Daewoo TACUMA Body Repair Manual
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Daewoo TACUMA Body Repair Manual

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  • Page 1 BODY REPAIR MANUAL TACUMA...

  • Page 2: Table Of Contents

    SEALING, CAULKING AND uct information available at the time of manual approval. DEADNER The right is reserved to make changes at any time without notice. RUST PREVENTION BODY-FRAME REPAIR DAEWOO MOTOR CO., LTD. EQUIPMENT INCHON, KOREA...

  • Page 3: How To Use This Manual

    TIONS, SAFETY STAND SUPPORT able ways in which service, whether or not recom- POINTS, ETC. 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-...
  • Page 4 SERVICE NOTICE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) NOTICE: The following precautions should be observed 3. Do not apply heat of more than 80°C(176°F) when when performing sheet metal work, paint work and re- drying painted surfaces anywhere around the loca- pair work around the locations of the SRS parts. tions of SRS parts.
  • Page 5 GENERAL INFORMATION 1–1 SECTION 1 GENERAL INFORMATION CONTENTS 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 ...................

  • Page 6: General Instruction

    1–2 GENERAL INFORMATION 1. GENERAL INSTRUCTION 2. IMPORTANT SAFETY NOTICE 2-1. BEFORE BEGINNING WORK This publication is designed to help you the body repair technician with your specialized work. Vehicle bodywork • Disconnect the battery to reduce the possibility of has changed a great deal over the years.

  • Page 7: Body Safety

    The durability of the bodywork, its associated long- term safety and retention of value largely depend on the corrosion protection given to the sheet metal. Here, DAEWOO takes a great deal of care in pro- Fig. 1 Body Shell duction.

  • Page 8: Zinc Treated Steel Plate Repair

    1–4 GENERAL INFORMATION 8. ZINC TREATED STEEL PLATE REPAIR The zinc plated steel plate used in some panels of the LANOS requires different repair techniques than ordinary steel plate. ZINC PLATING(45microns) Steel plate Fig. 2 1. Before spot welding the zinc plated steel plate, re- move the paint from both sides of the flange to be welded.
  • Page 9 GENERAL INFORMATION 1–5 BLANK...

  • Page 10: Technical Illustration

    1–6 GENERAL INFORMATION 9. TECHNICAL ILLUSTRATION Fig. 3...
  • Page 11 GENERAL INFORMATION 1–7 1. Panel Side Outer 15.Reinforce "D" Filler Rear 2. Panel Side Lower 16.Reinforce "C" Filler 3. Cap Fuel Filler 17.Reinforce Retract Rear 4. Panel Tail Lamp Housing Lower 18.Rear Seat Belt Upper 5. Panel Tail Lamp Housing Center 19.Patch Wheel House Inner 6.
  • Page 12 1–8 GENERAL INFORMATION Fig. 4...
  • Page 13 GENERAL INFORMATION 1–9 1. Front Panel Upper 32.Extension Front Longitudinal 2. Support Front Panel Center 33.Brace Front Longitudinal 3. Crossmember Radiator Rear 34.Longitudinal Front Inner 4. Crossmember Radiator Front 35.Reinf Front Longitudinal Inner 5. Support Front Panel Side Inner 36.Support Crossmember Radiator Inner 6.
  • Page 14 1–10 GENERAL INFORMATION Fig. 5...
  • Page 15 GENERAL INFORMATION 1–11 1. Panel Front Floor 20.Reinf Rear Longitudinal Rear 2. Reinf Tunnel 21.Hanger Extension Pipe Rear Inner 3. Tunnel Front 22.Hanger Extension Pipe Rear Inner 4. Reinf Tunnel Upper Rear 23.Crossmember Rear Floor Center Side 5. Panel Second Floor Rear 24.Reinf Rear Longitudinal 6.
  • Page 16 1–12 GENERAL INFORMATION Fig. 6...
  • Page 17 GENERAL INFORMATION 1–13 1. Front Panel 11.Rear Door 2. Front Wheel House 12.Floor Panel Side 3. Bracket Engine 13.Rear Frame 4. Dash Panel Lower 14.Front Floor 5. Front Longitudinal 15.Rear Floor 6. Brace Wheel House 16.Back Panel Lower 7. Fender 17.Tail Gate 8.

