pillar DAEWOO LACETTI 2004 Service Manual Online

6–4 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER NUBIRA/LACETTI
Fig. 4
S Remove the vise grips and temporarily install the fender
and doors, then check the clearances, level differences
and outer appearance.
6. Perform the main welding.
S Weld the front, rear frame door opening and center pillar
at the butt joints with a gas or MIG welder.
S Spot weld the frame door opening and center 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 welding con-
dition.
S Increase the number of spot by 20% for areas to be spot
welded.Fig. 5
7. Finish the welding areas.
S Level the gas or MIG welded areas with a disc sander,
then even out high areas with a hammer being careful
not to deform them.
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
S Use a hammer and dolly to even out the spot welded
flanges for a close fit with the surface of the frame door
opening panel.
S Fill in deformations and level differences of the welded
areas with solder or putty, then finish.
8. Apply the sealer.
S Apply the sealer to the matching surfaces of the floor
and frame door opening.
9. Apply the undercoat.
S Undercoat to the front floor.
10. 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 con tainer.
S Avoid contact with skin. Wear an approved respirator,
gloves, eye protection and appropriate clothing when

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.

6–10 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER NUBIRA/LACETTI
3–2. REPAIR PROCEDURE
1. Remove the related parts.
S Rear and trunk trims.
S Rear combination lamps and wiring harness.
S Rear bumper and related parts.
S Rear seat and rear seat belt.
S Chassis and fuel 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. Pull out and straighten the damaged area to approxi-
mately the original shape.
S Attach the car to the frame straightener by tightening the
underbody clamps at the four designated support points.
S Before cutting off the damaged sections, 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 damaged areas of the rear
side outer panel, side inner panel and wheelhouse inner.
Note : Check the rear door locking and unlocking condi-
tion.
3. Cut and pry off the side panel outer.
S Cut at the rear pillar and side outer(rear side of frame
door opening) along the bold lines as shown with a hand-
saw and snips carefully.
Fig. 12
S Center punch around the spot weld imprints with the rear
panel, side panel inner and arch area.
S Use the special spot cutter to drill holes at the spot weld
nuggets on the rear side outer panel.
Note : When drilling holes be careful not to drill down to
the side panel inner and rear panel themselves.
S Cut the panel from the body with an air chisel, leaving the
welding flanges at the side inner panel, wheelhouse in-
ner and back panel intact.S Level and finish the burrs from the pried off spot welds
with a hammer, dolly and disc sander.
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
Fig. 13
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 Sand off the paint and undercoat from both sides of the
flange to be welded.
5. Set the new side panel outer.
S Cut the new side panel outer so it will overlap by
30mm(1.18in.) in the frame door opening area with a
hand saw.
Fig. 14
S Grind both sides of the welding section of the prepared
side panel outer with a disk sander to remove the paint
and expose the steel plate.
S Clamp the new panel in place with the vise grips.

NUBIRA/LACETTI FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 6–11
Fig. 15
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 trunk
lid and doors, then check the clearances, level differ-
ences and outer appearance.
6. 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 and wheel arch of the side panel
outer 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. 16
Fig. 17
7. Finish the welding areas.
S Level the gas or MIG welded areas with a disc sander,
then even out high areas with a hammer being careful
not to deform them.
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
S Use a hammer and dolly to even out the spot welded
flanges for a close fit with the surface of the side panel
outer.
S Fill in deformations and level differences of the welded
areas with solder or putty, then finish.
8. Apply the sealer.
S Apply the sealer to the matching surfaces of the web
plate, back panel lower, rear combination lamp area and
side panel outer.
9. Apply the undercoat.
S Undercoat to the rear wheelhouse and designated rear
floor.
10. Apply the paint.
CAUTION
S Ventilate when spraying paint. Most paint contains sub-
stances that are harmful if inhaled or swallowed.
S 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.
11. Coating the anti–rust agents.
S Coating the anti–rust agents to the inside of frame door
opening areas sufficiently.
12. Apply the deadner.
S Apply the deadner to the inside of side panel outer cen-
ter.(Left side only)