Daewoo Tacuma: Body Repair Manual - part 13

4–20  FRONT

Fig. 29

•

Center punch around the spot weld imprints with

the rear wheelhouse, front body pillar inner, rein-
forcement front body pillar inner and floor panel
side.

•

Use the special spot cutter to drill holes at the

spot weld nuggets on the front pillar.

NOTE: When drilling holes be careful not to drill down
to the front body pillar inner, reinforcement front body
pillar inner and floor panel side themselves.

•

Pry off the remaining flanges from the body with

an air chisel and leaving the welding flanges.

•

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.

6. 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.

7. Set the new front pillar.

•

Align the new part with the top section, then cut

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.

•

Clamp the new panel in place with the vise grips.

•

Tack weld the clamped section for temporary in-

stallation.

Fig. 30

Fig. 31

30mm(1.18in.)

 FRONT  4–21

CAUTION: To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves and
safety shoes.

•

Remove the vise grips and temporarily install the

fender and doors, then check the clearances, level
differences and outer appearance.

8. Perform the main welding.

•

Weld the frame door opening area and pillar at

the butt joints with a gas or MIG welder.

•

Spot weld the flanges of the front pillar as shown.

CAUTION: To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves and
safety shoes.

•

Perform a trial welding first, and check the weld-

ing condition.

•

Increase the number of spot by 20% for areas to

be spot welded.

Fig. 32

9. Finish the welding areas.

•

Level the gas or MIG welded areas with a disc sander,
then even out high areas with a hammer being care-
ful not to deform them.

CAUTION:  To prevent eye injury, wear goggles or
safety glasses whenever sanding cutting or grinding.

•

Use a hammer and dolly to even out the spot welded
flanges for a close fit with the surface of the inner
panel.

•

Fill in deformations and level differences of the welded
areas with solder or putty, then finish.

10.Apply the sealer tape.

•

Apply the sealer tape to the hinge and brace

wheelhouse matching area as shown.

Fig. 33

SEALER TAPE

Fig. 34

11.Weld the brace wheelhouse.

•

Spot weld the brace wheelhouse as shown.

•

Make MIG or gas welds at the door hinge areas.

4–22  FRONT

12.Finish the welding areas.

•

Use a hammer and dolly to even out the brace

wheelhouse for a close fit with the surface of the
wheelhouse.

13.Apply the sealer.

•

Apply the sealer to the matching and overlapped

surface.

14.Apply the undercoat.

•

Undercoat to the inside of the front, rear wheel-

house and longitudinal.

15.Apply the paint.

CAUTION

•

Ventilate when spraying paint. Most paint contains

substances that are harmful if inhaled or swal-
lowed.

Read the paint label before opening paint con-

tainer.

•

Avoid contact with skin. Wear an approved res-

pirator, gloves, eye protection and appropriate
clothing when painting.

•

Paint is flammable. Store in a safe place, and

keep it away from sparks, flames or cigarettes.

16.Coating the anti-rust agents.

•

Coating the anti-rust agents to the end of front

panel side and the door hinge areas.

17.Install the related parts.

•

Clean the passenger compartment.

•

Windshield, cowl and wiper.

•

Wiring harness, instrument panel and related

parts.

•

Carpet, trims and weatherstrip.

•

Door.

•

Fender and hood.

•

Radiator grill, bumper and others.

•

Install in the reverse order in which they were re-

moved.

18.Check and adjust.

•

Check the door for proper installation and opera-

tion.

•

Check clearances and level differences.

•

Check the hood locking and unlocking condition.

•

Check all operation.

•

Check for water leaks in the passenger compart-

ment.

NOTE:  Use specified check sheet for operation
check properly.

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

•  Repair procedure ........................................................................................................................... 5-8

3.  REAR FLOOR PANEL .................................................................................................................. 5-11

•  General description ..................................................................................................................... 5-11

•  Repair procedure ......................................................................................................................... 5-12