2000 CHEVROLET REZZO Service Repair Manual

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.
1/2Body Repair ManualTacuma-Rezzo SERVICE NOTICE
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2/2Body Repair ManualTacuma-Rezzo SERVICE NOTICE

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.
1/9Body Repair ManualTacuma-Rezzo GENERAL INFORMATION

◦ 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.

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 sheet-
metal 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.

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
1. Panel Side Outer
2. Panel Side Lower
3. Cap Fuel Filler
4. Panel Tail Lamp Housing Lower
5. Panel Tail Lamp Housing Center
6. Panel Tail Lamp Housing Upper

7. Door Striker
8. Front Filler Lower
9. Reinforce Rocker
10. Center Filler Inner
11. Rail Roof Side
12. Extension Side Inner Front
13. Panel Side Inner Rear
14. Bracket Trim Mounting Rear Upper
15. Reinforce "D" Filler Rear
16. Reinforce "C" Filler
17. Reinforce Retract Rear
18. Rear Seat Belt Upper
19. Patch Wheel House Inner
20. Patch Wheel House Inner
21. Front Door Hinge
22. Front Door Hinge Upper
23. Front Filler Upper
24. Rocker Front
25. Seat Belt Front
26. Rear Door Hinge
27. Patch Center Filler
28. Reinforce Center Filler
1. Front Panel Upper
2. Support Front Panel Center
3. Crossmember Radiator Rear
4. Crossmember Radiator Front
5. Support Front Panel Side Inner
6. Support Front Panel Side Outer
7. Reinf Front Panel Side
8. Brace Wheel House
9. Rocator S/Absorber

10. Extension Wheel House Front
11. Bracket Fender
12. Wheel House Front
13. Wheel House Rear
14. Pannel Dash Upper Side
15. Stiffener Torque
16. Bracket Torque
17. Bracket Aircleaner
18. Bracket Engine Upper
19. Bracket Engine Rear
20. Bracket Power Steering Reserver
21. Support Tray Battery Inner
22. Tray Battery
23. Bracket Fuse Box Lower
24. Bracket Fuse Box Upper
25. Reinf Tray Battery
26. Bracket T/M
27. Bar Towing Front
28. Support Wheel Carrier Front
29. Reinf Front Longitudinal Outer Rear
30. Patch Reinf Longitudinal Outer
31. Reinf W/Carrier Rear
32. Extension Front Longitudinal
33. Brace Front Longitudinal
34. Longitudinal Front Inner
35. Reinf Front Longitudinal Inner
36. Support Crossmember Radiator Inner
37. Longitudinal Front Inner
38. Reinf Stay Front Bumper
39. Support Crossmember Radiator Outer
40. Cap Brake Booster
41. Panel Dash Lower Inner
42. Panel Dash Lower
43. Crossmember Dash Inner Lower Center
44. Crossmember Dash Inner Lower Side
45. Crossmember Dash Outer Lower Center
46. Reinf Wiper Motor
47. Crossmember Dash Outer Lower Side
48. Panel Front Filler Inner Center
49. Panel Front Filler Inner Lower
50. Bracket Steering Column Lower
51. Bracket Steering Column Rear
52. Bracket Steering Column Upper
53. Crossmember Dash Upper
54. Head Dash Upper
55. Panel Dash Upper
56. Panel Dash Top
57. Bracket Surgetank
58. Reinf Hinge Hood
59. Reinf Wiper Center
60. Patch Dash Lower Center
61. Reinf Tunnel Upper Front

1. Panel Front Floor
2. Reinf Tunnel
3. Tunnel Front
4. Reinf Tunnel Upper Rear
5. Panel Second Floor Rear
6. Reinf Second Floor Rear Inner
7. Reinf Second Floor Rear Outer
8. Longitudinal Floor Rear
9. Crossmember Front Seat Rear
10. Crossmember Front Seat Front
11. Support Front Seat Inner
12. Support Front Seat Outer
13. Tunnel Rear
14. Support Retracter
15. Reinf Floor Side
16. Bracket Rear Axle Outer
17. Crossmember Rear Floor Center
18. Panel Floor Side Rear
19. Longitudinal Rear
20. Reinf Rear Longitudinal Rear
21. Hanger Extension Pipe Rear Inner
22. Hanger Extension Pipe Rear Inner
23. Crossmember Rear Floor Center Side
24. Reinf Rear Longitudinal
25. Crossmember Rear Floor Rear
26. Crossmember Rear Floor Rear Side
27. Panel Rear Floor Rear Side
28. Crossmember Rear Floor Front

29. Support Rear Seat Rear
30. Seat Upper Spring
31. Crossmember Rear Seat Front
32. Crossmember Rear Seat Rear
33. Panel Rear Floor Rear
34. Reinf Striker
35. Reinf Back Panel Lower Center
36. Reinf Back Panel Lower Side
37. Panel Back Lower20.Reinf Rear Longitudinal Rear
1. Front Panel
2. Front Wheel House
3. Bracket Engine
4. Dash Panel Lower
5. Front Longitudinal
6. Brace Wheel House
7. Fender
8. Reinf Front Filler Lower
9. Side Body
10. Front Door
11. Rear Door
12. Floor Panel Side
13. Rear Frame
14. Front Floor
15. Rear Floor
16. Back Panel Lower
17. Tail Gate

18. Roof
19. Engine Hood
20. Dash Panel Upper
BODY REPAIR PROCEDURES
No. Operation Procedure Remarks
1
Inspection Inspect the damaged parts and the extent of damage and
make plans for the repair.
.
2 Preparation Prepare the new parts, special repair tools and others. .
3 Removal Remove the related parts for repair. .
4 Pull out Roughly pull out and straighten the damaged areas. .
5
Cut and pry off Cut off the damaged areas and drills on the spot weld
nuggets and pry off the remaining spot weld flanges.
.
6 Peel off Peel off the undercoat and sealer. .
7
Molding Mold damaged areas and even out the welding flanges and
fill any holes.
.
8
Set the new
parts
Grind both sides of the welding section and set the new parts
and tack welds for temporary installation.
.
9
Inspection Inspect the dimensions for correct position and preinstall the
exterior parts and check the clearances and level
differences.
.
10 Welding Perform a trial welding and the main welding. .
11
Finish Finish the welding areas and even out the flanges for a close
fit.
.
12 Sealing Apply the sealer to the matching and over lapped surface. .
13 Undercoating Apply the undercoat to the required areas. .
14 Painting Apply the paint. .
15 Deadner Apply the deadner to the designated areas. .
16
Anti-rust
agents
Coating the anti-rust agents to the designated areas. .
17
Installation Install the related parts and rub in grease to the moving parts
and replenish the cooling liquid, oil, aircon gas and others.
.
18
Check and
adjust
Check all operations, wheel alignments, leaks, head lamp
aim and others with the specified check sheet.
.

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
1/5Body 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:

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
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
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
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.

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)

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

Thank you very much
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2000 CHEVROLET REZZO Service Repair Manual

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