spark DAEWOO LACETTI 2004 Service Owners Manual

9P – 6IDOORS
DAEWOO V–121 BL4
DIAGNOSIS
POWER WINDOWS
System With Only Front Power Windows, One or Both Windows
are Inoperative
CAUTION : When powering the window motors directly from a battery with jumper wires, make sure one of the
jumper wires contains a fuse. If the jumpers are accidentally touched together, the fuse will prevent sparking
and burns from sudden terminal heating.
Step
ActionValue(s)YesNo
11. Turn the ignition ON.
2. Attempt to operate both power windows.
Is either window working?–Go to
Step 18Go to
Step 2
2Visually inspect the connection at the dual
power window switch.
Is the electrical connector correctly attached
to the switch?–Go to
Step 4Go to
Step 3
3Correctly attach the electrical connector to
the dual power window switch.
Is the repair complete?–System
OK–
41. Disconnect the electrical connector from the
dual power window switch.
2. Turn the ignition ON.
3. Check the voltage at terminal 4 and 5 of the
power window main switch connector.
Is the voltage equal to the specified value?11–14 vGo to
Step 16Go to
Step 5
5Check fuses EF14 and EF9.
Is either fuse blown?–Go to
Step 6Go to
Step 7
61. Check for a short circuit and repair if neces-
sary.
2. Replace the blown fuse(s).
Is the repair complete?–System
OK–
71. Turn the ignition ON.
2. Check the voltages at fuses EF9 and EF14.
Are both voltages equal to the specified val-
ue?11–14 vGo to
Step 9Go to
Step 8
8Repair the power supply to the fuse which did
not indicate battery voltage with the ignition
on.
Is the repair complete?–System
OK–
91. Remove the power window relay.
2. Turn the ignition ON.
3. Check the voltage at terminal 30 and terminal
85 of the power window relay socket. (Termi-
nals of the relay socket can be identified by
the markings on the bottom of the relay.)
Does the voltmeter indicate the specified val-
ue at terminals 30 and 85?11–14 vGo to
Step 11Go to
Step 10
10Repair the open circuit between the fuses and
the power window relay.
Is the repair complete?–System
OK–

DOORS 9P – 9
DAEWOO V–121 BL4
System With Front and Rear Power Windows, One or Both Front
Windows are Inoperative
CAUTION : When powering the window motors directly from a battery with jumper wires, make sure one of the
jumper wires contains a fuse. If the jumpers are accidentally touched together, the fuse will prevent sparking
and burns from sudden terminal heating.
Step
ActionValue(s)YesNo
11. Turn the ignition ON.
2. Attempt to operate each front power window.
Is either window working?–Go to
Step 18Go to
Step 2
2Visually inspect the connection at the power
window main switch.
Is the electrical connector correctly attached
to the main switch?–Go to
Step 4Go to
Step 3
3Correctly attach the electrical connector to
the power window main switch.
Is the repair complete?–System
OK–
41. Disconnect the electrical connector from the
power window main switch.
2. Turn the ignition ON.
3. Check the voltage at terminal 3 and 10 of the
power window main switch connector.
Is the voltage equal to the specified value?11–14 vGo to
Step 16Go to
Step 5
5Check fuses EF14 and EF9.
Is either fuse blown?–Go to
Step 6Go to
Step 7
61. Check for a short circuit and repair, if neces-
sary.
2. Replace the blown fuse(s).
Is the repair complete?–System
OK–
71. Turn the ignition ON.
2. Check the voltages at fuses Ef9 and EF14.
Are both voltages equal to the specified val-
ue?11–14 vGo to
Step 9Go to
Step 8
8Repair the power supply to the fuse which did
not indicate battery voltage with the ignition
on.
Is the repair complete?–System
OK–
91. Remove the power window relay.
2. Turn the ignition ON.
3. Check the voltage at terminal 30 and terminal
86 of the power window relay socket. (Termi-
nals of the relay socket can be identified by
the markings on the bottom of the relay.)
Does the voltmeter indicate the specified val-
ue?11–14 vGo to
Step 11Go to
Step 10
10Repair the open circuit between the fuses and
the power window relay.
Is the repair complete?–System
OK–

