Iat DAEWOO LACETTI 2004 Service Repair Manual

9R – 6IBODY FRONT END
DAEWOO V–121 BL4
Installation Procedure
1. Install the radiator grille with the screws and clips.
HATCHBACK RADIATOR GRILLE
Removal Procedure
1. Open the hood.
2. Remove the screws.
3. Pree the clips with the screw driver.
Installation Procedure
1. Install the radiator grille with the screws.
FRONT WHEEL WELL SPLASH
SHIELD
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the front wheel. Refer to Section 2E, Tires
and Wheels.
3. Remove the front mud guard. Refer to Section 9M,
Exterior Trim.
4. Remove the screws and the front wheel well splash
shield.

9R – 10IBODY FRONT END
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
BODY FRONT END
This vehicle has a unitized body with a frame assembly
supporting the engine and the transaxle. The fender pan-
els and the radiator support are also integral parts of the
body.

REMOTE KEYLESS ENTRY AND ANTI–THEFT SYSTEM 9T1 – 7
DAEWOO V–121 BL4
REMOTE KEYLESS ENTRY
TRANSMITTER PROGRAMMING
The Remote Keyless Entry System allows for the use of
as many as four(4) transmitters for each vehicle. Replace-
ment Remote Keyless Entry System Transmitters must
first be programmend to specific vehicle using the
Scan100 Secan tool.
This process is completed using serial data communica-
tion between the Scan 100 Scan tool and the Remote Key-
less Entry Control Unit and is the only method available for
programming Transmitters.
Notice : All Transmitters for a specific vehicle must be pro-
grammed at same time.
Notice : Once the programming function of the Remote
Keyless Entry System is activated, any Transmitter(exist-
ing or new) that is not programmed(or reprogrammed)
during the programming procedure will no longer operate
the Remote Keyless Entry System of that vehicle.
Notice : Ensure that the doors, hood and trunk/rear hatch
are closed prior to starting the programming procedure.
1. Connect the Scan 100 Scan Tool to the Data Link
Connector(DLC)
2. Turn the Scan 100 Scan Tool ”ON” by pressing the
”Power” Button, then wait for the MAIN MENU
screen to be displayed.
3. From the MAIN MENU screen, select ”Diagnostics”
by pressing #1 on the Key Pad.
4. From the MODEL YEAR screen, select the ap-
propriate model year of the specific vehicle by ei-
ther scrolling down to the year and pressing ”EN-
TER”, or by pressing the respective item number on
the Key Pad.
5. From the VEHICLE TYPE screen, select the specif-
ic vehicle model by either scrolling down to the
model name and pressing ”ENTER”, or by pressing
the respective item number on the Key Pad.
6. From the SYSTEM SELECTION MENU screen,
select ”Body” by pressing #2 on the Key Pad.
7. From the BODY SELECTION MENU screen, select
”Coding” by pressing #2 on the Key Pad.8. From the CODY SELECTION MENU screen, select
”Coding” by pressing #1 on the Key Pad.
9. From the SECRET NUMBER OF CODINGS
screen, enter for(4) zero’s (0–0–0–0) in the for(4)
boxes labeled ”1–2–3–4–”.
10. From the CODING SYSTEM SELECT screen, se-
lect ”Keyless Entry” by pressing #2 on the Key Pad.
Notice : A slight delay may occur and ”PLEASE WAIT”
may be displayed before the next screen appears.
11. From the KEYLESS ENTRY CODING SYSTEM
screen, select ”Coding Transmitter” by pressing #1
on the Key Pad.
12. When directed by the Scan 100 Scan Tool, press
any Button on the first Transmitter to be pro-
grammed.
CAUTION : Ensure that Transmitters from other ve-
hicles in the immediate area are not activated during
this procedure.
13. Continue programming Transmitters when directed
by the Scan 100 Scan Tool until all Transmitters
have been programmed.
Notice : A maximum of four(4) Transmitters may be pro-
grammed to a vehicle.
14. Once all Transmitters have been programmed,
press the ”ESC” Button on the Key Pad. The dis-
play will confirm the number of Transmitters pro-
grammed. If the number displayed does not match
the number of Transmitters programmed, repeat
the procedure.
15. Turn the Scan 100 Scan Tool ”OFF” by pressing the
”POWER” Button, then disconnect it from the Data
Link Connector.
16. Wait approximately 10 seconds, then test the op-
eration of each programmed Transmitter to ensure
it operates properly.
The control module/receiver leaves the programming
mode automatically and switches to the normal operating
mode when either of the following conditions occurs:
S the scan tool is disconnected from the ALDL.
S Four passwords are recorded in the control module/
receiver.

