DAEWOO LACETTI 2004 Service Repair Manual

NUBIRA/LACETTIWELDING AND TOOLS 3–5
Note : Below is an example of how not to perform gas
welding, avoid operations like this.
Fig. 6
3. CARBON DIOXIDE ARC WELDER(MIG
ARC WELDING)
This welding process uses inexpensive carbon dioxide
instead of expensive inert gases as a shielding means.
Consumable metal electrodes are employed. It has a
wide range of applications, including butt welding of thin
plate, fillet welding, plug welding, and MIG spot welding.
In terms of the weld strength, it is also highly stable.
Fig. 7

3–6 WELDING AND TOOLSNUBIRA/LACETTI
4. REPAIR TOOLS
ItemWorkTools. equipment used
Protective toolsOperator
Vehicle body
Processing toolsPlug hole
drilling

NUBIRA/LACETTIWELDING AND TOOLS 3–7
Item Tools. equipment usedWork
Fixing toolsBase metal fixing
Shaping toolsSkin panel shaping
Body, frame shaping
Measuring toolsMeasuring

3–8 WELDING AND TOOLSNUBIRA/LACETTI
Item Tools. equipment usedWork
Flange toolsEdge preparation
Cutting tools.
Sanding toolsCleaning

NUBIRA/LACETTIFRONT 4–1
SECTION 4
FRONT
CONTENTS
1. FRONT PANEL 4 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.GENERAL DESCRIPTION4–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.REPAIR PROCEDURE4–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. FRONT WHEELHOUSE 4 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.GENERAL DESCRIPTION4–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.REPAIR PROCEDURE4–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. FRONT LONGITUDINAL 4 – 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.GENERAL DESCRIPTION4–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.REPAIR PROCEDURE4–11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. FRONT PILLAR 4 – 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.GENERAL DESCRIPTION4–14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.REPAIR PROCEDURE4–15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–2 FRONTNUBIRA/LACETTI
1. FRONT PANEL
1–1. GENERAL DESCRIPTION
.
The front panel is joined to the front wheelhouse and
front longitudinal. It forms the base for the headlampsand other parts and maintains the rigidity of the front
section of the body. Pay particular attention to twists
and parallelism and check mounting of related parts
when welding.
.
Fig. 1 Front Welding Assembly

NUBIRA/LACETTIFRONT 4–3
1–2. REPAIR PROCEDURE
1. Remove the related parts.
S Hood, radiator grill and front bumper.
S Head lamps and fender.
S Engine, radiator and related parts.
S Aircon condenser and related parts.
S Others.
Fig. 2
2. Roughly pull out and straighten the damaged area.
S Check the damage to the front wheelhouse and front
longitudinal before removing the front panel. Use the
frame straightener to roughly pull out and repair the
damaged front panel before removing the front panel.
Note : Check the fit of the door, taking care not to pull
the damaged area out more than necessary.
S Use the horizontal pinch weld clamps and attach the car
to the frame straightener at the clamping points secure-
ly.
3. Keep the body, level.
S Jack up the body, and place safety stands at the four
designated places of the frame door opening.
4. Cut and pry off the front panel.
S Center punch around the spot weld imprints.
S Use the special spot cutter to drill holes at the spot weld
nuggets on the front wheel house and longitudinal.
Note : When drilling holes be careful not to drill down to
the front wheelhouse and longitudinal themselves.
S Cut off the front panel with an air chisel, leaving the weld-
ing flanges intact.
S Level and finish the burrs from the pried off spot welds
with disc sander.
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
Fig. 3
5. Mold damaged related parts.
S Use a hammer and dolly to mold damaged areas of the
front wheelhouse and longitudinal.
S Even out the welding flanges with a hammer and dolly.
S Fill any holes drilled by welding.
Fig. 4
6. Set the front panel.
S Grind both sides of the welding section of the front panel
with a 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.
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.

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 4–5
S Aircon condenser and related parts.
S Head lamps and fenders.
S Hood, radiator grill, and bumper.
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.
14. Check and adjust
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.

4–6 FRONTNUBIRA/LACETTI
2. FRONT WHEELHOUSE
2–1. GENERAL DESCRIPTION
The front wheelhouse component is constructed as a
unit with the locator shockabsorber. Therefore, replace-
ment of the component affects the front wheel align-ment. When assembling it, either use a jig or follow di-
mensions on the body repair chart for positioning. It
must be welded carefully.
Fig. 9 Front Wheelhouse Welding Assembly