Daewoo Tacuma: Body Repair Manual - part 16

5–10   ROOF, BACK PANEL AND REAR FLOOR PANEL

10.Apply the sealer.

•

Apply the sealer to the rear side outer joint and

around the rear lamps areas of the rear panel.

•

Apply the sealer to the extension rear floor panel

and rear panel joint.

11.Apply the undercoat.

•

Undercoat to the joint and overlapped areas of

the rear floor under side.

12.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.

13.Install the related parts.

•

Clean the trunk compartment.

•

Install in the reverse order in which they were re-

moved.

14.Check and adjust.

•

Check clearances and level differences.

•

Check the trunk locking and unlocking condition.

•

Check all operation.

•

Check for water leaks in the trunk compartment.

NOTE:  Use specified check sheet for operation
check properly.

ROOF, BACK PANEL AND REAR FLOOR PANEL  5–11

3. REAR FLOOR PANEL

3-1. GENERAL DESCRIPTION

The rear floor panel is the base of the rear body and it
is critical for the rigidity of the rear body. During replace-
ment, refer to the body dimension chart or body repair
chart and determine the position to set the rear floor
properly.

Be sure that the rear floor is not bent or deformed. Weld
securely to maintain the rigidity of the rear body.

Fig. 14  Rear Floor Welding Assembly

5–12   ROOF, BACK PANEL AND REAR FLOOR PANEL

Fig. 15

Fig. 16

NOTE: When drilling holes be careful not to drill down
to the rear longitudinal, extension rear longitudinal
and web plate themselves.

•

Cut and pry off the remaining rear floor and ex-

tension rear floor panel with an air chisel, leaving
the welding flanges intact.

•

Level and finish the burrs from the pried off spot

welds with disc sander and repair all cracks, holes
or other defects by welding also repair the rear
longitudinal and extension rear longitudinal if nec-
essary.

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

CROSS MEMBER REAR SEAT

REAR FLOOR

FORWARD

3-2. REPAIR PROCEDURE

1. Remove the related parts.

•

Parts to be removed when removing the back

panel.

•

Rear seat belt and rear seat.

•

Muffler, fuel tank and related parts.

•

Chassis parts.

•

Other related parts.

CAUTION: Do not smoke while working near the fuel
system. Keep open flame away from the fuel sys-
tem. If necessary, remove the fuel tank and off lines.

2. Roughly pull out and straighten the damaged area.

•

Check the damage and roughly pull out and re-

pair the related back panel, side panel, wheel-
house inner, rear longitudinal and other damaged
parts with the frame straightener before remov-
ing the extension rear floor panel, rear floor panel
and back panel.

•

Attach the car to the frame straightener by tight-

ening the underbody clamps located at the jack
up designated points on the bottom of the frame
door opening.

NOTE:  Measure in reference to the dimensions on
the body repair chart.

3. Cut and pry off the back panel.

•

The back panel to be cut and pried off when re-

moving the back panel.

4. Cut and pry off the rear floor and extension rear floor

panel.

•

Cut off the rear floor and extension rear floor with

a gas torch or air chisel leaving the spot welded
flanges of the rear longitudinal along the bold line
in the figure below.

NOTE: Cut the rear floor 15mm(0.59in.) from welded
flange of the cross member rear seat.

•

Center punch around the spot weld imprints with

the rear longitudinal, extension rear longitudinal
and web plate.

•

Use the special spot cutter to drill holes at the

spot weld nuggets on the center punched areas.

15  mm

(0.59in.)

ROOF, BACK PANEL AND REAR FLOOR PANEL  5–13

7. Cut the new rear floor to align it with the body, then

set the new rear floor and extension rear floor.

•

Cut the new part so it overlaps the cross member

rear seat by approximately 40mm.

Fig. 17

5. Peel off the undercoat and sealer.

•

Heat the undercoat and sealer at the welding

areas with a gas torch and peel off the undercoat
and sealer with a steel spatula.

6. Mold damaged related parts.

•

Use a hammer and dolly to mold damaged areas

of the rear longitudinal and extension rear longi-
tudinal.

•

Even out the welding flanges with a hammer and

dolly.

•

Fill any holes drilled by welding.

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

•

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. 18

FORWARD

REAR FLOOR

NEW REAR FLOOR

CROSS MEMBER REAR SEAT

4 0 m m

•

Grind both sides of the welding section of the rear

floor and extension rear floor with a disk 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.

•

Set and clamp the new panel in place with the vise

grips.

NOTE: Use of jigs is recommended for correct posi-
tions and check that the both rear logitudinal is par-
allel.

•

Tack weld the clamped section for temporary in-

stallation.

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

rear panel, then check the alignment, level dif-
ferences and outer appearance.