9P – 12IDOORS
DAEWOO V–121 BL4
System With Front and Rear Power Windows, One or Both Rear
Windows are Inoperative
CAUTION : When powering the window motors directly from a battery with jumper wires, make sure one of the
jumper wires contains a fuse. If the jumpers are accidentally touched together, the fuse will prevent sparking
and burns from sudden terminal heating.
Step
ActionValue(s)YesNo
11. Turn the ignition ON.
2. Make sure that the window lock position has
not been selected on the power window main
switch.
Is either rear power window working?–Go to
Step 18Go to
Step 2
2Visually inspect the connection at the power
window main switch.
Is the electrical connector correctly attached
to the main switch?–Go to
Step 4Go to
Step 3
3Correctly attach the electrical connector to
the power window main switch.
Is the repair complete?–System
OK–
41. Disconnect the electrical connector from the
power window main switch.
2. Turn the ignition ON.
3. Check the voltage at terminal 3 and 10 of the
power window main switch connector.
Is the voltage equal to the specified value?11–14 vGo to
Step 16Go to
Step 5
5Check fuses EF9 and EF14.
Is either fuse blown?–Go to
Step 6Go to
Step 7
61. Check for a short circuit and repair, if neces-
sary.
2. Replace the blown fuse(s).
Is the repair complete?–System
OK–
71. Turn the ignition ON.
2. Check the voltages at fuses Ef9 and EF14.
Are both voltages equal to the specified val-
ue?11–14 vGo to
Step 9Go to
Step 8
8Repair the power supply to the fuse which did
not indicate battery voltage with the ignition
on.
Is the repair complete?–System
OK–
91. Turn the ignition ON.
2. Remove the power window relay.
3. Check the voltage at terminal 30 and terminal
86 of the power window relay socket. (Termi-
nals of the relay socket can be identified by
the markings on the bottom of the relay.)
Does the voltmeter indicate the specified val-
ue?11–14 vGo to
Step 11Go to
Step 10
10Repair the open circuit between the fuses and
the power window relay.
Is the repair complete?–System
OK–

4–4 FRONTNUBIRA/LACETTI
Fig. 5
Note : Make sure that the right and left front panels are
in line with each others.
7. Measure the front compartment diagonally.
S Measure the front compartment diagonally with a track-
ing gauge or convex rule as shown to check it for twisting
or bending.
S Temporarily assemble the fender, head lamps and hood,
then check the clearances and level differences.
Fig. 6
8. Perform the main welding.
S Spot weld the front panel as shown.
CAUTION : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
S Perform a trial welding first, and check the weldng condi-
tion.
S Increase the number of spot by 20% for areas to be spot
welded.
Fig. 7
9. Finish the welding areas.
S Use a hammer and dolly to even out the front wheel-
house and longitudinal flanges for a close fit with the sur-
face of the front panel.
10. Apply the undercoat.
S Undercoat to the damaged areas of front wheelhouse
and longitudinal if necessary.
11. Apply the paint.
CAUTION
S Ventilate when spraying paint. Most paint contains sub-
stances that are harmful if inhaled or swallowed. Rear
the paint label before opening paint container.
S Avoid contact with skin. Wear an approved respirator,
gloves, eye protection and appropriate clothing when
painting.
S Paint is flammable. Store in a safe place, and keep it
away from sparks, flames or cigarettes.
12. Coating the anti–rust agents.
S Coating the anti–rust agents to the end of front panel
side and the door hinge areas.
Fig. 8
13. Install the related parts.
S Engine, radiator and related parts.

NUBIRA/LACETTIFRONT 4–9
Fig. 14
11. Weld the brace wheelhouse.
S Spot weld the brace wheelhouse as shown.
S Make MIG or gas welds at the door hinge areas.
Fig. 15
12. Finish the welding areas.
S Use a hammer and dolly to even out the rear wheel-
house and front longitudinal flanges for a close fit with
the surface of the front wheelhouse.
13. Apply the sealer
S Apply the sealer to the matching and overlapped sur-
face.
14. Apply the undercoat.
S Undercoat to the inside of the front, rear wheelhouse
and longitudinal.
15. Apply the paint.
CAUTION
S Ventilate when spraying paint. Most paint contains sub-
stances that are harmful if inhaled or swallowed. Read
the paint label before opening paint container.
S Avoid contact with skin. Wear an approved respirator,
gloves, eye protection and appropriate clothing when
panting.S Paint is flammable. Store in a safe place, and keep it
away from sparks, flames or cigarettes.
16. Coating the anti–rust agents.
S Coating the anti–rust agents to the end of front panel
side and the door hinge areas.
17. Install the related parts.
S Wiring harness, instrument panel and related parts.
S Parts of the passenger compartment.
S Parts to be installed when install the front panel.
S Others.
S Install in the reverse order in which they were removed..
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
S Measure the front wheel alignment.
S Check clearances and level differences.
S Check the hood locking and unlocking condition.
S Adjust the head lamp aim.
S Check all operation.
S Check for gas, oil and liquid leaks.
Note : Use specified check sheet for operation check
properly.

