Daewoo Tacuma: Body Repair Manual - part 10

4–8  FRONT

•

Use a hammer and dolly to mold damaged areas

of the front longitudinal, rear wheelhouse and
other panels.

•

Even out the welding flanges with a hammer and

dolly.

7. Set the new front wheelhouse panel.

•

Grind both sides of the welding section of the

front, rear wheelhouse and front longitudinal 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.

•

Clamp to the front longitudinal with vise grips and

squill vises.

•

Clamp the front panel with vise grips.

NOTE: Use of jigs is recommended.

•

Weld the clamped sections for temporary instal-

lation.

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

8. Measure the front compartment diagonally.

•

Measure the front compartment diagonally with a

tracking gauge or convex rule to check it for twist-
ing or bending.

•

Temporarily assemble the fender and hood, then

check the clearances and level differences.

9. Perform the main welding.

•

Weld as much as possible with the jig still

mounted.

•

Perform a trial welding first, and check the weld-

ing condition.

•

Perform the welding.

Fig. 12

NOTE:

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If damage has occurred only front side, cut the

damaged section of the front wheelhouse, trim
the new panel to fit the remaining section, then
butt weld both parts at the inner ends.

6. Mold damaged related parts.

•

Fill any holes drilled by welding.

Fig. 13

 FRONT  4–9

Fig. 14

Fig. 15

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

•

Increase the number of spot by 20% for areas to

be spot welded.

10.Apply the sealer tape.

•

Apply the sealer tape to the hinge and brace

wheelhouse matching area as shown.

11.Weld the brace wheelhouse.

•

Spot weld the brace wheelhouse as shown.

•

Make MIG or gas welds at the door hinge areas.

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7

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6

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2

1

2

2

5

12  

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7

5

7

3

3

11

6

1

1

11

4

2

2

WHEN REPLACING THE
FRONT SIDE ONLY.

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6

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7

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3

SEALER TAPE

Fig. 16

12.Finish the welding areas.

•

Use a hammer and dolly to even out the rear

wheelhouse and front longitudinal flanges for a
close fit with the surface of the front wheelhouse.

4–10  FRONT

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 panting.

•

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.

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Wiring harness, instrument panel and related

parts.

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Parts of the passenger compartment.

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Parts to be installed when install the front panel.

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Others.

•

Install in the reverse order in which they were re-

moved.

NOTE: After install the all related parts, rub in grease
to the moving parts and replenish cooling liquid,
break oil, aircon gas and others.

18.Check and adjust

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Measure the front wheel alignment.

•

Check clearances and level differences.

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Check the hood locking and unlocking condition.

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Adjust the head lamp aim.

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Check all operation.

•

Check for gas, oil and liquid leaks.

NOTE: Use specified check sheet for operation check
properly.

 FRONT  4–11

3. FRONT LONGITUDINAL

3-1. GENERAL DESCRIPTION

The front longitudinal is joined to the wheelhouse and
front panel, it forms the base for the front suspension,
engine, transmission and others. Therefore, replace-
ment of the component affects the front wheel alignment
and maintains the rigidity of the front section. When
assembling it, either use a jig or follow dimensions on
the body repair chart for positioning. It must be welded
carefully.

3-2. REPAIR PROCEDURE

1. Remove the related parts.

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Parts to be removed when removing the front panel

and front wheelhouse.

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Parts on passenger side of dash panel lower which

are especially flammable.

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Instrument panel, wiring harness, related parts and

others.

NOTE: Remove according to part damaged.

2. Roughly pull out and straighten the damaged area to

approximately the original shape.

•

Attach the car to the frame straightener by tight-

ening the underbody clamps at the horizontal pinch
weld points.

•

Before cutting off the damaged sections, pull them

out so that they are restored to the original shape.

•

Roughly cut off the front longitudinal according to

the extent of damage before roughly pulling out the
damage makes repair of the related parts difficult.

•

Do not pull out more than necessary.

NOTE: Check the condition of the door and hinges.

3. Peel off the undercoat and sealer.

•

Heat the undercoat and sealer at the welding ar-

eas of the damaged parts with a gas torch and
peel off the undercoat and sealer with a steel
spatula.

CAUTION: Be careful not to burn the fittings inside
the passenger compartment when heating.

4. Cut and pry off the front longitudinal.

NOTE: It's not necessary to separate the wheelhouse
from the front longitudinal if the wheelhouse is to be
replaced also.

•

Center punch around the spot weld imprints on the

wheelhouse and other related parts.

•

Use the special spot cutter to drill holes at the

spot weld nuggets on the center punched areas.

•

Cut off the front longitudinal with an air chisel, leav-

ing the welding flanges intact.

•

Level and finish the burrs from the pried off spot

welds with a disc sander.

CAUTION: To prevent eye injury, wear goggles or

safety glasses whenever sanding, cutting, or grind-
ing.

Fig. 17

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11

3

5. 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.

•

Reshape the wheelhouse and other damaged

parts and even out the welding flanges with a
hammer and dolly.