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BODY REPAIR MANUAL (TACUMA/REZZO)
ISSUED BY
OVERSEAS SERVICE
DIVISION
DAEWOO MOTOR CO., LTD.
409-7 CHONG CHON-DONG, PU PYONG-KU,
INCHON, KOREA
TELEPHONE
:
82-32-509-7320~7326, 7350
FACSIMILE
:
82-32-509-7205, 7206
125
Table of Contents
Main Page
Section Index Body Repair Manual
2
Table of Contents
2
How to Use this Manual
3
General Instruction
6
Important Safety Notice
6
Body Safety
7
Corrosion Protection
7
Loads on Body Parts
7
Use of New High-Quality Materials
7
Zinc Treated Steel Plate Repair
8
Technical Illustration
10
Body Repair Procedures
18
Section 2 Preparations of Bodywork
19
General Description
20
Preparations of
20
Checkpoints
21
Correction of the Damaged Area
22
Measuring Systems (Without Small Damage)
23
Section 3 Welding and Tools
24
Spot Welding
25
General Description
25
Welding Conditions
25
Welding and Tools
25
Welding Strength Test
26
Gas Welding
27
Carbon Dioxide Arc Welder
28
Mig Arc Welding
28
Repair Tools
29
Section 4 Front
32
Default Chapter
32
Front
32
1 Front Panel
33
General Description
33
Repair Procedure
34
2 Front Wheelhouse
37
General Description
37
Repair Procedure
38
3 Front Longitudinal
42
General Description
42
Repair Procedure
42
4 Support Control Arm
45
General Description
45
Repair Procedure
46
5 Front Pillar
49
General Description
49
Repair Procedure
50
Section 5 Roof, Back Panel and Rear Floor Panel
54
Default Chapter
54
Roof, Back Panel and
54
1 Roof
55
General Description
55
Repair Procedure
56
2 Back Panel
60
General Description
60
Repair Procedure
61
3 Rear Floor Panel
64
General Description
64
Repair Procedure
65
Section 6 Frame Door Opening, Door and Side Panel Outer
69
1 Frame Door Opening
70
General Description
70
Repair Procedure
71
2 Door
74
Repair Procedure
74
3 Side Panel Outer
76
General Description
76
Repair Procedure
77
Section 7 Fender, Hood and Trunk Lid
80
Default Chapter
80
Fender, Hood and
80
1 Fender
81
Repair Procedure
81
2 Hood
83
Repair Procedure
83
3 Trunk Lid
85
Repair Procedure
85
Section 8 Body Dimension
87
Default Chapter
87
Body Dimension
87
1 Body Drawing
88
Under Body
89
Front Frame
90
Rear Frame
91
Front Panel
92
Engine Room
93
Side Outer
96
2 Body Welding Diagram
97
Front Panel Upper
97
Front Wheel House
98
Brace Wheel House
99
Dash Panel Upper
100
Dash Panel Lower
101
Roof
103
Body Side and Wheel House Inner
104
Rear Frame
105
Tail Gate
106
3 Gap Chart
107
Section 9 Sealing, Caulking and Deadner
109
Default Chapter
109
Sealing, Caulking and
109
Sealing & Caulking
110
Engine Room
110
Roof
113
Inside Room
114
Floor & Trunk Room
115
Hood
116
Trunk Lid
117
Front/Rear Door
118
Sealing
110
Caulking
119
Engine Room
119
Under Body
120
Back Panel
121
General Description
122
Repair Procedure
122
Under Body
124
Roof, Door
125
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