roof DAEWOO LACETTI 2004 Service Workshop Manual

5–2 ROOF, BACK PANEL AND REAR FLOOR PANEL NUBIRA/LACETTI
1. ROOF
1–1. GENERAL DESCRIPTION
Deformation of the roof panel is highly noticeable in
terms of the vehicle’s outer appearance. Before replac-
ing the roof, make sure that the body is horizontal. Be-fore welding the roof panel, adjust the frame door open-
ing flanges so that they contact the roof panel. Pay
particular attention to twists and parallelism.
Fig. 1

NUBIRA/LACETTI ROOF, BACK PANEL AND REAR FLOOR PANEL 5–3
1–2. REPAIR PROCEDURE
1. Remove the related parts.
S Room lamp, door weatherstrip and pillar trims.
S Headlining and wiring harness.
S Wiper, cowl and windshield.
S Rear glass and others.
2. Pull out and straighten the damaged area to approxi-
mately the original shape.
Note : Use heat–resistant protective cover for protect
painting areas, seats, carpets and other parts.
S Attach the car to the frame straightener by tightening the
underbody clamps at the horizontal pinch welds.
S Before cutting off the roof panel, pull them out so that
they are restored to the original shape.
S Do not pull out more than necessary.
S Pull out and straighten the related damaged parts to
approximately their original shape.
Note : Make sure that the right and left pillars are parallel
with the windshield surface. Check the door for proper
opening and closing.
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 off the shaded areas of the roof panel.
S Cut the roof weld flanges with a hand saw and snips at
the roof panel and roof frames.
Fig. 2
S Using a chisel, pry off the roof panel along the bold lines
as shown.
S Center punch around the spot weld imprints of the roof
welded flange.
S Drill holes using the spot cutter.
S Using a chisel and a disc sander, pry off the welded
flange from the front, rear body pillar and roof panel.
S Level and finish the burrs of welded flanges with a disc
sander.CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
5. Peel off the sealer.
S Peel off the sealer with a steel spatula at the welding
areas of the frame door opening.
6. Mold damaged related parts.
S Use a hammer and dolly to mold damaged areas of the
front, rear body pillar inner and frame door opening.
S Even out the welding flanges with a hammer and dolly
for close fit with the roof panel welding flange.
S Fill any holes drilled by welding.
7. Set the new panels.
S Grind both sides of the welding section of the rail wind-
shield header, support roof panel, frame rear roof panel
and roof panel with a disc 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 Temporarily set the new three frames and roof panel and
clamp with the vise grips.
Note : Check that the flange surface fit closely. Be care-
ful not to twist or deform the roof panel.
Fig. 3
S Measure the dimensions diagonally at the windshield
area and rear glass area with a tracking gauge or convex
rule as shown to check it for twisting or bending.

5–4 ROOF, BACK PANEL AND REAR FLOOR PANEL NUBIRA/LACETTI
Fig. 4
S Dismantle the new roof panel.
S Weld the clamped sections of the roof frames and front,
rear body pillar inner for temporary installation.
Fig. 5
S Set the new roof panel and clamp again.
S Temporarily set the windshield and rear glass, and
check the roof panel for proper installation.
S Install the roof molding and check the clearance and out-
er appearance.
8. Apply the sealer to the roof frames.
S Dismantle the new roof panel again.
S Apply the sealer to one groove of the rail windshieldheader, two grooves of the support roof panel and one
groove of the frame rear roof panel.
S Set and tack weld the roof panel.
Fig. 6
9. Perform the main welding and finish.
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.
S Use a hammer and dolly to smooth the spot weld areas
on the windshield and rear glass.
S Cut off the irregular and unuseful flanges and even out
the flanges for a close fit with the surface of the roof pan-
el.

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.

5–6 ROOF, BACK PANEL AND REAR FLOOR PANEL NUBIRA/LACETTI
2. BACK PANEL
2–1. GENERAL DESCRIPTION
The back panel is joined to the side panel outer, rear
extension longitudinal and extension rear floor. It forms
the base for the rear combination lamps and other partsand maintains the rigidity of the rear body. Pay particu-
lar attention to twists and parallelism and check mount-
ing of related parts when welding.
Fig. 9 Back Panel Welding Assembly

