Section 5 DAEWOO LACETTI 2004 Service Repair Manual

0–2 SERVICE NOTICENUBIRA/LACETTI
SECTION 0
SERVICE NOTICE
CONTENTS
1. HOW TO USE THIS MANUAL 0 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. SPECIAL INFORMATION 0 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 0 – 4. . . . . . . . . . . . . . . . . . . . . . . .

NUBIRA/LACETTIGENERAL INFORMATION 1–1
SECTION 1
GENERAL INFORMATION
CONTENTS
1. GENERAL INSTRUCTION 1 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. IMPORTANT SAFETY NOTICE 1 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.BEFORE BEGINNING WORK1–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.DURING WORK1–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. BODY SAFETY 1 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. LOADS ON BODY PARTS 1 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. USE OF NEW HIGH–QUALITY MATERIALS 1 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
6. CORROSION PROTECTION 1 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. SUMMARY 1 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. ZINC TREATED STEEL PLATE REPAIR 1 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. TECHNICAL ILLUSTRATION 1 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10. BODY REPAIR PROCEDURES 1 – 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–12 GENERAL INFORMATIONNUBIRA/LACETTI
10. BODY REPAIR PROCEDURES
No.OperationProcedureRemarks
1InspectionInspect the damaged parts and the extent of damage and make
plans for the repair..
2PreparationPrepare the new parts, special repair tools and others..
3RemovalRemove the related parts for repair..
4Pull outRoughly pull out and straighten the damaged areas..
5Cut and pry offCut off the damaged areas and drills on the spot weld nuggets
and pry off the remaining spot weld flanges..
6Peel offPeel off the undercoat and sealer..
7MoldingMold damaged areas and even out the welding flanges and fill
any holes..
8Set the new partsGrind both sides of the welding section and set the new parts
and tack welds for temporary installation..
9InspectionInspect the dimensions for correct position and preinstall the ex-
terior parts and check the clearances and level differences..
10WeldingPerform a trial welding and the main welding..
11FinishFinish the welding areas and even out the flanges for a close fit..
12SealingApply the sealer to the matching and over lapped surface..
13UndercoatingApply the undercoat to the required areas..
14PaintingApply the paint..
15DeadnerApply the deadner to the designated areas..
16Anti–rust agentsCoating the anti–rust agents to the designated areas..
17InstallationInstall the related parts and rub in grease to the moving parts and
replenish the cooling liquid, oil, aircon gas and others..
18Check and adjustCheck all operations, wheel alignments, leaks, head lamp aim
and others with the specified check sheet..

NUBIRA/LACETTI PREPARATIONS OF BODYWORK 2–1
SECTION 2
PREPARATIONS OF BODYWORK
CONTENTS
1. GENERAL DESCRIPTION 2 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. CHECKPOINTS 2 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. CORRECTION OF THE DAMAGED AREA 2 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. MEASURING SYSTEMS (WITHOUT SMALL DAMAGE) 2 – 6. . . . . . . . . . . . . . . .

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.

NUBIRA/LACETTI PREPARATIONS OF BODYWORK 2–5
3. CORRECTION OF THE DAMAGED
AREAS Set the frame corrector on the car body.
S The side frame is to allow reshaping by pulling it out.
S Use the horizontal pinch welds for anchoring the car.
.
Fig. 3
Fig. 4 S Apply load to the damaged section and pull it out until the
section is almost restored to the original shape.
Underbody Clamp Specifications
.
Standard typeC–typeU–type
Frame
correctors
S Dataliner
S Car–o–liner
S Celette
S Flex–o–liner
S etc.S Korek
S Auto pole
S etc.S U–Base
S Pro–Tec
S etc.

NUBIRA/LACETTIWELDING AND TOOLS 3–1
SECTION 3
WELDING AND TOOLS
CONTENTS
1. SPOT WELDING 3 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.GENERAL DESCRIPTION3–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.WELDING CONDITIONS3–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.WELDING STRENGTH TEST3–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. GAS WELDING 3 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. CARBON DIOXIDE ARC WELDER(MIG ARC WELDING) 3 – 5. . . . . . . . . . . . . . .
4. REPAIR TOOLS 3 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NUBIRA/LACETTIWELDING AND TOOLS 3–3
S Plate thickness and tip diameter
Plate thickness
0.6mm0.9mm1.2mm1.6mm
Minimum inter-
vals4.5Ø5.0Ø5.5Ø6.0Ø
Fig. 3
1–3. WELDING STRENGTH TEST
.Even if you perform the welding in accordance with the
conditions, the strength of the welded sections may fluc-
tuate widely with drops in the voltage and other factors.
The quality of the welding cannot be evaluated unless
the welded sections are destroyed.
.
Provide yourself with a steel plate of the same thickness
and conduct a destruction test.
.
S If holes appear in the steel plates, this means that the
welding is standard strength.
S Drive a wedge between two panels near the nugget. If
the welded parts do not come apart and the diameter of
the nugget appears more than 3 mm, the welding should
be satisfactory.
Fig. 4

3–4 WELDING AND TOOLSNUBIRA/LACETTI
Note : It is difficult to perform spot welding in the following
circumstances.
S When it is not possible to remove any rust or paint at-
tached to the welding surfaces.
S When the tip of the spot welder cannot be inserted into
the welding section.
S When the welding surfaces can be seen from the outside
and welding will impair the exterior appearance.
.
In all these cases, it is recommended that the gas weld-
ing method be employed. However, if it is not possible
to perform spot welding because of space restrictions,
plug welding based on the arc welding method may be
performed instead. Here the welding sections must be
close together.2. GAS WELDING
.
Gas welding is indispensable for body repair because of
the broad range of its applications from joining the body
panels, cutting the materials that construct the body and
applying heat to reform panels, and also because it is
easy to get hold of the tools.
However, this method requires experience.
Fig. 5

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .