2004 DAEWOO LACETTI Rod

9S – 10IBODY REAR END
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
FUEL FILLER DOOR
The fuel filler door attaches to the fuel tank pocket on the
right side of the vehicle. The door is opened by pulling on
the fuel filler door remote handle located on the floor in
front of the driver’s seat.
REAR DECK LID (NOTCHBACK)
The rear deck lid consists of an inner and outer panel thatis hemmed around the perimeter and bonded together
with structural adhesive. The deck lid torque rods assist in
the opening of the rear deck lid and hold it in the open posi-
tion.
HATCHBACK DOOR
The Hatchback door consists of the rear hatch glass within
a steel frame. The steel frame is made of an inner and an
outer panel hemmed around the perimeter, and bonded
together with structural adhesive. The gas support assem-
blies assist in the opening of the hatchback door, and can
hold the door open.

NUBIRA/LACETTISERVICE NOTICE 0–1
FOREWORD
This manual includes procedure for maintenance, adjustment, service operation and removal
and installation of components.
All information, illustrations and specifications contained in this manual are based on the latest
product information available at the time of manual approval.
The right is reserved to make changes at any time without notice.

NUBIRA/LACETTISERVICE NOTICE 0–3
1. HOW TO USE THIS MANUAL
.
This manual covers the repairs of NUBIRA/LACETTI
automobile which has been involved in accidents, and it
describes the work related to the replacement of dam-
aged body parts.
Please read through these instructions and familiarize
yourself with them before actually using this manual.
.
Note : Refer to NUBIRA/LACETTI Service Manual for
specifications, wire harness locations, safety stand sup-
port points, etc.
2. SPECIAL INFORMATION
.
Indicates a strong possibility of personal injury or equip-
ment damage if instructions are not followed.
.
Note : Gives helpful information.
.
CAUTION : Detailed descriptions of standard work-
shop procedures, safety principles and service op-
erations are not included. Please note that this manu-
al does contain warnings and cautions against some
specific service methods which could cause PER-
SONAL INJURY, or could damage a vehicle or make
it unsafe. Please understand that these warnings can-
not cover all conceivable ways in which service,
whether or not recommended by GM DAEWOO might
be done or of the possible hazardous consequences
of each conceivable way, not could GM DAEWOO in-
vestigate all such ways. Anyone using service proce-
dures or tools, whether or not recommended by GM
DAEWOO, must satisfy himself thoroughly that nei-
ther personal safety or tools, whether or not recom-
mended by GM DAEWOO, must satisfy himself thor-
oughly that neither personal safety or vehicle safety
will be jeopardized.
.
All information contained in this manual is based on the
latest product information available at the time of print-
ing. We reserve the right to make changes at any time
without notice. No part of this publication may be repro-
duced, stored in retrieval system, or transmitted, in any
form by any means, electronic, mechanical, photocopy-
ing, recording, or otherwise, without the prior written
permission of the publisher. This includes text, figures
and tables.

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.

NUBIRA/LACETTIGENERAL INFORMATION 1–3
3. BODY SAFETY
Modern stressed–skin bodies are designed so as to
have a sturdy passenger cell protected by front and rear
crumple zones.
S In an accident the crumple zones are designed to con-
vert impact energy into deformation work.
S The shape, material and metal thickness must all be pre-
cisely matched.
Fig. 1 Body Shell
S Many years of experience, refined computational meth-
ods and expensive series of crash tests mean that GM
DAEWOO now builds bodies giving optimum deforma-
tion in the crumple zones in frontal or rear impacts.
Fig. 2 Crumple Zones
When repairing body damage, it is therefore imperative
to restore the original structure and strength in order to
guarantee the safety of the occupants.
4. LOADS ON BODY PARTS
S The earlier practice of making a distinction between load
bearing and non–loading bearing parts of vehicles with
a chassis and body is no longer justified now. Every part,
even the windows, contributes to the overall strength of
the vehicle.
.
Therefore, with modern GM DAEWOO bodies, one
talks of highly stressed and less highly stressed parts.
.
.
5. USE OF NEW HIGH–QUALITY
MATERIALS
S The requirement for reduced body weight has lead to a
reduction in the amount of steel used, e.g. through the
use of thinner sheet steels. This has been achieved with
HIGH STRENGTH SHEET STEELS, in spite of the
need to meet higher body strength requirements at the
same time. High strength steels have a tensile strength
and a yield strength as much as 30% higher than con-
ventional steel. These properties must not be destroyed
when carrying out repairs, e.g. by using excessive heat.
.
.
6. CORROSION PROTECTION
S The durability of the bodywork, its associated long–term
safety and retention of value largely depend on the cor-
rosion protection given to the sheet metal. Here, GM
DAEWOO takes a great deal of care in production.
S Therefore, this corrosion protection must be preserved
or restored when repairs are carried out.

