2001 chevrolet rezzo service repair manual

Body Repair ManualTacuma-Rezzo SERVICE NOTICE

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Tacuma-Rezzo

SERVICE NOTICE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Notice : The following precautions should be observed when performing sheet metal work, paint work and repair work around the locations of the SRS parts.

1. SDM(Sensing and Diagnosis Module) are located under the console ass'y. Avoid strong impact with ass'y hammer or other tools when repairing the front side frame and the lower part of the dashboard. Do not apply heat to these areas with a gas burner, etc.

2. SRS harness is located under the lower part of the dashboard below the dashboard panel.

(SRS harness is covered with a yellow corrugated tube.) Care should be taken not to damage the harness when repairing this area.

3. Do not apply heat of more than 80°C(176°F) when drying painted surfaces anywhere around the locations of SRS parts.

4. If strong impact or high temperature needs to be applied to the areas around the locations of SRS parts, remove the part before performing repair work.

5. If any of the SRS related parts is damaged or deformed, be sure to replace it.

Note : Refer to the Service Manual(Supplemental Restraint System) for removal and replacement of SRS related parts.

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Body Repair ManualTacuma-Rezzo SERVICE NOTICE

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Body Repair ManualTacuma-Rezzo GENERAL INFORMATION

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Tacuma-Rezzo

GENERAL INFORMATION GENERAL INSTRUCTION This publication is designed to help you the body repair technician with your specialized work. Vehicle bodywork has changed a great deal over the years. As vehicles have developed technically, vehicle bodywork has also had to meet new requirements with design, changes to reconcile apparently conflicting demands to name just a few examples: • strength and safety ; low weight • spaciousness ; good aerodynamics • high quality ; low price The durability and ease of repair of the bodywork also plays an important part.

Nowadays, the use of highly automated production equipment makes it possible to maintain the tightest tolerances and thus ensure a high level of quality.

When bodywork is damaged, the customer rightly expects it to be expertly repaired to the same quality standards.

At the same time, for his safety, the customer expects you to have comprehensive knowledge of materials, measuring and straightening methods, possible distortion, optimum corrosion prevention and much more besides.

This publication is designed to help you update your knowledge and give you an idea of what you require to rectify moderate or severe accident damage, for your own safety and for the satisfaction of your customers.

IMPORTANT SAFETY NOTICE BEFORE BEGINNING WORK ◦ Disconnect the battery to reduce the possibility of fire caused by electrical shorts. ◦ Check for fuel leaks and repair as necessary. ◦ Remove the fuel tank and/or fuel lines if welding equipment is to be used near the fuel system. ◦ Before welding, sanding or cutting, protect carpets and seats with fire-proof covers. ◦ Follow standard safety practices when using toxic or flammable liquids. ◦ Use standard safety equipment when spraying paint, welding, cutting, sanding or grinding. Standard safety equipment includes. ◦ Respirator and filter masks: Designed to filter out toxic fumes, mist, dust or other airborn particles. Use a respirator or filter mask designed to protect you from the hazards of the particular job; some respirators, for example, are designed to filter out only dust and airborn particles, not toxic fumes. ◦ Safety goggles or glasses: Designed to protect your eyes from projectiles, dust particles or splashing liquid. ◦ Gloves: Rubber gloves protect against corrosive chemicals. Welding gloves protect against burns and abrasions caused by welding, sanding or grinding. ◦ Safety shoes: Non-slip soles protect against slipping. Metal toe inserts protect against falling objects. ◦ Ear plugs: Protect eardrums from harmful noise levels.

DURING WORK ◦ Do not smoke while working near the fuel system. ◦ Deposit gas or solvent-soaked shop towels in an approved container.

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◦ Brake lining contains asbestos, which can cause cancer. Do not use an air hose to blow off brake assemblies: use only an approved vacuum cleaner, and wear an approved filter mask or respirator. ◦ Always attach a safety cable when using a hydraulic ram or a frame straightening table: do not stand in direct line with the chains used on such equipment.

BODY SAFETY Modern stressed-skin bodies are designed so as to have a sturdy passenger cell protected by front and rear crumple zones.

• In an accident the crumple zones are designed to convert impact energy into deformation work.

