roof DAEWOO LACETTI 2004 Service Manual PDF

5–12 ROOF, BACK PANEL AND REAR FLOOR PANEL NUBIRA/LACETTI
CAUTION : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
S Level and finish the burrs from the pried off spot welds
with disc sander.
S Sand off the paint and undercoat from both sides of the
flange to be welded.
7. Cut the new rear floor to align it with the body, then set
the new rear floor and extension rear floor.
S Cut the new part so it overlaps the cross member rear
seat by approximately 40mm(1.57in.).
Fig. 20
S Grind both sides of the welding section of the rear floor
and extension rear floor with a disk 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 Set and clamp the new panel in place with the vise grips.
Note : Use of jigs is recommended for correct positions
and check that the both rear logitudinal is parallel.
S Tack weld the clamped section for temporary installa-
tion.
CAUTION : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.S Remove the vise grips and temporarily install the rear
panel, then check the alignment, level differences and
outer appearance.
8. Remove the main welding.
S Weld the rear floor and cross member rear seat with a
MIG welder fillet weldings as shown.Fig. 21
S Spot weld the rear floor and extension rear floor with rear
longitudinal flange areas and web plate flanges 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 weld ing con-
dition.
S Increase the number of spot by 20% for areas to be spot
welded.
9. Weld the back panel
S The back panel to be welded when replacement the
back panel.
10. Finish the welding area.
S Level the MIG welded areas with a disc sander, then
even out high areas with a hammer being careful not to
deform them.

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.

6–2 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER NUBIRA/LACETTI
1. FRAME DOOR OPENING
1–1. GENERAL DESCRIPTION
The frame door opening consist of frame door area and
side outer area. It forms the base for the front, rear
doors and other parts and maintains the rigidity of thedoors and roof. The frame door opening area should,
depending on the degree of damage, be repaired as
much as possible rather than repalced.(Repair by pull-
ing out)
Fig. 1 Frame Door Opening Welding Assembly

NUBIRA/LACETTI FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 6–3
1–2. REPAIR PROCEDURE
1. Remove the related parts.
S Doors.
S Weather strips, pillar trims and related parts.
S Carpet.
S Seat belt assembly
S Door switch and wiring harness.
S Fuel pipe and brake oil pipe.
S Other related parts.
Note : Pull out and straighten the damaged area to
approximately the original shape.
2. Remove the related parts.
S Damage may extend to the inner roof frame, the inner
frame door opening and the floor. Determine the extent
of the damage first, so the frame can be pulled out prop-
erly.
Note : Use heat–resistant protective cover for protect
painting areas, seats, carpets and other parts.
S Pull out and straighten the damaged areas.
S Do not pull out more than necessary.
3. Cut and pry off the frame door opening.
S Check the damage on the frame door opening, then cut
the new frame door opening so it will overlap by
30mm(1.18in.) in the pillar, front and rear.
S Cut the damaged area with a hand saw along the bold
line as shown.
Note : Be careful not to cut the inner panel. This could
result in extensive repair.
Fig. 2
S If the damage involves part of the center pillar, cut them
as shown.
Fig. 3
S Center punch around the spot weld imprints on the
welded flange.
S Use the special spot cutter to drill holes at the spot weld
nuggets.
Note : When drilling holes be careful not to drill down to
the inner panel..
S Pry off the frame door opening panel with an air chisel,
leaving the welding flanges intact.
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
4. Mold damaged related parts.
S Fill any holes drilled by welding.
CAUTION : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
S Use a hammer and dolly to mold damaged areas of the
remaining inner panel and even out the welding flanges.
S Level and finish the burrs from the pried off spot welds
with disc sander.
S Sand off the paint and undercoat from both sides of the
flange to be welded.
5. Set the new frame door opening.
S Grind both sides of the welding section of the prepared
frame door opening part with a disk sander to remove
the paint and expose the steel plate.
S Clamp the new panel in place with the vise grips.
S Tack weld the clamped section for temporary installa-
tion.
CAUTION : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.

6–6 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER NUBIRA/LACETTI
2. DOOR
2–1. REPAIR PROCEDURE
1. Remove the related parts.
S Door trim and related parts.
S Wiring harness and solenoid valve.
S Glass and window lifter.
S Linkage, lock set and handle.
S Others.
Note : Inspection and choose the usable parts.
2. Remove the door.
S Remove the bolt from door check hinge(1) and remove
the four bolts from door assembly(2).
Fig. 7
3. Preparation of the new door.
S Preparation of the new door and check damaged areas.
4. Preinstall the door.
S Fix the four bolts.
S Check and adjust the clearances and level differences
of doors, fender, pillar, roof and side panel outers.
Fig. 8
S Check any deformation.
5. Remove the new door.
S Remove the four bolts from door assembly.
6. 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 t
away from sparks, flames or cigarettes.
7. Coating the anti–rust agents.
S Coating the anti–rust agents to the inside of bottom
areas.
Fig. 9
8. Install the door.
S Install the door with four bolts.
S Install the door check link set in the door and fix the bolt.
S Check clearances and level differences.
9. Install the related parts.
S Handle, linkage and lock set.

9–8 SEALING, CAULKING AND DEADNER NUBIRA/LACETTI
ROOF
Fig. 7 Roof

NUBIRA/LACETTI SEALING, CAULKING AND DEADNER 9–9
ROOF
Fig. 8 Roof

9–10 SEALING, CAULKING AND DEADNER NUBIRA/LACETTI
SUN ROOF
Fig. 9 Sun Roof