pillar DAEWOO LACETTI 2004 Service Manual PDF

9S – 4IBODY REAR END
DAEWOO V–121 BL4
8. Install the lower B–pillar seat belt anchor with the
bolt.
Tighten
Tighten the lower B–pillar seat belt anchor bolt to 38
NSm (28 lb–ft).
9. Connect the cable to the fuel filler door.
10. Install the luggage compartment wheelhouse trim
panels and the luggage compartment rear trim pan-
el. Refer to Section 9G, Interior Trim.
11. Close the luggage compartment.
REAR DECK LID
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector.
3. Remove the electrical harness from the rear deck
lid hinge arm.
4. Remove the bolts and the rear deck lid.
Installation Procedure
Notice : Dissimilar metals in direct contact with each other
may corrode rapidly. Make sure to use the correct fasten-
ers to prevent premature corrosion.
1. Install the rear deck lid with the bolts.
Tighten
Tighten the rear deck lid bolts to 10 NSm (89 lb–in).
2. Install the electrical harness to the rear deck lid
hinge arm.
3. Connect the electrical connector.
4. Connect the negative battery cable.

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/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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–14 FRONTNUBIRA/LACETTI
4. FRONT PILLAR
4–1. GENERAL DESCRIPTION
The front pillar area is part of the frame door opening
panel. It’s connected to the roof, windshield, door
hinges and floor frame and is important as a support forthe front side of the cabin. Connection of the front pillar
determines the position of the windshield and front door.
Align the fender, door and windshield while the front pil-
lar is temporary mounted, and check the clearances and
level differences.
Fig. 22 Front Pillar Welding Assembly

NUBIRA/LACETTIFRONT 4–15
4–2. REPAIR PROCEDURE
1. Remove the related parts.
S Hood, radiator grill and front bumper.
S Door and fender.
S Wiper, cowl and windshield.
S Weatherstrip and pillar trims.
S Instrument panel and wiring harness.
S Carpet and others.
2. Roughly pull out and straighten the damaged area.
S Check the damage to the wheelhouse and roof before
removing the brace wheelhouse and front pillar and de-
termine the extent of the damage.
S Use the frame straightener to roughly pull out and repair
the damaged front pillar before removing the brace
wheelhouse and front panel.
Note : Pull out until the pillar is lined up with the surface
of the windshield and do not pull out more than neces-
sary.
Fig. 23
3. Remove the brace wheelhouse.
S Center punch around the spot weld imprints.
S Use the special spot cutter to drill holes at the spot weld
nuggets on the brace wheelhouse.
S Remove the MIG weld areas with a disc sander.
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind–
ing.
S Using a chisel, pry off the welded flange from the front
body pillar and wheelhouse.
Fig. 24
4. Peel off the undercoat and sealer.
S Heat the undercoat and sealer at the welding areas of
the wheelhouse and longitudinal with a gas torch and
peel off the undercoat and sealer with a steel spatula.
5. Cut and pry off the front pillar.
S Cut off the front pillar along the bold lines as shown in the
figure below with a handsaw and snips carefully.
Note : Be careful not to cut the inner section.
Fig. 25
S Center punch around the spot weld imprints with the rear
wheelhouse, front body pillar inner, rein– forcement front
body pillar inner and floor panel side.
S Use the special spot cutter to drill holes at the spot weld
nuggets on the front pillar.
Note : When drilling holes be careful not to drill down to
the front body pillar inner, reinforcement front body pillar
inner and floor panel side themselves.
S Pry off the remaining flanges from the body with an air
chisel and leaving the welding flanges.
S Level and finish the burrs from the pried off spot welds
with a hammer, dolly and disc sander.

4–16 FRONTNUBIRA/LACETTI
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind–
ing.
6. 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.
7. Set the new front pillar.
S Align the new part with the top section, then cut it with
a hand saw.
S Cut the floor panel side joint area so it will overlap by
30mm(1.18in.) in the floor panel side with a hand saw.
S Grind both sides of the welding section with a disk sand-
er 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.
Fig. 26
Fig. 27
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 fender
and doors, then check the clearances, level differences
and outer appearance.
8. Perform the main welding.
S Weld the frame door opening area and pillar at the butt
joints with a gas or MIG welder.
S Spot weld the flanges of the front pillar 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.

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.

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.