Repair Procedure - Daewoo TACUMA Body Repair Manual

3-2. REPAIR PROCEDURE

1. Remove the related parts.
• Rear and trunk trims.
• Rear combination lamps and wiring harness.
• Rear bumper and related parts.
• Rear seat and rear seat belt.
• Chassis and fuel parts.
• Other related parts.
CAUTION: Do not smoke while working near the fuel
system. Keep open flame away from the fuel system.
If necessary, remove the fuel tank and off lines.
2. Pull out and straighten the damaged area to approxi-
mately the original shape.
• Attach the car to the frame straightener by tight-
ening the underbody clamps at the four designated
support points.
• Before cutting off the damaged sections, pull them
out so that they are restored to the original shape.
• Do not pull out more than necessary.
• Pull out and straighten the damaged areas of the
rear side outer panel, side inner panel and wheel-
house inner.
NOTE: Check the rear door locking and unlocking
condition.
3. Cut and pry off the side panel outer.
• Cut at the rear pillar and side outer(rear side of
frame 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 with an air chisel,
leaving the welding flanges at the side inner panel,
wheelhouse inner and back panel intact.
• Level and finish the burrs from the pried off spot
welds with a hammer, dolly and disc sander.
CAUTION: To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 6–9
4. 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.
• Sand off the paint and undercoat from both sides
of the flange to be welded.
5. Set the new side panel outer.
• Cut the new side panel outer so it will overlap by
30mm in the frame door opening area with a hand
saw.
Fig. 10
Fig. 11