  • Page 18: Body Repair Procedures

    1–14 GENERAL INFORMATION 10. BODY REPAIR PROCEDURES Operation Procedure Remarks Inspect the damaged parts and the extent of damage and make Inspection plans for the repair. Preparation Prepare the new parts, special repair tools and others. Removal Remove the related parts for repair. Pull out Roughly pull out and straighten the damaged areas.
  • 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: General Description

    2–2 PREPARATIONS OF BODYWORK 1. GENERAL DESCRIPTION Damage to the exterior of the body can be inspected • Most monocoque bodies are composed as a single visually, but where there has been an external impact, unit by welding together pressed parts made of steel plates which come in a variety of different shapes it is necessary to inspect the extent of the damage.

  • Page 21: Checkpoints

    PREPARATIONS OF BODYWORK 2–3 2. CHECKPOINTS Rear Section: 1. Is there any twisting, bulging or denting of the rear • Accurate Inspection of Damaged Parts(Visual) floor any rear bolsters? Have any of the connected sections come apart? Seat Belts 2. Is there any irregular bulging or denting in the rear fender? Always replace the seat belt if: 3.

  • Page 22: Correction Of The Damaged Area

    2–4 PREPARATIONS OF BODYWORK 3. CORRECTION OF THE DAMAGED AREA • Set the frame corrector on the car body. • The side frame is to allow reshaping by pulling it out. • Use the horizontal pinch welds for anchoring the car. UNDERBODY CLAMPS •...

  • Page 23: Measuring Systems (Without Small Damage)

    PREPARATIONS OF BODYWORK 2–5 4. MEASURING SYSTEMS • If there are any deviations, use a tram tracking gauge and measure parts of the body.(Below Fig. 4-1) (WITHOUT SMALL DAMAGE) • If there is any twisting to the body, measure using a •...
  • Page 24 WELDING AND TOOLS 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.............................

  • Page 25: Spot Welding

    3–2 WELDING AND TOOLS 1. SPOT WELDING 1-1. GENERAL DESCRIPTION Spot welding is also known as resistance spot welding and it is the most suitable method of welding for auto- mobiles. It has three main features: the welding can be performed instantaneously, it exercises very little effect on the mother material, and it reduces the generation of distortion to the absolute minimum.

  • Page 26: Welding Strength Test

    WELDING AND TOOLS 3–3 1-3. WELDING STRENGTH TEST • Plate thickness and tip diameter (Unit : mm) Even if you perform the welding in accordance with the Plate thickness conditions, the strength of the welded sections may fluc- tuate widely with drops in the voltage and other factors. Tip diamter ø4.5 ø5.0...

  • Page 27: Gas Welding

    3–4 WELDING AND TOOLS NOTE: 2. GAS WELDING It is difficult to perform spot welding in the following cir- Gas welding is indispensable for body repair because cumstances. of the broad range of its applications from joining the • When it is not possible to remove any rust or paint body panels, cutting the materials that construct the attached to the welding surfaces.

  • Page 28: Carbon Dioxide Arc Welder

    WELDING AND TOOLS 3–5 NOTE: Below is an example of how not to perform gas 3. CARBON DIOXIDE ARC welding, avoid operations like this. WELDER(MIG ARC WELDING) This welding process uses inexpensive carbon dioxide instead of expensive inert gases as a shielding means. Consumable metal electrodes are employed.

  • Page 29: Repair Tools

    3–6 WELDING AND TOOLS 4. REPAIR TOOLS Item Work Tools. equipment used 1. Protective goggles 7. Protective apron Protective tools Operator 2. Cap 8. Welding gloves 3. Ear plug 9. Foot protectors 4. Shield for eyes 10.Safety shoes 5. Overalls with long sleeves 11.Work gloves 6.
  • Page 30 WELDING AND TOOLS 3–7 Item Work Tools. equipment used Fixing tools Base metal fixing VISE GRIPS SCREW CLAMP SQUILL VISE Shaping tools Skin panel shaping HAMMERS DOLLIES SPOONS FILE/FILE HOLDER SNIPS/SHEARS Body, frame shaping WELDER BODY JACK SLIDER HAMMER...
  • Page 31 3–8 WELDING AND TOOLS Item Work Tools. equipment used Measuring tools Measuring RULES CONVEX RULES Flange tools Edge preparation Cutting tools AIR JIGSAW AIR IMPACT CUTTER HAND NIBBLER HANDSAW CHISEL Sanding tools Cleaning DISC SANDER Air type: Electric type: BELT SANDER...

