Repair Procedure - Daewoo TACUMA Body Repair Manual

1-2. REPAIR PROCEDURE

1. Remove the related parts.
• Doors.
• Weather strips, pillar trims and related parts.
• Carpet.
• Seat belt assembly
• Door switch and wiring harness.
• Fuel pipe and brake oil pipe.
• Other related parts.
NOTE: Remove according to part damaged.
2. Pull out and straighten the damaged area to approxi-
mately the original shape.
• Damage may extend to the inner roof frame, the
inner frame door opening and the floor. Determine
the extent of the damage first, so the frame can
be pulled out properly.
NOTE: Use heat-resistant protective cover for pro-
tect painting areas, seats, carpets and other parts.
• Pull out and straighten the damaged areas.
• Do not pull out more than necessary.
3. Cut and pry off the frame door opening.
• Check the damage on the frame door opening, then
cut the new frame door opening so it will overlap
by 30mm in the 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.
Fig. 2
FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 6–3
• 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 careful not to drill down
to the inner panel.
• Pry off the frame door opening panel with an air
chisel, leaving the welding flanges intact.
CAUTION: To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
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.
• Level 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. 3