2004 DAEWOO LACETTI tow

GLASS AND MIRRORS 9L – 17
DAEWOO V–121 BL4
INSIDE REARVIEW MIRROR
The inside rearview mirror is attached to a support which
is secured to the windshield glass. The support is installed
by the glass supplier using a plastic–polyvinyl butyl adhe-
sive.
Service replacement windshield glass has the mirror sup-
port bonded to the glass assembly. In order to install a de-
tached mirror support or to install a new part, the following
items will be needed:
S Loctite® Minute–Bond Adhesive.
S Original or replacement mirror support.
S Wax marking pencil or crayon.
S Rubbing alcohol.
S Clean paper towel.
S Fine grit sandpaper (grit #320 or #360).
S 2 mm allen wrench.
Installation Procedure
1. Measure the distance from the headliner to the bot-
tom of the location where the mirror support will be
mounted on the windshield.
2. Mark this position on the outside of the glass with a
wax pencil or crayon. Draw a large diameter circle
around the mirror support location on the outside of
the glass.
3. Clean the inside surface of the glass with a domes-
tic scouring cleanser, a glass cleaning solution, or a
polishing compound and paper towels. Rub the
glass until the area is completely dry. When the
area is dry, clean the area with an alcohol–satu-
rated paper towel in order to remove any traces of
the scouring powder or the glass cleaning solution.
4. If the mirror support is new, clean the bonding sur-
face with fine grit sandpaper #320 or #360. If the
original mirror support is being used, all traces of
factory installed adhesive must be removed prior to
reinstallation.
5. Wipe the sanded mirror support with a clean paper
towel saturated with rubbing alcohol. Allow the sup-
port to dry.
6. Follow the adhesive kit manufacturer’s directions
for adhesive application and mirror support prepa-
ration before installing the mirror support to the
glass.
7. Position the mirror support to its premarked posi-
tion. Use steady pressure and press the support
against the glass for 30 to 60 seconds.
8. After 5 minutes, remove the excess adhesive with
an alcohol–moistened towel or a glass–cleaning
solution.
9. Install the inside rearview mirror to the mirror sup-
port with the mounting screw.
Tighten
Tighten the rearview mirror mounting bolt to 1.2 NSm
(11 lb–in).

9N – 8IFRAME AND UNDERBODY
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
GENERAL BODY CONSTRUCTION
This vehicle is constructed with a unitized body which in-
corporates integral front and rear frame side rails.
The front suspension lower control arms are bolted to and
retained by supports, one each on the right and left sides.
The front suspension lower control arm supports are at-
tached to the underbody with three bolts at two locations.
The engine is bolted to the integral front side rails. The
suspension strut towers must be dimensionally correct in
relation to the remainder of the underbody in order to main-
tain specified suspension strut and caster/ camber angles.Since the individual underbody parts contribute directly to
the overall strength of the body, it is essential to observe
proper welding techniques during service repair opera-
tions. The underbody parts should be properly sealed and
rustproofed whenever body repair operations destroy or
damage the original sealing and rustproofing. When rust-
proofing critical underbody parts, use a good–quality type
of air–dry primer, such as a corrosion–resistant chromate
or an equivalent material. Combination–type primer/sur-
facers are not recommended.
ENGINE UNDER COVERS
The engine under covers are molded pieces of plastic that
serve as shields for the underside of the engine. The cov-
ers help protect the engine from small rocks, gravel and
other objects that would otherwise come into contact with
the engine during normal driving conditions.

1–2 GENERAL INFORMATIONNUBIRA/LACETTI
1. GENERAL INSTRUCTION
This publication is designed to help you the body repair
technician with your specialized work. Vehicle bodywork
has changed a great deal over the years. As vehicles
have developed technically, vehicle bodywork has also
had to meet new requirements with design, changes to
reconcile apparently conflicting demands to name just a
few examples:
S strength and safety ; low weight
S spaciousness ; good aerodynamices
S high quality ; low price
.
The durability and ease of repair of the bodywork also
plays an important part.
.
Nowadays, the use of highly automated production
equipment makes it possible to maintain the tightest
tolerances and thus ensure a high level of quality.
.
When bodywork is damaged, the customer rightly ex-
pects it to be expertly repaired to the same quality stan-
dards.
.
At the same time, for his safety, the customer expects
you to have comprehensive knowledge of materials,
measuring and straightening methods, possible distor-
tion, optimum corrosion prevention and much more be-
sides.
.
This publication is designed to help you update your
knowledge and give you an idea of what you require to
rectify moderate or severe accident damage, for your
own safety and for the satisfaction of your customers.
2. IMPORTANT SAFETY NOTICE
2–1. BEFORE BEGINNING WORK
S Disconnect the battery to reduce the possibility of fire
caused by electrical shorts.
S Check for fuel leaks and repair as necessary.
S Remove the fuel tank and/or fuel lines if welding equip-
ment is to be used near the fuel system.
S Before welding, sanding or cutting, protect carpets and
seats with fire–proof covers.
S Follow standard safety practices when using toxic or
flammable liquids.
S Use standard safety equipment when spraying paint,
welding, cutting, sanding or grinding. Standard safety
equipment includes.
S Respirator and filter masks: Designed to filter out toxic
fumes, mist, dust or other airborn particles. Use a respi-
rator or filter mask designed to protect you from the haz-
ards of the particular job; some respirators, for example,
are designed to filter out only dust and airborn particles,
not toxic fumes.
S Safety goggles or glasses: Designed to protect your
eyes from projectiles, dust particles or splashing liquid.
S Gloves: Rubber gloves protect against corrosive chemi-
cals. Welding gloves protect against burns and abra-
sions caused by welding, sanding or grinding.
S Safety shoes: Non–slip soles protect against slipping.
Metal toe inserts protect against falling objects.
S Ear plugs: Protect eardrums from harmful noise levels.
.
2–2. DURING WORK
S Do not smoke while working near the fuel system.
S Deposit gas or solvent–soaked shop towels in an ap-
proved container.
S Brake lining contains asbestos, which can cause cancer.
Do not use an air hose to blow off brake assemblies: use
only an approved vacuum cleaner, and wear an ap-
proved filter mask or respirator.
S Always attach a safety cable when using a hydraulic ram
or a frame straightening table: do not stand in direct line
with the chains used on such equipment.

