Daewoo Tacuma: Body Repair Manual - part 12


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Daewoo Tacuma: Body Repair Manual - part 12



4–16  FRONT

6. Mold damaged related parts.

Reshape the dash panel lower, crossmember

front floor panel and other related parts with a
hammer and dolly.

Even out the welding areas with a hammer and


Fill any holes drilled by welding.

7. Set the new support control arm.

Preset the new support control arm at the posi-

tion and marked welding position and will be
welded by MIG plug welding.

Increase the number of plug welding by 20%.

Drill holes through the marked position with a 5

mm drill for MIG plug welding.

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

Set the support control arm in place using a jack

and clamp with the vise grips.

NOTE: Use of jigs is recommended for correct posi-

Check the clearance and even out the flanges for

with a hammer and dolly.

 8. Perform the main welding.

Plug weld the holes of support control arm with a

MIG welder.

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

 9. Finish the welding areas.

Level the plug welded areas with a disc sander.

10.Apply the sealer.

Apply the sealer to the inside of passenger com-

partment joint areas.

11.Apply the undercoat.

Undercoat to the surface of front floor,

crossmember front floor, support control arm and

12.Apply the paint.


Ventilate when spraying paint. Most paint contains

substances that are harmful if inhaled or swal-

Read the paint label before opening paint con-


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.

Grind both sides of the welding section of the sup-

port control arm and the matching surface of parts
with a disk sander to remove the paint and ex-
pose the steel plate.

Fig. 24






 FRONT  4–17

13.Apply the deadner.

Clean the passenger compartment.

Apply the deadner to the surface of floor panel.

Fig. 25

14.Install the related parts.

Clean the passenger compartment.

Wiring harness and related parts.

Parts of the passenger compartment.

Chassis components.

Parts of the front compartment.

Hood, radiator grill, and bumper.


Install in the reverse order in which they were re-


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

15.Check and adjust

Measure the front wheel alignment.

Check clearances and level differences.

Check the hood locking and unlocking condition.

Adjust the head lamp aim.

Check all operation.

Check for gas, oil and liquid leaks.

Check for water leaks in the passenger compart-


NOTE: Use specified check sheet for operation
check properly.


4–18  FRONT



The front pillar area is part of the frame door opening
panel. It's connected to the roof, windshield, door hinges
and floor frame and is important as a support for the
front side of the cabin. Connection of the front pillar
determines the position of the windshield and front door.
Align the fender, door and windshield while the front
pillar is temporary mounted, and check the clearances
and level differences.

Fig. 26  Front Pillar Welding Assembly

 FRONT  4–19


1. Remove the related parts.

Hood, radiator grill and front bumper.

Door and fender.

Wiper, cowl and windshield.

Weatherstrip and pillar trims.

Instrument panel and wiring harness.

Carpet and others.

2. Roughly pull out and straighten the damaged area.

Check the damage to the wheelhouse and roof

before removing the brace wheelhouse and front
pillar and determine the extent of the damage.

Use the frame straightener to roughly pull out and

repair the damaged front pillar before removing
the brace wheelhouse and front panel.

NOTE: Pull out until the pillar is lined up with the
surface of the windshield and do not pull out more
than necessary.

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

Using a chisel, pry off the welded flange from the

front body pillar and wheelhouse.

Fig. 27

3. Remove the brace wheelhouse.

Center punch around the spot weld imprints.

Use the special spot cutter to drill holes at the

spot weld nuggets on the brace wheelhouse.

Remove the MIG weld areas with a disc sander.

Fig. 28

4. Peel off the undercoat and sealer.

Heat the undercoat and sealer at the welding

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

5. Cut and pry off the front pillar.

Cut off the front pillar along the bold lines as

shown in the figure below with a handsaw and
snips carefully.

NOTE: Be careful not to cut the inner section.








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