• The shape, material and metal thickness must all be precisely matched.

• Many years of experience, refined computational methods and expensive series of crash tests mean that DAEWOO now builds bodies giving optimum deformation in the crumple zones in frontal or rear impacts.

When repairing body damage, it is therefore imperative to restore the original structure and strength in order to guarantee the safety of the occupants.

LOADS ON BODY PARTS • The earlier practice of making a distinction between load bearing and non-loading bearing parts of vehicles with a chassis and body is no longer justified now. Every part, even the windows, contributes to the overall strength of the vehicle.

THEREFORE, WITH MODERN DAEWOO BODIES, ONE TALKS OF HIGHLY STRESSED AND LESS HIGHLY STRESSED PARTS.

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USE OF NEW HIGH-QUALITY MATERIALS • The requirement for reduced body weight has lead to a reduction in the amount of steel used, e.g. through the use of thinner sheet steels.

This has been achieved with HIGH STRENGTH SHEET STEELS, in spite of the need to meet higher body strength requirements at the same time.

High strength steels have a tensile strength and a yield strength as much as 30% higher than conventional steel. These properties must not be destroyed when carrying out repairs, e.g. by using excessive heat.

CORROSION PROTECTION • The durability of the bodywork, its associated long-term safety and retention of value largely depend on the corrosion protection given to the sheet metal. Here, DAEWOO takes a great deal of care in production.

• Therefore, this corrosion protection must be preserved or restored when repairs are carried out.

SUMMARY • All DAEWOO vehicles are built to the highest standards in terms of styling and material properties.

• These high quality standards must be maintained when accident repairs are carried out.

• Mistakes made when carrying out repair operations such as straightening, welding sheetmetal parts, etc. not only produce visible defects, but may also compromise the safety of the vehicle.

• Mistakes made when restoring the corrosion protection compromise durability.

ZINC TREATED STEEL PLATE REPAIR The zinc plated steel plate used in some panels of the LANOS requires different repair techniques than ordinary steel plate.

1. Before spot welding the zinc plated steel plate, remove the paint from both sides of the flange to be welded. Apply sealer to the flange after welding.

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Caution : To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or grinding.

Note : Seal the sanded surfaces thoroughly to prevent rust.

2. The electric continuity properties of zinc plated steel plate is different from ordinary steel plate.

When spot welding, increase the current by 10-20%, or increase the resistance welding time.

Increase the number of weld spots by 10-20% also.

Note : The MIG welding procedures for zinc plated steel plate are the same as for ordinary steel plate.

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

3. Before applying putty or body filler to the zinc plated steel plate, sand the zinc plating thoroughly to promote adhesion and prevent blistering.

Note : Use only epoxy-based putties and fillers on zinc plated steel plate.

BLANK

TECHNICAL ILLUSTRATION

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Panel Side Outer Panel Side Lower Cap Fuel Filler Panel Tail Lamp Housing Lower Panel Tail Lamp Housing Center Panel Tail Lamp Housing Upper

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Door Striker Front Filler Lower Reinforce Rocker Center Filler Inner Rail Roof Side Extension Side Inner Front Panel Side Inner Rear Bracket Trim Mounting Rear Upper Reinforce "D" Filler Rear Reinforce "C" Filler Reinforce Retract Rear Rear Seat Belt Upper Patch Wheel House Inner Patch Wheel House Inner Front Door Hinge Front Door Hinge Upper Front Filler Upper Rocker Front Seat Belt Front Rear Door Hinge Patch Center Filler Reinforce Center Filler

Front Panel Upper Support Front Panel Center Crossmember Radiator Rear Crossmember Radiator Front Support Front Panel Side Inner Support Front Panel Side Outer Reinf Front Panel Side Brace Wheel House Rocator S/Absorber

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Body Repair ManualTacuma-Rezzo GENERAL INFORMATION