1–4 GENERAL INFORMATIONNUBIRA/LACETTI
7. SUMMARY
S All GM DAEWOO vehicles are built to the highest stan-
dards in terms of styling and material properties.
S These high quality standards must be maintained when
accident repairs are carried out.
S Mistakes made when carrying out repair operations
such as straightening, welding sheet–metal parts, etc.
not only produce visible defects, but may also compro-
mise the safety of the vehicle.
S Mistakes made when restoring the corrosion protection
compromise durability.
.
.
8. ZINC TREATED STEEL PLATE
REPAIR
The zinc plated steel plate used in some panels of the
NUBIRA/LACETTI requires different repair techniques
than ordinary steel plate.
Fig. 31. Before spot welding the zinc plated steel plate, re-
move the paint from both sides of the flange to be
welded. Apply sealer to the flange after welding.
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting or grind-
ing.
Note : Seal the sanded surfaces thoroughly to prevent
rust.
2. The electric continuity properties of zinc plated steel
plate is different from ordinary steel plate. When spot
welding, increase the current by 10–20%, or increase
the resistance welding time.
Increase the number of weld spots by 10–20% also.
Note : The MIG welding procedures for zinc plated steel
plate are the same as for ordinary steel plate.
CAUTION : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
3. Before applying putty or body filler to the zinc plated
steel plate, sand the zinc plating thoroughly to promote
adhesion and prevent blistering.
Note : Use only epoxy–based putties and fillers on zinc
plated steel plate.

NUBIRA/LACETTIWELDING AND TOOLS 3–5
Note : Below is an example of how not to perform gas
welding, avoid operations like this.
Fig. 6
3. CARBON DIOXIDE ARC WELDER(MIG
ARC WELDING)
This welding process uses inexpensive carbon dioxide
instead of expensive inert gases as a shielding means.
Consumable metal electrodes are employed. It has a
wide range of applications, including butt welding of thin
plate, fillet welding, plug welding, and MIG spot welding.
In terms of the weld strength, it is also highly stable.
Fig. 7

NUBIRA/LACETTIRUST PREVENTION 10–3
2. RUST PREVENTIVE PROCEDURE
2–1. GENERAL INFORMATION
.
Corrosion starts immediately after the steel base con-
tacts the atmosphere. The condition is aggravated by
sea wind, road salt, rain, snow and industrial fallout.
There are many ways to protect automobiles against
corrosion. Primers, primer surfacers and paints are ap-
plied by electrodeposition or spray to protect the car
body.Anti–rust Agents and Spray Guns
Use the following anti–rust agents or equivalents when
making a body repair.
.
CAUTION : ANTI–RUST agents contain substances
that are harmful if you breathe or swallow them, or get
them on your skin. Wear converalls, gloves, eye
protection, and an approved respirator while using
such agents.
.
.
Anti–rust agents:
RUSTOP
DEOX #100
WAXOYL
U.S.A. MARKET
AUTO ARMOR 1031
(made by E.C.P)To be applied to welded joints
inside body panels.
NOX–RUST 409–20S
SOLTION 1000SAUTO ARMOR OUTSIDE COATING
(made by E.C.P)To be appled to under floor
and wheelhouse.
Spray guns:
Use the correct gun for the agent being used.
S Use of a pressure type spray gun is recommended when
work involves a considerable number of cars.
For RUSTOP
DEOX#100For WAXOYLFor NOXRUST 409–20S/
SOLTION 1000S
Protectors: Wear gloves, mask and suitable eye protection.
S Use light oil and a rag to clean up spilled anti–rust agents.