  • Page 32: Front

    FRONT 4–1 SECTION 4 FRONT CONTENTS 1. FRONT PANEL ..........................4-2 • General description ........................4-2 • Repair procedure ........................... 4-3 2. FRONT WHEELHOUSE ......................... 4-6 • General description ........................4-6 • Repair procedure ........................... 4-7 3. FRONT LONGITUDINAL ......................4-11 •...

  • Page 33: Front Panel

    4–2 FRONT 1. FRONT PANEL 1-1. GENERAL DESCRIPTION The front panel is joined to the 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.

  • Page 34: Repair Procedure

    FRONT 4–3 1-2. REPAIR PROCEDURE 4. Cut and pry off the front panel. • Center punch around the spot weld imprints. 1. Remove the related parts. • Use the special spot cutter to drill holes at the • Hood, radiator grill and front bumper. spot weld nuggets on the front wheel house and •...
  • Page 35 4–4 FRONT 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.
  • Page 36 FRONT 4–5 12.Coating the anti-rust agents. • Coating the anti-rust agents to the end of front panel side and the door hinge areas. Fig. 8 13.Install the related parts. • Engine, radiator and related parts. • Aircon condenser and related parts. •...

  • Page 37: Front Wheelhouse

    4–6 FRONT 2. FRONT WHEELHOUSE 2-1. GENERAL DESCRIPTION The front wheelhouse component is constructed 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.

  • Page 38: Repair Procedure

    FRONT 4–7 2-2. REPAIR PROCEDURE CAUTION: To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting, or grind- 1. Remove the related parts. ing. • Parts to be removed when removing the front panel. • Parts on passenger side of dash panel lower which are especially flammable.
  • Page 39 4–8 FRONT • Use a hammer and dolly to mold damaged areas of the front longitudinal, rear wheelhouse and other panels. • Even out the welding flanges with a hammer and dolly. 7. Set the new front wheelhouse panel. • Grind both sides of the welding section of the front, rear wheelhouse and front longitudinal with a disc sander to remove the paint and expose the steel plate.
  • Page 40 FRONT 4–9 SEALER TAPE Fig. 15 11.Weld the brace wheelhouse. • Spot weld the brace wheelhouse as shown. • Make MIG or gas welds at the door hinge areas. WHEN REPLACING THE FRONT SIDE ONLY. Fig. 14 CAUTION : To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.
  • Page 41 4–10 FRONT 13.Apply the sealer 18.Check and adjust • Apply the sealer to the matching and overlapped • Measure the front wheel alignment. surface. • Check clearances and level differences. • Check the hood locking and unlocking condition. 14.Apply the undercoat. •...

  • Page 42: Front Longitudinal

    FRONT 4–11 3. FRONT LONGITUDINAL 3-1. GENERAL DESCRIPTION 4. Cut and pry off the front longitudinal. The front longitudinal is joined to the wheelhouse and NOTE: It's not necessary to separate the wheelhouse front panel, it forms the base for the front suspension, from the front longitudinal if the wheelhouse is to be engine, transmission and others.
  • Page 43 4–12 FRONT FRONT WHEELHOUSE Fig. 18 Fig. 19 6. Cut the new front longitudinal to align it with body, • Spot weld the wheelhouse with the front longitu- then set the wheelhouse and front panel. dinal flange areas and front panel. •...
  • Page 44 FRONT 4–13 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. • Aircon condenser and related parts. •...

  • Page 45: Support Control Arm

    4–14 FRONT 4. SUPPORT CONTROL ARM 4-1. GENERAL DESCRIPTION The support control arm is joined to the front longitudi- 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.