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Extension Wheel House Front Bracket Fender Wheel House Front Wheel House Rear Pannel Dash Upper Side Stiffener Torque Bracket Torque Bracket Aircleaner Bracket Engine Upper Bracket Engine Rear Bracket Power Steering Reserver Support Tray Battery Inner Tray Battery Bracket Fuse Box Lower Bracket Fuse Box Upper Reinf Tray Battery Bracket T/M Bar Towing Front Support Wheel Carrier Front Reinf Front Longitudinal Outer Rear Patch Reinf Longitudinal Outer Reinf W/Carrier Rear Extension Front Longitudinal Brace Front Longitudinal Longitudinal Front Inner Reinf Front Longitudinal Inner Support Crossmember Radiator Inner Longitudinal Front Inner Reinf Stay Front Bumper Support Crossmember Radiator Outer Cap Brake Booster Panel Dash Lower Inner Panel Dash Lower Crossmember Dash Inner Lower Center Crossmember Dash Inner Lower Side Crossmember Dash Outer Lower Center Reinf Wiper Motor Crossmember Dash Outer Lower Side Panel Front Filler Inner Center Panel Front Filler Inner Lower Bracket Steering Column Lower Bracket Steering Column Rear Bracket Steering Column Upper Crossmember Dash Upper Head Dash Upper Panel Dash Upper Panel Dash Top Bracket Surgetank Reinf Hinge Hood Reinf Wiper Center Patch Dash Lower Center Reinf Tunnel Upper Front

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Body Repair ManualTacuma-Rezzo GENERAL INFORMATION

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Panel Front Floor Reinf Tunnel Tunnel Front Reinf Tunnel Upper Rear Panel Second Floor Rear Reinf Second Floor Rear Inner Reinf Second Floor Rear Outer Longitudinal Floor Rear Crossmember Front Seat Rear Crossmember Front Seat Front Support Front Seat Inner Support Front Seat Outer Tunnel Rear Support Retracter Reinf Floor Side Bracket Rear Axle Outer Crossmember Rear Floor Center Panel Floor Side Rear Longitudinal Rear Reinf Rear Longitudinal Rear Hanger Extension Pipe Rear Inner Hanger Extension Pipe Rear Inner Crossmember Rear Floor Center Side Reinf Rear Longitudinal Crossmember Rear Floor Rear Crossmember Rear Floor Rear Side Panel Rear Floor Rear Side Crossmember Rear Floor Front

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Body Repair ManualTacuma-Rezzo GENERAL INFORMATION

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Support Rear Seat Rear Seat Upper Spring Crossmember Rear Seat Front Crossmember Rear Seat Rear Panel Rear Floor Rear Reinf Striker Reinf Back Panel Lower Center Reinf Back Panel Lower Side Panel Back Lower20.Reinf Rear Longitudinal Rear

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Front Panel Front Wheel House Bracket Engine Dash Panel Lower Front Longitudinal Brace Wheel House Fender Reinf Front Filler Lower Side Body Front Door Rear Door Floor Panel Side Rear Frame Front Floor Rear Floor Back Panel Lower Tail Gate

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Body Repair ManualTacuma-Rezzo GENERAL INFORMATION

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18. Roof 19. Engine Hood 20. Dash Panel Upper

BODY REPAIR PROCEDURES No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Operation

Procedure

Remarks

Inspection

Inspect the damaged parts and the extent of damage and . make plans for the repair.

Preparation Prepare the new parts, special repair tools and others. .

Removal Remove the related parts for repair. .

Pull out Roughly pull out and straighten the damaged areas. .

Cut and pry off Cut off the damaged areas and drills on the spot weld . nuggets and pry off the remaining spot weld flanges.

Peel off Peel off the undercoat and sealer. .

Molding Mold damaged areas and even out the welding flanges and . fill any holes.

Set the new Grind both sides of the welding section and set the new parts . parts and tack welds for temporary installation.

Inspection Inspect the dimensions for correct position and preinstall the . exterior parts and check the clearances and level differences.

Welding Perform a trial welding and the main welding. .

Finish Finish the welding areas and even out the flanges for a close . fit.

Sealing Apply the sealer to the matching and over lapped surface. .

Undercoating Apply the undercoat to the required areas. .

Painting Apply the paint. .

Deadner Apply the deadner to the designated areas. .

Anti-rust Coating the anti-rust agents to the designated areas. . agents Installation Install the related parts and rub in grease to the moving parts . and replenish the cooling liquid, oil, aircon gas and others.

