Daewoo Tacuma: Body Repair Manual - part 19

FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER  6–7

9. Install the door.

•

Install the door with four bolts.

•

Install the door check link set in the door and fix

the bolt.

•

Check clearances and level differences.

10.Install the related parts.

•

Handle, linkage and lock set.

•

Glass and window lifter.

•

Solenoid valve and wiring harness.

•

Install door trim and others.

NOTE: Before install the door trim and related parts,
rub in grease to the moving parts and check all op-
eration.

11.Check and adjust.

•

Check clearance and level differences.

•

Check the door locking and unlocking condition.

•

Check for water leaks in the passenger compart-

ment.

6–8   FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER

3. SIDE PANEL OUTER

3-1. GENERAL DESCRIPTION

The side panel outer consists of side outer area and
frame door area. The side outer area is a conspicuous
part of the outer appearance of the vehicle. It is espe-
cially important for the body line continuing from door.
Therefore, pay particular attention to it when conducting
work. This part must be aligned with the rear door, trunk
lid, rear glass and other parts.

Fig. 9  Side Panel Outer Welding Assembly

FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER  6–9

3-2. REPAIR PROCEDURE

1. Remove the related parts.

•

Rear and trunk trims.

•

Rear combination lamps and wiring harness.

•

Rear bumper and related parts.

•

Rear seat and rear seat belt.

•

Chassis and fuel parts.

•

Other related parts.

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

2. Pull out and straighten the damaged area to approxi-

mately the original shape.

•

Attach the car to the frame straightener by tight-

ening the underbody clamps at the four designated
support points.

•

Before cutting off the damaged sections, pull them

out so that they are restored to the original shape.

•

Do not pull out more than necessary.

•

Pull out and straighten the damaged areas of the

rear side outer panel, side inner panel and wheel-
house inner.

NOTE:  Check the rear door locking and unlocking
condition.

3. Cut and pry off the side panel outer.

•

Cut at the rear pillar and side outer(rear side of

frame door opening) along the bold lines as shown
with a handsaw and snips carefully.

•

Center punch around the spot weld imprints with

the rear panel, side panel inner and arch area.

•

Use the special spot cutter to drill holes at the

spot weld nuggets on the rear side outer panel.

NOTE: When drilling holes be careful not to drill down
to the side panel inner and rear panel themselves.

•

Cut the panel from the body with an air chisel,

leaving the welding flanges at the side inner panel,
wheelhouse inner and back panel intact.

•

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.

Fig. 10

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.

•

Sand off the paint and undercoat from both sides

of the flange to be welded.

5. Set the new side panel outer.

•

Cut the new side panel outer so it will overlap by

30mm in the frame door opening area with a hand
saw.

Fig. 11

6–10   FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER

•

Grind both sides of the welding section of the pre-

pared side panel outer with a disk sander to re-
move 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.

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

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

6. 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 and wheel arch of the side

panel outer 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. 12

7. Finish the welding areas.

•

Level the gas or MIG welded areas with a disc

sander, then even out high areas with a hammer
being careful not to deform them.

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

•

Use a hammer and dolly to even out the spot

welded flanges for a close fit with the surface of
the side panel outer.

•

Fill in deformations and level differences of the

welded areas with solder or putty, then finish.

8. Apply the sealer.

•

Apply the sealer to the matching surfaces of the

web plate, back panel lower, rear combination
lamp area and side panel outer.

9. Apply the undercoat.

•

Undercoat to the rear wheelhouse and designated

rear floor.

10.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.

11.Coating the anti-rust agents.

•

Coating the anti-rust agents to the inside of frame

door opening areas sufficiently.

12.Apply the deadner.

•

Apply the deadner to the inside of side panel outer

center.(Left side only)