  • Page 46: Repair Procedure

    FRONT 4–15 4-2. REPAIR PROCEDURE 5. Cut and pry off the support control arm. • Center punch around the spot weld imprints on the 1. Check the damaged areas. support control arm. • Check the damaged parts and the extent of dam- •...
  • Page 47 4–16 FRONT 6. Mold damaged related parts. CAUTION: To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting, or grind- • Reshape the dash panel lower, crossmember ing. front floor panel and other related parts with a hammer and dolly. •...
  • Page 48 FRONT 4–17 13.Apply the deadner. 14.Install the related parts. • Clean the passenger compartment. • Clean the passenger compartment. • Apply the deadner to the surface of floor panel. • Wiring harness and related parts. • Parts of the passenger compartment. •...

  • Page 49: Front Pillar

    4–18 FRONT 5. FRONT PILLAR 5-1. GENERAL DESCRIPTION The front pillar area is part of the frame door opening panel. It's connected to the roof, windshield, 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.

  • Page 50: Repair Procedure

    FRONT 4–19 5-2. REPAIR PROCEDURE CAUTION: To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting, or grind- 1. Remove the related parts. ing. • Hood, radiator grill and front bumper. • Using a chisel, pry off the welded flange from the •...
  • Page 51 4–20 FRONT it with a hand saw. • Cut the floor panel side joint area so it will over- lap by 30mm(1.18in.) in the floor panel side with a hand saw. • Grind both sides of the welding section with a disk sander to remove the paint and expose the steel plate.
  • Page 52 FRONT 4–21 CAUTION: To prevent eye injury and burns when • Use a hammer and dolly to even out the spot welded welding, wear an approved welding helmet, gloves and flanges for a close fit with the surface of the inner safety shoes.
  • Page 53 4–22 FRONT 12.Finish the welding areas. 18.Check and adjust. • Use a hammer and dolly to even out the brace • Check the door for proper installation and opera- wheelhouse for a close fit with the surface of the tion. wheelhouse.

  • Page 54: Roof, Back Panel And

    ROOF, BACK PANEL AND REAR FLOOR PANEL 5–1 SECTION 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 •...

  • Page 55: Roof

    5–2 ROOF, BACK PANEL AND REAR FLOOR PANEL 1. ROOF 1-1. GENERAL DESCRIPTION Deformation of the roof panel is 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.

  • Page 56: Repair Procedure

    ROOF, BACK PANEL AND REAR FLOOR PANEL 5–3 1-2. REPAIR PROCEDURE CAUTION: To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting, or grind- 1. Remove the related parts. ing. • Room lamp, door weatherstrip and pillar trims. •...
  • Page 57 5–4 ROOF, BACK PANEL AND REAR FLOOR PANEL • Measure the dimensions diagonally at the wind- shield area and rear glass area with a tracking gauge or convex rule as shown to check it for twisting or bending. Fig. 4 •...
  • Page 58 ROOF, BACK PANEL AND REAR FLOOR PANEL 5–5 9. Perform the main welding and finish. 10.Apply the sealer. • Spot weld the roof panel. • Apply the sealer to the welded areas. CAUTION: To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.
  • Page 59 5–6 ROOF, BACK PANEL AND REAR FLOOR PANEL 13.Install the related parts. • Windshield and rear glass. • Cowl, wiper and related parts. • Wiring harness and headlining. • Pillar trims, door weatherstrip and others. • Install in the reverse order in which they were re- moved.

  • Page 60: Back Panel

    ROOF, BACK PANEL AND REAR FLOOR PANEL 5–7 2. BACK PANEL 2-1. GENERAL DESCRIPTION The back panel is joined to the 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.

  • Page 61: Repair Procedure

    5–8 ROOF, BACK PANEL AND REAR FLOOR PANEL 2-2. REPAIR PROCEDURE • Level and finish the burrs from the fried off spot welds with disc sander and repair all cracks, holes 1. Remove the related parts. or other defects by welding also repair the floor •...
  • Page 62 ROOF, BACK PANEL AND REAR FLOOR PANEL 5–9 4. Peel off the undercoat and sealer. 7. Measure and check. • Heat the undercoat and sealer at the welding • Measure the trunk compartment diagonally to areas of the rear side outer panel and extension check it for twisting or bending and its correct rear floor with a gas torch and peel off the under- position with the rear bumper installed.
  • Page 63 5–10 ROOF, BACK PANEL AND REAR FLOOR PANEL 10.Apply the sealer. • Apply the sealer to the rear side outer joint and around the rear lamps areas of the rear panel. • Apply the sealer to the extension rear floor panel and rear panel joint.