Check and Check all operations, wheel alignments, leaks, head lamp . adjust aim and others with the specified check sheet.

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Body Repair ManualTacuma-Rezzo PREPARATIONS OF BODYWORK

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Tacuma-Rezzo

PREPARATIONS OF BODYWORK GENERAL DESCRIPTION • Most monocoque bodies are composed as a single unit by welding together pressed parts made of steel plates which come in a variety of different shapes and sizes. Each part is responsible for displaying a certain strength and durability in order that it may play its role in meeting the functions of the body as a whole.

Damage to the exterior of the body can be inspected visually, but where there has been an external impact, it is necessary to inspect the extent of the damage. In some cases, the deformation has spread beyond the actual areas which were in the collision and so this has to be inspected closely.

Unit: mm

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Body Repair ManualTacuma-Rezzo PREPARATIONS OF BODYWORK

CHECKPOINTS • Accurate Inspection of Damaged Parts(Visual) Seat Belts Always replace the seat belt if: 1. The belt material is cut, punctured, burned or in any way damaged.

2. The buckle or retractor does not work properly.

3. They were being worn at the time of a collision(also check for damage at the seat belt anchor points).

4. Their condition is questionable.

Front Section:

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Body Repair ManualTacuma-Rezzo PREPARATIONS OF BODYWORK

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1. Is there any bending, splitting, denting or other damage to the suspension and its related parts?

2. Is there any deformation of the front panel or radiator crossmember? Have any of the connected sections come apart?

3. Are there any creases or distortion in the front wheel-house or side frame? Have any of the connected sections come apart?

4. Is there any bending or twisting of the whole front area?

5. Is there any deformation like creases, bulges, or dents in the front pillar, dash panel, floor, etc.?

6. Is there any vertical twisting or misaligned clearance in the door?

7. Is the windshield seal broken?

8. Is there any deformation in the vicinity of the top part of the roof panel's center pillar?

9. Is there any damage inside the automobile(is there any twisting of the dash panel, or anything irregular with the clearances or sheet-mounting parts)?

10. Is there any damage to the steering wheel? Is there any deformation in the column and the column-mounted parts?

11. Is there any oil or water leakage and damage to the engine, transmission or brakes?

12. Is there any irregular noise in the gear changing operation, engine and transmission rotation?

13. Are there any traces of contact between the engine block and the center crossmember?

14. Is there any damage to brake or fuel lines, or wire harnesses?

Rear Section: 1. Is there any twisting, bulging or denting of the rear floor any rear bolsters? Have any of the connected sections come apart?

2. Is there any irregular bulging or denting in the rear fender?

3. Is there any distortion in the rear inner panel? Is there any bending and denting in the vicinity of the rear pillar?

4. Is there any distortion or creasing is the rear wheel-house and arch sections? Have any of the connected sections come apart?

5. Is there anything irregular in the rear glass seal clearance?

6. Is there any twisting or misalignment of the clearance of the trunk lid opening section?

7. Is there any bending, splitting, denting or other damage to the suspension and its related parts?

8. Is there any deformation of the rear floor crossmember, trunk floor panel and back panel?

Have any of the connected sections come apart?

Impact Beam : Always replace the door assembly if: 1. The external force makes the impact beam of door inner deform. Always replace impact beam if: 2. The external force makes the impact beam of front bumper and rear bumper deform.

CORRECTION OF THE DAMAGED AREA • Set the frame corrector on the car body. • The side frame is to allow reshaping by pulling it out. • Use the horizontal pinch welds for anchoring the car. and pull it out until the section is almost restored to the original shape.

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MEASURING SYSTEMS (WITHOUT SMALL DAMAGE) • Whenever possible, make judgements and conclusions based on measurement. Measure the wheel alignment(see pages 2-2, 2-3) so as to prevent any future trouble like unsymmetrical wear of the tires or catching of the steering wheel.

• If there are any deviations, use a tram tracking gauge and measure parts of the body.(Below Fig. 4-1) • If there is any twisting to the body, measure using a frame centering gauge.(Below Fig. 4-2)

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Body Repair ManualTacuma-Rezzo PREPARATIONS OF BODYWORK

• When measuring body dimensions, use a universal tram gauge.(Below Fig. 4-3)

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