NUBIRA/LACETTI ROOF, BACK PANEL AND REAR FLOOR PANEL 5–7
2–2. REPAIR PROCEDURE
1. Remove the related parts.
S Rear and trunk trims
S Trunk lid lock and related parts.
S Rear combination lamps and wiring harness.
S Rear bumper and related parts.
S Other related parts.
Fig. 10
2. Roughly pull out and straighten the damaged area.
S Check the damage and roughly pull out and repair the
related side panel inner, rear floor, rear longitudinal and
other damaged parts with the frame straightener before
removing the back panel.
S Attach the car to the frame straightener by tightening the
underbody clamps located at the jack up designated
points on the bottom of the frame door opening.
3. Cut and pry off the rear panel.
S Center punch around the spot weld imprints with the rear
side outer and extension rear floor panel.
S Use the special spot cutter to drill holes at the spot weld
nuggets on the rear side outer and extension rear floor
panel.
Note : When drilling holes be careful not to drill down to
the side outer and extension rear floor panel them–
selves.
S Cut off the rear panel with an air chisel, leaving the weld-
ing flanges intact.
S Level and finish the burrs from the fried off spot welds
with disc sander and repair all cracks, holes or other de-
fects by welding also repair the floor panel if necessary.
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
Fig. 11
NOTE:
S I f damage has occurred only on one side, cut the dam-
aged section of the rear panel, trim the new panel to fit
the remaining section, then butt weld both parts at the
inner ends.
S Where damage has not extended into the rear side outer
panel, cut the rear panel from the body on either panel.
Fig. 12
4. Peel off the undercoat and sealer.
S Heat the undercoat and sealer at the welding areas of
the rear side outer panel and extension rear floor with a
gas torch and peel off the undercoat and sealer with a
steel spatula.
5. Mold damaged related parts.
S Use a hammer and dolly to mold damaged areas of the
rear side outer and extension rear floor panel.
S Even out the welding flanges with a hammer and dolly.
S Fill any holes drilled by welding.
6. Set the new rear panel.
S Grind both sides of the welding section of the rear 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.

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 5–9
3. REAR FLOOR PANEL
3–1. GENERAL DESCRIPTION
The rear floor panel is the base of the rear body and it is
critical for the rigidity of the rear body. During replace-
ment, refer to the body dimension chart or body repair
chart and determine the position to set the rear floor
properly.Be sure that the rear floor is not bent or deformed. Weld
securely to maintain the rigidity of the rear body.
2
Fig. 15 Rear Floor Welding Assembly (NOTCHBACK)

5–10 ROOF, BACK PANEL AND REAR FLOOR PANEL NUBIRA/LACETTI
4
13
1
97 7 911 3 314
Fig. 16 Rear Floor Welding Assembly (HATCHBACK)

NUBIRA/LACETTI ROOF, BACK PANEL AND REAR FLOOR PANEL 5–11
3–2. REPAIR PROCEDURE
1. Remove the related parts.
S Parts to be removed when removing the back panel.
S Rear seat belt and rear seat.
S Muffler, fuel tank and related parts.
S Chassis parts.
S Other related parts.
CAUTION : Do not smoke while working near the
fuel system. Keep open flame away from the fuel
system. If necessary, remove the fuel tank and off
lines.
2. Roughly pull out and straighten the damaged area.
S Check the damage and roughly pull out and re pair the
related back panel, side panel, wheel house inner, rear
longitudinal and other damaged parts with the frame
straightener before remov ing the extension rear floor
panel, rear floor pane and back panel.
S Attach the car to the frame straightener by tightening the
underbody clamps located at the jack up designated
points on the bottom of the frame door opening.
Note : Measure in reference to the dimensions on the
body repair chart.
3. Cut and pry off the back panel.
S The back panel to be cut and pried off when removing
the back panel.
4. Cut and pry off the rear floor and extension rear floor
panel.
S Cut off the rear floor and extension rear floor with a gas
torch or air chisel leaving the spot welded flanges of the
rear longitudinal along the bold line in the figure below.
Note : Cut the rear floor 15mm(0.59in.) from welded
flange of the cross member rear seat.
S Center punch around the spot weld imprints with the rear
longitudinal, extension rear longitudinal and web plate.
S Use the special spot cutter to drill holes at the spot weld
nuggets on the center punched areas.
Fig. 17
Fig. 18
Note : When drilling holes be careful not to drill down to
the rear longitudinal, extension rear longitudinal and
web plate themselves.
S Cut and pry off the remaining rear floor and extension
rear floor panel with an air chisel, leaving the welding
flanges intact.
S Level and finish the burrs from the pried off spot welds
with disc sander and repair all cracks, holes or other de-
fects by welding also repair the rear longitudinal and ex-
tension rear longitudinal if necessary.
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
Fig. 19
5. Peel off the undercoat and sealer.
S Heat the undercoat and sealer at the welding areas with
a gas torch and peel off the undercoat and sealer with
a steel spatula.
6. Mold damaged related parts.
S Use a hammer and dolly to mold damaged areas of the
rear longitudinal and extension rear longitudinal.
S Even out the welding flanges with a hammer and dolly.
S Fill any holes drilled by welding.