOF ...

Page 104: ...8 18 BODY DIMENSION Fig 17 2 7 BODY SIDE AND WHEEL HOUSE INNER ...

Page 105: ...BODY DIMENSION 8 19 Fig 18 2 8 REAR FRAME ...

Page 106: ...8 20 BODY DIMENSION Fig 19 2 9 TAIL GATE ...

Page 107: ...d Lamp Head Lamp x Front Bumper Side Outer x Trunk Lid Side Outer x Tail lamp Trunk Lid x Tail Lamp Trunk Lid x Rear Bumper A B C D E F G H I J 5 2 5 2 3 1 2 1 3 1 3 1 1 9 3 5 1 5 2 4 1 Check proper installation Check clearance and level differences of main body exterior panels lamps and bumper Check for water leaks in the passenger and trunk compartment ...

Page 108: ...illar A pillar x Front Door Fender x Head Lamp Hood x Fender Location Gap mm A B C D E F Description Rear Door x Side Outer Side Outer x Tail Lamp Trunk Lid x Side Outer Location Gap mm G H I J K L Front Door x Rear Door Rocker Panel x Door 5 1 4 1 4 1 3 5 1 3 1 1 9 3 1 2 1 5 1 5 1 5 1 3 5 1 ...

Page 109: ...ING CAULKING 9 2 Sealing 9 2 Engine room 9 2 Roof 9 5 Inside Room 9 6 Floor Trunk Room 9 7 Hood 9 8 Trunk Lid 9 9 Front Rear Door 9 10 Caulking 9 11 Engine room 9 11 Under Body 9 12 Back Panel 9 13 2 DEADER 9 14 General description 9 14 Repair procedure 9 14 Under Body 9 16 Roof Door 9 17 ...

Page 110: ...9 2 SEALING CAULKING AND DEADNER Fig 1 Engine Room 1 SEALING CAULKING NOTE Seal the following areas to prevent air leaks water leaks and rust 1 1 SEALING ENGINE ROOM SECT A A SECT B B SECT D D SECT C C ...

Page 111: ...SEALING CAULKING AND DEADNER 9 3 A B A C B A B A B C SECT A A SECT B B SECT C C Fig 2 ENGINE ROOM Continued ...

Page 112: ...9 4 SEALING CAULKING AND DEADNER ENGINE ROOM Continued Fig 3 C A B VIEW B VIEW A VIEW C ...

Page 113: ...SEALING CAULKING AND DEADNER 9 5 ROOF Fig 4 A A RUB AFTER SEALING SECT A A ...

Page 114: ...9 6 SEALING CAULKING AND DEADNER INSIDE ROOM Fig 5 B C C A A B SECT A A SECT B B SECT C C ...

Page 115: ...SEALING CAULKING AND DEADNER 9 7 FLOOR TRUNK ROOM Fig 6 SECT A A SECT B B SECT C C SECT D D SECT E E RUB AFTER SEALING ...

Page 116: ...9 8 SEALING CAULKING AND DEADNER HOOD Fig 7 A A A SECT A A RUB AFTER SEALING VIEW A ...

Page 117: ...SEALING CAULKING AND DEADNER 9 9 A A A TRUNK LID Fig 8 SECT A A VIEW A RUB AFTER SEALING RUB AFTER SEALING RUB AFTER SEALING ...

Page 118: ...KING AND DEADNER E C B D A F A FRONT REAR DOOR Fig 9 SECT A A DOOR OUTER DOOR INNER VIEW C VIEW D VIEW F RUB AFTER SEALING EXCEPT SEALING 3POINTS RUB AFTER SEALING RUB AFTER SEALING EXCEPT SEALING 3POINTS VIEW E VIEW B ...

Page 119: ...SEALING CAULKING AND DEADNER 9 11 Fig 10 1 2 CAULKING ENGINE ROOM ...

Page 120: ...9 12 SEALING CAULKING AND DEADNER UNDER BODY Fig 11 ...

Page 121: ...SEALING CAULKING AND DEADNER 9 13 BACK PANEL Fig 12 ...

Page 122: ... Peel off the damaged deadner with a steel spatula carefully 3 Clean and dry Before applying the deadner thoroughly clean and dry the areas to be applied 4 Prelocation the new deadner Prelocation the new deadner on the panels to be applied NOTE Avoid the parts mounting holes and service holes 5 Adhension of deadner Heat the surface of deadner with a torch or heat ing gun until it adheres itself Pu...

Page 123: ...EL 4 0 625x340 7 DEADNER A PILLAR LH 1 5 140x80 8 DEADNER A PILLAR RH 1 5 140x80 9 DEADNER A PILLAR UPPER LH 1 5 70x50 10 DEADNER A PILLAR UPPER RH 1 5 70x50 11 DEADNER FRT WHEEL HOUSING LH 3 2 264x165 12 DEADNER FRT WHEEL HOUSING RH 3 2 264x165 13 DEADNER A PILLAR LH 1 5 140x80 14 DEADNER A PILLAR RH 1 5 140x80 15 DEADNER TRUNK SIDE LH 3 2 300x200 RECTANGULAR NO DESCRIPTION REMARKS DEADNER CHART ...

Page 124: ...9 16 SEALING CAULKING AND DEADNER Fig 16 UNDER BODY ...

Page 125: ...SEALING CAULKING AND DEADNER 9 17 ROOF DOOR Fig 17 ...

Page 126: ...BODY REPAIR MANUAL TACUMA REZZO ISSUED BY OVERSEAS SERVICE DIVISION DAEWOO MOTOR CO LTD 409 7 CHONG CHON DONG PU PYONG KU INCHON KOREA TELEPHONE 82 32 509 7320 7326 7350 FACSIMILE 82 32 509 7205 7206 ...

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