10–2 RUST PREVENTIONNUBIRA/LACETTI
1. ZINC TREATED STEEL PLATE
REPAIR
Avoid puttying as much as possible when repairing a
new car. Use alternative methods as much as possible.
.
CAUTION
S Most paints contain substances that are harmful if in-
haled or swallowed. Read the paint label before openingthe container. Spray paint only in a well ventilated area.
S Cover spilled paint with sand, or wipe it up at once.
S Wear an approved respirator, gloves, eye protection and
appropriate clothing when painting. Avoid contact with
skin.
S If paint gets in your mouth or on your skin, rinse or wash
thoroughly with water. If paint gets in your eyes, flush
with water and get prompt medical attention.
S Paint is flammable. Store it in a safe place, and keep it
away from sparks, flames or cigarettes.
Operation
Tools/MaterialsProcedureRemarks
1. Prep the repair
area.Double–action sander, #80 sand-
paper.Sand the area with a double–action sander
and #80 sandpaper. Clean with wax and
grease remover..
2. Apply putty
Note : Putty can be
applied after priming
as described in step 4.
Epoxy–based putty.
S Mix the putty and hardener ac-
cording to the manufacturer’s di-
recctions.
S Polyester resin putty. Body filler.Apply in several thin coats if necessary. Try
to avoid leaving pinholes in the putty.
S Follow the manufacturer’s recommenda-
tions for preparaton.
.
3. Sand and clean
the puttied area.Double–action sander, orbital
sander, hand sanding file, #80,
#120, #240 sandpaper, wax and
grease remover, shop towels.Rough–sand the area with a double– action
sander and #80 sandpaper, then sand with
#120 sandpaper. Featheredge with #240
sandpaper. Clean with wax and grease re-
mover..
4. Coat with primer.
Note : Apply to bare
sheet metal and put-
tied area.
Epoxy–based primer and harden-
er, epoxy thinner.
S Mix and thin the primer accord-
ing to the manufacturer’s direc-
tions.
Apply 2–4 coats, allowing sufficient flash time
between coats.
Force dry at 60–70
C(140–158
F) for at
least 30 minutes.Spray to
a thick-
ness of
30–35
microns.
5. Sand and clean
the whole area.Double–action sander, #400
sandpaper, wax and greases re-
mover, shop towels.Sand the whole area to be repainted with a
double–action sander and #400 sandpaper.
Blow off with compressed air. Clean with wax
and grease remover..
6. Coat the whole
area to be repainted
with primer/ surfacer.
Polyester/urethane resin primer/
surfacer.
S Mix and thin the primer accord-
ing to the manufacturer’s direc-
tions.
Apply 2–4 coats, allowing sufficient flash time
between coats.
Force dry at 60–70
C(140–158
F) for at
least 30 minutes.Spray to
a thick-
ness of
30–35
microns.
7. Sand and clean
the whole area to be
repainted.Hand sanding file, double–action
sander, #240, #320, #400, #600
sandpaper, wax grease and re-
mover, shop towels.Sand the repair area by hand with #240
sandpaper until it’s level. Sand the whole
area to repainted with #320– 600 sandpaper.
Clean with wax and grease remover..
8. Top–coat the
whole area to re-
painted.
Acrylic urethane resin top coat
paint, hardener, and thinner.
S Mix and thin the paint according
to the manufacturer’s directions.
Apply 2–4 coats, allowing sufficient flash time
between coats.
Force dry at 60–70
C(140–158
F) for at
least 30 minutes.Spray to
a thick-
ness of
40–50
microns.