ESP DAEWOO NUBIRA 2004 Service Manual PDF

NUBIRA/LACETTIFRONT 4–11
3–2. REPAIR PROCEDURE
1. Remove the related parts.
S Parts to be removed when removing the front panel and
front wheelhouse.
S Parts on passenger side of dash panel lower which are
especially flammable.
S Instrument panel, wiring harness, related parts and oth-
ers.
Note : Remove according to part damaged.
2. Roughly pull out and straighten the damaged area to
approximately the original shape.
S Attach the car to the frame straightener by tightening the
underbody clamps at the horizontal pinch weld points.
S Before cutting off the damaged sections, pull them out
so that they are restored to the original shape.
S Roughly cut off the front longitudinal according to the ex-
tent of damage before roughly pulling out the damage
makes repair of the related parts difficult.
S Do not pull out more than necessary.
Note : Check the condition of the door and hinges.
3. Peel off the undercoat and sealer.
S Heat the undercoat and sealer at the welding areas of
the damaged parts with a gas torch and peel off the un-
dercoat and sealer with a steel spatula.
CAUTION : Be careful not to burn the fittings inside
the passenger compartment when heating.
4. Cut and pry off the front longitudinal.
Note : It’s not necessary to separate the wheelhouse
from the front longitudinal if the wheelhouse is to be re-
placed also.
S Center punch around the spot weld imprints on the
wheelhouse and other related parts.
S Use the special spot cutter to drill holes at the spot weld
nuggets on the center punched areas.
S Cut off the front longitudinal with an air chisel, leaving the
welding flanges intact.
S Level and finish the burrs from the pried off spot welds
with a disc sander.
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
Fig. 17
5. 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 Reshape the wheelhouse and other damaged parts and
even out the welding flanges with a hammer and dolly.
Fig. 18
6. Cut the new front longitudinal to align it with body, then
set the wheelhouse and front panel.
S Cut the new front longitudinal with a hand saw and it will
be butt welded.
S Grind both sides of the welding section of the front longi-
tudinal and wheelhouse 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 Tighten the new front longitudinal against remaining
parts with the vise grips and pliers.
S Place a jack under the front longitudinal end and support
it, and measure the positions for correct setting.
S Set and clamp the front panel in place with the vise grips.

4–12 FRONTNUBIRA/LACETTI
Note : Use of jigs is recommended for correct positions
and check that the both front longitudinal and wheel-
house are parallel.
S Tack weld the clamped section for temporary installa-
tion.
7. Perform the main welding.
S Weld as much as possible with the jig still mounted.
S Make MIG or gas welds at the butt joints at the front lon-
gitudinal, carefully.
Fig. 19
S Spot weld the wheelhouse with the front longitudinal
flange areas and front panel.
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. 20
S Level the weld beads at the longitudinal butt joints area
with disc sander.
S Make the stiffener(Thickness: 2.8 mm Min., Width: 80
mm) according to the form of longitudinal butt joint areasand weld the stiffener at the longitudinal butt joint areas
with MIG welder.
Fig. 21
8. Finish the welding areas.
S Level the gas or MIG welded areas with disc sander.
S Use a hammer and dolly to even out the wheelhouse and
longitudinal flanges for a close fit.
9. Apply the sealer.
S Apply the sealer to the joint areas of the dash panel lower
and floor panel areas.
10. Apply the undercoat.
S Undercoat to the joint and overlapped areas of the front
floor, longitudinal under side and the inside of front, rear
wheelhouse.
11. 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.
12. Coating the anti–rust agents.
S Coating the anti–rust agents to the end of front panel
side and the front door hinge areas.
13. Install the related parts.
S Clean the passenger compartment.
S Wiring harness, instrument panel and related parts.
S Parts of the passenger compartment.
S Chassis components.
S Engine, radiator and related parts.
S Aircon condenser and related parts.
S Head lamps and fenders.
S Heed, radiator grill, and bumper.
S Others.
S Install in the reverse order in which they were removed.

NUBIRA/LACETTIFRONT 4–17
Fig. 28
9. 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 inner panel.
S Fill in deformations and level differences of the welded
areas with solder or putty, then finish.
10. Apply the sealer tape.
S Apply the sealer tape to the hinge and brace wheelhouse
matching area as shown.
Fig. 2911. Weld the brace wheelhouse.
S Spot weld the brace wheelhouse as shown.
S Make MIG or gas welds at the door hinge areas.
Fig. 30
12. Finish the welding areas.
S Use a hammer and dolly to even out the brace wheel-
house for a close fit with the surface of the wheelhouse.
13. Apply the sealer.
S Apply the sealer to the matching and overlapped sur-
face.
14. Apply the undercoat.
S Undercoat to the inside of the front, rear wheelhouse
and longitudinal.
15. 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.
16. Coating the anti–rust agents.
S Coating the anti–rust agents to the end of front panel
side and the door hinge areas.
17. Install the related parts.
S Clean the passenger compartment.
S Windshield, cowl and wiper.
S Wiring harness, instrument panel and related parts.
S Carpet, trims and weatherstrip.
S Door
S Fender and hood.
S Radiator grill, bumper and others.
S Install in the reverse order in which they were removed.
18. Check and adjust.
S Check the door for proper installation and operation.
S Check clearances and level differences.

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.

5–8 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 5–13
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.

6–4 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.

6–8 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER NUBIRA/LACETTI
3. SIDE PANEL OUTER
3–1. GENERAL DESCRIPTION
The side panel outer consists of side outer area and
frame door area. The side outer area is a conspicuous
part of the outer appearance of the vehicle. It is espe-cially important for the body line continuing from door.
Therefore, pay particular attention to it when conducting
work. This part must be aligned with the rear door, trunk
lid, rear glass and other parts.
Fig. 10 Side Panel Outer Welding Assembly (NOTCHBACK)

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)