Daewoo Tacuma: Body Repair Manual - part 1

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

SERVICE NOTICE

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

NOTICE: The following precautions should be observed
when performing sheet metal work, paint work and re-
pair work around the locations of the SRS parts.

1. SDM(Sensing and Diagnosis Module) are located

under the console ass'y. Avoid strong impact with
ass'y hammer or other tools when repairing the front
side frame and the lower part of the dashboard. Do
not apply heat to these areas with a gas burner, etc.

2. SRS harness is located under the lower part of the

dashboard 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 performing repair work.

5. If any of the SRS related parts is damaged or de-

formed, be sure to replace it.

NOTE: Refer to the Service Manual(Supplemental Re-
straint System) for removal and replacement of SRS
related parts.

DRIVE SIDE
AIRBAG MODULE

STEERING WHEEL

PASSENGER SIDE
A I R B A G M O D U L E

CONTACT COIL

A I R B A G M O D U L E
( S D M )

  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 ........................................................................................... 1-4

TECHNICAL ILLUSTRATION .............................................................................................................. 1-6

BODY REPAIR PROCEDURES ........................................................................................................ 1-14

1–2  GENERAL INFORMATION

1. GENERAL INSTRUCTION

This publication is designed to help you the body repair
technician with your specialized work. Vehicle bodywork
has changed a great deal over the years. As vehicles
have developed technically, vehicle bodywork has also
had to meet new requirements with design, changes to
reconcile apparently conflicting demands to name just
a few examples:

•

strength and safety

;

low weight

•

spaciousness

;

good aerodynamics

•

high quality

;

low price

The durability and ease of repair of the bodywork also
plays an important part.

Nowadays, the use of highly automated production
equipment makes it possible to maintain the tightest
tolerances and thus ensure a high level of quality.

When bodywork is damaged, the customer rightly ex-
pects it to be expertly repaired to the same quality stan-
dards.

At the same time, for his safety, the customer expects
you to have comprehensive knowledge of materials,
measuring and straightening methods, possible distor-
tion, optimum corrosion prevention and much more
besides.

This publication is designed to help you update your
knowledge and give you an idea of what you require to
rectify moderate or severe accident damage, for your
own safety and for the satisfaction of your customers.

2. IMPORTANT SAFETY NOTICE

2-1. BEFORE BEGINNING WORK

•

Disconnect the battery to reduce the possibility of
fire caused by electrical shorts.

•

Check for fuel 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.

•

Respirator and filter masks: Designed to filter out
toxic fumes, mist, dust or other airborn particles. Use
a respirator or filter mask designed to protect you
from the hazards of the particular job; some respira-
tors, for example, are designed to filter out only dust
and airborn particles, not toxic fumes.

•

Safety goggles or glasses: Designed to protect your
eyes from projectiles, dust particles or splashing liq-
uid.

•

Gloves: Rubber gloves protect against corrosive
chemicals. Welding gloves protect against burns and
abrasions caused by welding, sanding or grinding.

•

Safety shoes: Non-slip soles protect against slipping.
Metal toe inserts protect against falling objects.

•

Ear plugs: Protect eardrums from harmful noise lev-
els.

2-2. DURING WORK

•

Do not smoke while working near the fuel system.

•

Deposit gas or solvent-soaked shop towels in an
approved container.

•

Brake lining contains asbestos, which can cause
cancer. Do not use an air hose to blow off brake
assemblies: use only an approved vacuum cleaner,
and wear an approved filter mask or respirator.

•

Always attach a safety cable when using a hydrau-
lic ram or a frame straightening table: do not stand
in direct line with the chains used on such equip-
ment.