Repair Procedure - Daewoo TACUMA Body Repair Manual

1-2. REPAIR PROCEDURE

1. Remove the related parts.
• Room lamp, door weatherstrip and pillar trims.
• Headlining and wiring harness.
• Wiper, cowl and windshield.
• Rear glass and others.
2. Pull out and straighten the damaged area to approxi-
mately the original shape.
NOTE: Use heat-resistant protective cover for pro-
tect painting areas, seats, carpets and other parts.
• Attach the car to the frame straightener by tight-
ening the underbody clamps at the horizontal
pinch welds.
• Before cutting off the roof panel, pull them out so
that they are restored to the original shape.
• Do not pull out more than necessary.
• Pull out and straighten the related damaged parts
to approximately their original shape.
NOTE: Make sure that the right and left pillars are
parallel with the windshield surface. Check the door
for proper opening and closing.
3. Keep the body, level.
• Jack up the body, and place safety stands at the
four designated places of the frame door open-
ing.
4. Cut off the shaded areas of the roof panel.
• Cut the roof weld flanges with a hand saw and
snips at the roof panel and roof frames.
• Using 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.
ROOF, BACK PANEL AND REAR FLOOR PANEL 5–3
CAUTION: To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
5. Peel off the sealer.
• Peel off the sealer with a steel spatula at the weld-
ing areas of the frame door opening.
6. Mold damaged related parts.
• Use a hammer and dolly to mold damaged areas
of the front, rear body pillar inner and frame door
opening.
• Even out the welding flanges with a hammer and
dolly for close fit with the roof panel welding
flange.
• Fill any holes drilled by welding.
7. Set the new panels.
• Grind both sides of the welding section of the rail
windshield header, support roof panel, frame rear
roof panel and roof panel with a disc sander to
remove the paint and expose the steel plate.
CAUTION: To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
• Temporarily set the new three frames and roof
panel and clamp with the vise grips.
NOTE: Check that the flange surface fit closely. Be
careful not to twist or deform the roof panel.
Fig. 2