  • Page 64: Rear Floor Panel

    ROOF, BACK PANEL AND REAR FLOOR PANEL 5–11 3. REAR FLOOR PANEL 3-1. GENERAL DESCRIPTION The rear floor panel is the base of the rear body 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.

  • Page 65: Repair Procedure

    5–12 ROOF, BACK PANEL AND REAR FLOOR PANEL 3-2. REPAIR PROCEDURE 1. Remove the related parts. • Parts to be removed when removing the back panel. • Rear seat belt and rear seat. • Muffler, fuel tank and related parts. •...
  • Page 66 ROOF, BACK PANEL AND REAR FLOOR PANEL 5–13 7. Cut the new rear floor to align it with the body, then set the new rear floor and extension rear floor. • Cut the new part so it overlaps the cross member rear seat by approximately 40mm.
  • Page 67 5–14 ROOF, BACK PANEL AND REAR FLOOR PANEL 8. Remove the main welding. • Weld the rear floor and cross member rear seat with a MIG welder fillet weldings as shown. NEW REAR FLOOR REAR FLOOR FORWARD CROSS MEMBER REAR SEAT Fig.
  • Page 68 ROOF, BACK PANEL AND REAR FLOOR PANEL 5–15 • Avoid contact with skin. Wear an approved respi- 15.Install the related parts. rator, gloves, eye protection and appropriate cloth- • Install in the reverse order in which they were re- ing when painting. moved.
  • Page 69 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 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 •...

  • Page 70: Frame Door Opening

    6–2 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 1. FRAME DOOR OPENING 1-1. GENERAL DESCRIPTION The frame door opening consist of 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.

  • Page 71: Repair Procedure

    FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 6–3 1-2. REPAIR PROCEDURE • If the damage involves part of the center pillar, cut them as shown. 1. Remove the related parts. • Doors. • Weather strips, pillar trims and related parts. •...
  • Page 72 6–4 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 5. Set the new frame door opening. • Perform a trial welding first, and check the weld- ing condition. • Grind both sides of the welding section of the pre- pared frame door opening part with a disk sander •...
  • Page 73 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 6–5 9. Apply the undercoat. 12.Install the related parts. • Undercoat to the front floor. • Clean the passenger compartment. • Wiring harness and related parts. 10.Apply the paint. • Seat belt assembly and carpet. •...

  • Page 74: Door

    6–6 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 2. DOOR • Check and adjust the clearances and level differ- ences of doors, fender, pillar, roof and side panel outers. 2-1. REPAIR PROCEDURE 1. Remove the related parts. • Check any deformation. •...
  • Page 75 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 6–7 9. Install the door. • Install the door with four bolts. • Install the door check link set in the door and fix the bolt. • Check clearances and level differences. 10.Install the related parts.

  • Page 76: Side Panel Outer

    6–8 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 3. SIDE PANEL OUTER 3-1. GENERAL DESCRIPTION The side panel outer consists of side outer area and 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.

  • Page 77: Repair Procedure

    FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 6–9 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. •...
  • Page 78 6–10 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER • Grind both sides of the welding section of the pre- 7. Finish the welding areas. pared side panel outer with a disk sander to re- • Level the gas or MIG welded areas with a disc move the paint and expose the steel plate.
  • Page 79 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 6–11 Fig. 13 13.Install the related parts. • Clean the passengers compartment. • Wiring harness and related parts. • Seat belt assembly and carpet. • Trims and weather strips. • Door and others. •...

  • Page 80: Fender, Hood And

    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: Fender

    7–2 FENDER, HOOD AND TRUNK LID 1. FENDER 5. Coating the anti-rust agents. • Coating the anti-rust agents to door hinge areas. 1-1. REPAIR PROCEDURE 1. Remove the related parts. • Radiator grill and front bumper. • Mud guard and fender liner. 2.
  • Page 82 FENDER, HOOD AND TRUNK LID 7–3 6. Apply the mastic sealer. 7. Preinstall the fender. • Apply the mastic sealer to the mounting bolts. • Fasten to the wheelhouse at two places with bolts. Close the hood and check the front and rear clear- NOTE: Before apply the new sealer, check the cur- ances and level differences of the hood and door.