9T2 – 12IIMMOBILIZER ANTI–THEFT SYSTEM
DAEWOO V–121 BL4
The VIN code is transmitted from the Immobilizer in the re-
lease message communication only incase of using an au-
thorized key. Without an authorized key it is not possible
to getthe system VIN code.In case of ECM internal state
is in Virgin mode or neutral mode the ECM learns the sys-
tem VIN code automatically after receiving the first release
response message.
To get a synchronized Immobilizer system (same VIN–
code in Immobilizer and ECM,authorized key) the DLC
test equipment has to be used for authorization of the
keys(first key coding). The usage of this test equipment is
restricted to authorized persons.
S Communication with the DLC–test equipment. Main
functions are the key coding procedure, the VIN–
code handling and the support for system test func-
tions.
S Handling of the software watchdog
Operation
In the active mode of immobilizer (engine OFF, IG key
OFF) the status LED isblinking as mode A. When ignition
is turned ON, the system wakes up and tries to read out
the transponder.
In case of the detection of a valid key , The release mes-
sage communication with the ECM takes place. The sta-
tus LED displays the Immobilizer state ”valid key”.
After turning off the ignition(ignition OFF detection similar
to the ECM ignition OFF detection), the Immobilizer
changes to the active mode. The status LED is blinking as
Mode A.
Data Link Connector (DLC) Mode
When the ignition is on, a scan tool can switch the immobi-
lizer control unit to the DLC mode for diagnostics, key cod-
ing and ID coding.
S The status LED is turned off during DLC–mode
S The Immobilizer will answer all correct messages,
which are defined as Immobilizer messages.
ID Code Handling
One of 65,535 VIN codes is stored in the immobilizer EE-
PROM.
The VIN code can be erased by using ”Reset VIN code”
command of the scan tool.
When the immobilizer control unit calculates a new VIN
code, ECM VIN code should be reset to get identical with
the immobilizer control unit’s.
During diagnostic procedures, the VIN code can be read
for comparison with the ECM VIN code by using the scan
tool’s ”Read immobilizer control unit VIN code” command.
SERIAL DATA LINK
Serial data can be exchanged between a scan tool and the
ECM and the Immobilizer control unit.
ELECTRONIC CONTROL MOUDLE
(ECM)
S ECM in Virgin mode
In this mode, the ECM knows only the model
vehicle identifier code.
The engine can be locked/unlocked.
ECM requests to ICU the VIN number. As soon
as the ECM receives two correct consecutive
communication frames with the same VIN code
the ECM learns it.
The VIN code will be stored in non–volatile
memory at the end of power latch phase. ECM
enters in Learnt mode.
S ECM in Learnt mode
In such a state, ECM checks on every commu-
nication, the correct encoding of the ICU.
If the code received is not correct, then the vehicle is im-
mobilized.
The coded 5 bytes of data emitted by ECM are
a mixture of MIN code and random.
The coded 5 bytes of data emitted by ICU are a
mixture of VIN code and random.
S ECM in Neutral mode
This mode is a special intermediate mode, used
for ICU replacement or immobilizer option instal-
lation.
ECM request to ICU the VIN number. As soon
as the ECM receives two correct consecutive
communication frames with the same VIN code
the ECM learns it. The VIN code will be stored
in non–volatile memory at the end of power latch
phase. ECM enters in Learnt mode.
S After turning on the ignition the ECM will control the
engine in a normal way for starting and running
while waiting for a valid release response message
from the Immobilizer.

NUBIRA/LACETTIGENERAL INFORMATION 1–3
3. BODY SAFETY
Modern stressed–skin bodies are designed so as to
have a sturdy passenger cell protected by front and rear
crumple zones.
S In an accident the crumple zones are designed to con-
vert impact energy into deformation work.
S The shape, material and metal thickness must all be pre-
cisely matched.
Fig. 1 Body Shell
S Many years of experience, refined computational meth-
ods and expensive series of crash tests mean that GM
DAEWOO now builds bodies giving optimum deforma-
tion in the crumple zones in frontal or rear impacts.
Fig. 2 Crumple Zones
When repairing body damage, it is therefore imperative
to restore the original structure and strength in order to
guarantee the safety of the occupants.
4. LOADS ON BODY PARTS
S 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 GM DAEWOO bodies, one
talks of highly stressed and less highly stressed parts.
.
.
5. USE OF NEW HIGH–QUALITY
MATERIALS
S 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 con-
ventional steel. These properties must not be destroyed
when carrying out repairs, e.g. by using excessive heat.
.
.
6. CORROSION PROTECTION
S The durability of the bodywork, its associated long–term
safety and retention of value largely depend on the cor-
rosion protection given to the sheet metal. Here, GM
DAEWOO takes a great deal of care in production.
S Therefore, this corrosion protection must be preserved
or restored when repairs are carried out.

2–4 PREPARATIONS OF BODYWORK NUBIRA/LACETTI
2. CHECKPOINTS
S 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 dam-
age 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 sec-
tions 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 en-
gine, transmission or brakes?
12. Is there any irregular noise in the gear changing opera-
tion, 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 har-
nesses?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 clear-
ance?
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 dam-
age to the suspension and its related parts?
8. Is there any deformation of the rear floor crossmem-
ber, 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 in-
ner deform.
Always replace impact beam if :
2. The external force makes the impact beam of front
bumper and rear bumper deform.

2–6 PREPARATIONS OF BODYWORK NUBIRA/LACETTI
4. MEASURING SYSTEMS (WITHOUT
SMALL DAMAGE)
S Whenever possible, make judgements and conclusions
based on measurement. Measure the wheel align-
ment(see pages 2–2, 2–3) so as to prevent any future
trouble like unsymmetrical wear of the tires or catchingof the steering wheel.
S If there are any deviations, use a tram tracking gauge
and measure parts of the body.(Below Fig. 5–1)
S If there is any twisting to the body, measure using a
frame centering gauge.(Below Fig. 5–2)
S When measuring body dimensions, use a universal tram
gauge.(Below Fig. 5–3)
.
Fig. 5–1
Fig. 5–2
Fig. 5–3
Fig. 5

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.