4–12 FRONTNUBIRA/LACETTI
Note : Use of jigs is recommended for correct positions
and check that the both front longitudinal and wheel-
house are parallel.
S Tack weld the clamped section for temporary installa-
tion.
7. Perform the main welding.
S Weld as much as possible with the jig still mounted.
S Make MIG or gas welds at the butt joints at the front lon-
gitudinal, carefully.
Fig. 19
S Spot weld the wheelhouse with the front longitudinal
flange areas and front panel.
CAUTION : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
S Perform a trial welding first, and check the welding con-
dition.
S Increase the number of spot by 20% for areas to be spot
welded.
Fig. 20
S Level the weld beads at the longitudinal butt joints area
with disc sander.
S Make the stiffener(Thickness: 2.8 mm Min., Width: 80
mm) according to the form of longitudinal butt joint areasand weld the stiffener at the longitudinal butt joint areas
with MIG welder.
Fig. 21
8. Finish the welding areas.
S Level the gas or MIG welded areas with disc sander.
S Use a hammer and dolly to even out the wheelhouse and
longitudinal flanges for a close fit.
9. Apply the sealer.
S Apply the sealer to the joint areas of the dash panel lower
and floor panel areas.
10. Apply the undercoat.
S Undercoat to the joint and overlapped areas of the front
floor, longitudinal under side and the inside of front, rear
wheelhouse.
11. Apply the paint.
CAUTION
S Ventilate when spraying paint. Most paint contains sub-
stances that are harmful if inhaled or swallowed. Read
the paint label before opening paint container.
S Avoid contact with skin. Wear an approved respirator,
gloves, eye protection and appropriate clothing when
painting.
S Paint is flammable. Store in a safe place, and keep it
away from sparks, flames or cigarettes.
12. Coating the anti–rust agents.
S Coating the anti–rust agents to the end of front panel
side and the front door hinge areas.
13. Install the related parts.
S Clean the passenger compartment.
S Wiring harness, instrument panel and related parts.
S Parts of the passenger compartment.
S Chassis components.
S Engine, radiator and related parts.
S Aircon condenser and related parts.
S Head lamps and fenders.
S Heed, radiator grill, and bumper.
S Others.
S Install in the reverse order in which they were removed.

NUBIRA/LACETTIFRONT 4–17
Fig. 28
9. Finish the welding areas.
S Level the gas or MIG welded areas with a disc sander,
then even out high areas with a hammer being careful
not to deform them.
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding cutting or grind-
ing.
S Use a hammer and dolly to even out the spot welded
flanges for a close fit with the surface of the inner panel.
S Fill in deformations and level differences of the welded
areas with solder or putty, then finish.
10. Apply the sealer tape.
S Apply the sealer tape to the hinge and brace wheelhouse
matching area as shown.
Fig. 2911. Weld the brace wheelhouse.
S Spot weld the brace wheelhouse as shown.
S Make MIG or gas welds at the door hinge areas.
Fig. 30
12. Finish the welding areas.
S Use a hammer and dolly to even out the brace wheel-
house for a close fit with the surface of the wheelhouse.
13. Apply the sealer.
S Apply the sealer to the matching and overlapped sur-
face.
14. Apply the undercoat.
S Undercoat to the inside of the front, rear wheelhouse
and longitudinal.
15. Apply the paint.
CAUTION
S Ventilate when spraying paint. Most paint contains sub-
stances that are harmful if inhaled or swallowed. Read
the paint label before opening paint container.
S Avoid contact with skin. Wear an approved respirator,
gloves, eye protection and appropriate clothing when
painting.
S Paint is flammable. Store in a safe place, and keep it
away from sparks, flames or cigarettes.
16. Coating the anti–rust agents.
S Coating the anti–rust agents to the end of front panel
side and the door hinge areas.
17. Install the related parts.
S Clean the passenger compartment.
S Windshield, cowl and wiper.
S Wiring harness, instrument panel and related parts.
S Carpet, trims and weatherstrip.
S Door
S Fender and hood.
S Radiator grill, bumper and others.
S Install in the reverse order in which they were removed.
18. Check and adjust.
S Check the door for proper installation and operation.
S Check clearances and level differences.