  • Page 83: Hood

    7–4 FENDER, HOOD AND TRUNK LID 2. HOOD 4. Apply the paint. CAUTION 2-1. REPAIR PROCEDURE • Ventilate when spraying paint. Most paint contains 1. Remove the related parts. substances that are harmful if inhaled or swal- • Washer hose and nozzles. lowed.
  • Page 84 FENDER, HOOD AND TRUNK LID 7–5 • Close the hood and check the front and rear clear- 7. Install the related parts. ances and level difference of hood, fender and • Washer hose and nozzles. head lamps. • Install in the reverse order in which they were re- moved.

  • Page 85: Trunk Lid

    7–6 FENDER, HOOD AND TRUNK LID 3. TRUNK LID 4. Apply the paint. CAUTION 3-1. REPAIR PROCEDURE • Ventilate when spraying paint. Most paint contains 1. Remove the related parts. substances that are harmful if inhaled or swal- • Wiring harness and solenoid valve. lowed.
  • Page 86 FENDER, HOOD AND TRUNK LID 7–7 • Close the trunk lid and check the clearances and 6. Tighten fully. level difference of trunk lid, side panel outers and • After checking and adjusting the mounting posi- rear combination lamps. tion, tighten all bolts fully. 7.

  • Page 87: Body Dimension

    BODY DIMENSION 8–1 SECTION 8 BODY DIMENSION CONTENTS 1. BODY DRAWING ..........................8-2 • Under Body ............................ 8-3 • Front Frame ........................... 8-4 • Rear Frame ........................... 8-5 • Front Panel ............................ 8-6 • Engine Room ..........................8-7 • Side Outer ........................... 8-10 2.

  • Page 88: Body Drawing

    8–2 BODY DIMENSION 1. BODY DRAWING Front wheel alignment Rear wheel alignment Camber -20´ ± 45´ Camber -1°45´ ± 30 Toe-in(2-person load) Caster 3° 5´ ± 30´ Toe-in(2-person load) 0 ± 10´ Fig. 1...

  • Page 89: Under Body

    BODY DIMENSION 8–3 1-1. UNDER BODY Fig. 2...

  • Page 90: Front Frame

    8–4 BODY DIMENSION 1-2. FRONT FRAME Fig. 3...

  • Page 91: Rear Frame

    BODY DIMENSION 8–5 1-3. REAR FRAME Fig. 4...

  • Page 92: Front Panel

    8–6 BODY DIMENSION 1-4. FRONT PANEL Fig. 5...

  • Page 93: Engine Room

    BODY DIMENSION 8–7 1-5. ENGINE ROOM Fig. 6...
  • Page 94 8–8 BODY DIMENSION ENGINE ROOM(Continued) Fig. 7...
  • Page 95 BODY DIMENSION 8–9 ENGINE ROOM(Continued) Fig. 8...

  • Page 96: Side Outer

    8–10 BODY DIMENSION 1-6. SIDE OUTER Fig. 9...

  • Page 97: Body Welding Diagram

    BODY DIMENSION 8–11 2. BODY WELDING DIAGRAM 2-1. FRONT PANEL UPPER Fig. 10...

  • Page 98: Front Wheel House

    8–12 BODY DIMENSION 2-2. FRONT WHEEL HOUSE Fig. 11...

  • Page 99: Brace Wheel House

    BODY DIMENSION 8–13 2-3. BRACE WHEEL HOUSE Fig. 12...

  • Page 100: Dash Panel Upper

    8–14 BODY DIMENSION 2-4. DASH PANEL UPPER Fig. 13...

  • Page 101: Dash Panel Lower

    BODY DIMENSION 8–15 2-5. DASH PANEL LOWER Fig. 14...
  • Page 102 8–16 BODY DIMENSION DASH PANEL LOWER (Continued) Arc welding Arc welding Fig. 15...

  • Page 103: Roof

    BODY DIMENSION 8–17 2-6. ROOF Fig. 16...

  • Page 104: Body Side And Wheel House Inner

    8–18 BODY DIMENSION 2-7. BODY SIDE AND WHEEL HOUSE INNER Fig. 17...

