Daewoo Tacuma: Body Repair Manual - part 14

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. Pay
particular attention to twists and parallelism.

Fig. 1  Roof Welding Diagram

ROOF, BACK PANEL AND REAR FLOOR PANEL  5–3

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.

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

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

Fig. 3

•

Dismantle the new roof panel.

•

Weld the clamped sections of the roof frames and

front, rear body pillar inner for temporary instal-
lation.

•

Set the new roof panel and clamp again.

•

Temporarily set the windshield and rear glass, and

check the roof panel for proper installation.

•

Install the roof molding and check the clearance

and outer appearance.

8. Apply the sealer to the roof frames.

•

Dismantle the new roof panel again.

•

Apply the sealer to one groove of the rail wind-

shield header, two grooves of the support roof
panel and one groove of the frame rear roof panel.

•

Set and tack weld  the roof panel.

Fig. 5

ROOF, BACK PANEL AND REAR FLOOR PANEL  5–5

10.Apply the sealer.

•

Apply the sealer to the welded areas.

Fig. 7

11.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 respi-

rator, gloves, eye protection and appropriate cloth-
ing when painting.

•

Paint is flammable. Store in a safe place, and keep

it away from sparks, flames or cigarettes.

12.Apply the deadner.

•

Apply the deadner to the front inside of roof panel

as shown.

9. Perform the main welding and finish.

•

Spot weld the roof panel.

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.

•

Use a hammer and dolly to smooth the spot weld

areas on the windshield and rear glass.

•

Cut off the irregular and unuseful flanges and

even out the flanges for a close fit with the sur-
face of the roof panel.

Fig. 6