NUBIRA/LACETTI ROOF, BACK PANEL AND REAR FLOOR PANEL 5–5
Fig. 7
10. Apply the sealer.
S Apply the sealer to the welded areas.
Fig. 8
11. Apply the paint.
CAUTION
S Ventilate when spraying paint. Most paint contains sub-
stances that are harmful if inhaled or swallowed. Readthe paint label before opening paint container.
S Avoid contact with skin. Wear an approved respirator,
gloves, eye protection and appropriate clothing when
painting.
S Paint is flammable. Store in a safe place, and keep it
away from sparks, flames or cigarettes.
12. Apply the deadner.
S Apply the deadner to the front inside of roof panel as
shown.
13. Install the related parts.
S Windshield and rear glass.
S Cowl, wiper and related parts.
S Wiring harness and headlining.
S Pillar trims, door weatherstrip and others.
S Install in the reverse order in which they were removed.
14. Check and adjust.
S Clean the passenger compartment.
S Check the windshield and rear glass for water leaks.
S Wiring harness and headlining.

5–8 ROOF, BACK PANEL AND REAR FLOOR PANEL NUBIRA/LACETTI
S Clamp both the right and left sides with the vise grips as
shown.
S Weld the clamped sections for temporary installation.
CAUTION : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
Fig. 13
7. Measure and check.
S Measure the trunk compartment diagonally to check it
for twisting or bending and its correct position with the
rear bumper installed.
S Temporarily assemble the rear combination lamps and
trunk, then check the clearances and level differences.
8. Perform the main welding.
S Make MIG or gas welds at the butt joints.
S Spot weld the back panel as shown.
CAUTION : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
S Perform a trial welding first, and check the welding con-
dition.
S Increase the number of spot by 20% for areas to be spot
welded.
Fig. 14
9. Finish the welding areas.S Level the gas or MIG welded areas with disc sander,
then even out high areas with a hammer being careful
not to deform them.
S Use a hammer and dolly to even out the rear side outer
and extension rear floor panel flanges for a close fit with
the surface of the rear panel.
10. Apply the sealer.
S Apply the sealer to the rear side outer joint and around
the rear lamps areas of the rear panel.
S Apply the sealer to the extension rear floor panel and
rear panel joint.
11. Apply the undercoat.
S Undercoat to the joint and overlapped areas of the rear
floor under side.
12. Apply the paint.
CAUTION
S Ventilate when spraying paint. Most paint contains sub-
stances that are harmful if inhaled or swallowed. Read
the paint label before opening paint container.
S Avoid contact with skin. Wear an approved respirator,
gloves, eye protection and appropriate clothing when
painting.
S Paint is flammable. Store in a safe place, and keep it
away from sparks, flames or cigarettes.
13. Install the related parts.
S Clean the trunk compartment.
S Install in the reverse order in which they were removed.
14. Check and adjust.
S Check clearances and level differences.
S Check the trunk locking and unlocking condition.
S Check all operation.
S Check for water leaks in the trunk compartment.
Note : Use specified check sheet for operation check
properly.

NUBIRA/LACETTI ROOF, BACK PANEL AND REAR FLOOR PANEL 5–13
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever standing, cutting, or
grinding.
Fig. 22
S Use a hammer and dolly to even out the spot welded
areas for a close fill the flange surface together.
11. Apply the sealer.
S Apply the sealer at the overlapped areas of the rear floor
and extension rear floor, and welded surfaces of the
matching panel and all sealing gaps completely.
12. Apply the undercoat.
S Undercoat to the rear wheelhouse and designated rear
floor.
13. Apply the paintCAUTION
S Ventilate when spraying paint. Most paint contains sub-
stances that are harmful if inhaled or swallowed. Read
the paint label before opening paint container.
S Avoid contact with skin. Wear an approved respirator,
gloves, eye protection and appropriate clothing when
painting.
S Paint is flammable. Store in a safe place, and keep it
away from sparks, flames or cigarettes.
14. Apply the deadner.
S Clean the passenger and trunk compartment.
S Apply the deadner to the surface of rear floor and exten-
sion rear floor.
Fig. 23
15. Install the related parts.
S Install in the reverse order in which they were removed.
16. Check and adjust
S Check clearances and level differences.
S Check the trunk locking and unlocking condition.
S Check all operation.
S Check for water leaks in the trunk compartment.
Note : Use specified check sheet for operation check
properly.