  • Page 105: Rear Frame

    BODY DIMENSION 8–19 2-8. REAR FRAME Fig. 18...

  • Page 106: Tail Gate

    8–20 BODY DIMENSION 2-9. TAIL GATE Fig. 19...

  • Page 107: Gap Chart

    BODY DIMENSION 8–21 3. GAP CHART Fig. 20...
  • Page 108 8–22 BODY DIMENSION Fig. 21...

  • Page 109: Sealing, Caulking And

    SEALING, CAULKING AND DEADNER 9–1 SECTION 9 SEALING, CAULKING AND DEADNER CONTENTS 1. SEALING & CAULKING ......................... 9-2 Sealing............................... 9-2 • Engine room ..........................9-2 • Roof ..............................9-5 • Inside Room ..........................9-6 • Floor & Trunk Room ........................9-7 •...

  • Page 110: Sealing & Caulking

    9–2 SEALING, CAULKING AND DEADNER 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 C–C SECT D–D Fig. 1 Engine Room...
  • Page 111 SEALING, CAULKING AND DEADNER 9–3 ENGINE ROOM(Continued) SECT A–A SECT B–B SECT C–C Fig. 2...
  • Page 112 9–4 SEALING, CAULKING AND DEADNER ENGINE ROOM (Continued) VIEW B VIEW C VIEW A Fig. 3...

  • Page 113: Roof

    SEALING, CAULKING AND DEADNER 9–5 ROOF RUB AFTER SEALING SECT A–A Fig. 4...

  • Page 114: Inside Room

    9–6 SEALING, CAULKING AND DEADNER INSIDE ROOM SECT A–A SECT B–B SECT C–C Fig. 5...

  • Page 115: Floor & Trunk Room

    SEALING, CAULKING AND DEADNER 9–7 FLOOR & TRUNK ROOM RUB AFTER SEALING SECT A–A SECT B–B SECT C–C SECT D–D SECT E–E Fig. 6...

  • Page 116: Hood

    9–8 SEALING, CAULKING AND DEADNER HOOD VIEW A RUB AFTER SEALING SECT A–A Fig. 7...

  • Page 117: Trunk Lid

    SEALING, CAULKING AND DEADNER 9–9 TRUNK LID VIEW A RUB AFTER SEALING RUB AFTER SEALING RUB AFTER SEALING SECT A–A Fig. 8...

  • Page 118: Front/Rear Door

    9–10 SEALING, CAULKING AND DEADNER FRONT / REAR DOOR VIEW C VIEW D VIEW F VIEW E VIEW B RUB AFTER EXCEPT SEALING EXCEPT SEALING RUB AFTER SEALING (3POINTS) (3POINTS) RUB AFTER SEALING SEALING DOOR DOOR INNER OUTER SECT A–A Fig.

  • Page 119: Caulking

    SEALING, CAULKING AND DEADNER 9–11 1-2. CAULKING ENGINE ROOM Fig. 10...

  • Page 120: Under Body

    9–12 SEALING, CAULKING AND DEADNER UNDER BODY Fig. 11...

  • Page 121: Back Panel

    SEALING, CAULKING AND DEADNER 9–13 BACK PANEL Fig. 12...

  • Page 122: General Description

    9–14 SEALING, CAULKING AND DEADNER 2. DEADNER 2-1. GENERAL DESCRIPTION Deadner is properly designed and applied for reduce the vibration and noise. Also, it plays in maintaining the struc- tural rigidity of the panel. 2-2. REPAIR PROCEDURE 1. Remove the related parts. •...
  • Page 123 SEALING, CAULKING AND DEADNER 9–15 11,12 9,10 13,14 Fig. 15 Deadner Chart DEADNER CHART Unit : mm DESCRIPTION REMARKS THICKNESS MAX AREA DEADNER - FLOOR PANEL FRT, LH 778x428(30.63x16.85) DEADNER - FLOOR PANEL FRT, RH 778x428 DEADNER - FLOOR PANEL FRT, TUNNEL 740x360 DEADNER - FLOOR PANEL RR, LH 620x520...

  • Page 124: Under Body

    9–16 SEALING, CAULKING AND DEADNER UNDER BODY Fig. 16...

  • Page 125: Roof, Door

    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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