2004 DAEWOO LACETTI wheel

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.

2–6 PREPARATIONS OF BODYWORK NUBIRA/LACETTI
4. MEASURING SYSTEMS (WITHOUT
SMALL DAMAGE)
S Whenever possible, make judgements and conclusions
based on measurement. Measure the wheel align-
ment(see pages 2–2, 2–3) so as to prevent any future
trouble like unsymmetrical wear of the tires or catchingof the steering wheel.
S If there are any deviations, use a tram tracking gauge
and measure parts of the body.(Below Fig. 5–1)
S If there is any twisting to the body, measure using a
frame centering gauge.(Below Fig. 5–2)
S When measuring body dimensions, use a universal tram
gauge.(Below Fig. 5–3)
.
Fig. 5–1
Fig. 5–2
Fig. 5–3
Fig. 5

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–2 FRONTNUBIRA/LACETTI
1. FRONT PANEL
1–1. GENERAL DESCRIPTION
.
The front panel is joined to the front wheelhouse and
front longitudinal. It forms the base for the headlampsand other parts and maintains the rigidity of the front
section of the body. Pay particular attention to twists
and parallelism and check mounting of related parts
when welding.
.
Fig. 1 Front Welding Assembly

NUBIRA/LACETTIFRONT 4–3
1–2. REPAIR PROCEDURE
1. Remove the related parts.
S Hood, radiator grill and front bumper.
S Head lamps and fender.
S Engine, radiator and related parts.
S Aircon condenser and related parts.
S Others.
Fig. 2
2. Roughly pull out and straighten the damaged area.
S Check the damage to the front wheelhouse and front
longitudinal before removing the front panel. Use the
frame straightener to roughly pull out and repair the
damaged front panel before removing the front panel.
Note : Check the fit of the door, taking care not to pull
the damaged area out more than necessary.
S Use the horizontal pinch weld clamps and attach the car
to the frame straightener at the clamping points secure-
ly.
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 and pry off the front panel.
S Center punch around the spot weld imprints.
S Use the special spot cutter to drill holes at the spot weld
nuggets on the front wheel house and longitudinal.
Note : When drilling holes be careful not to drill down to
the front wheelhouse and longitudinal themselves.
S Cut off the front panel with an air chisel, leaving the weld-
ing flanges intact.
S Level and finish the burrs from the pried off spot welds
with disc sander.
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
Fig. 3
5. Mold damaged related parts.
S Use a hammer and dolly to mold damaged areas of the
front wheelhouse and longitudinal.
S Even out the welding flanges with a hammer and dolly.
S Fill any holes drilled by welding.
Fig. 4
6. Set the front panel.
S Grind both sides of the welding section of the front panel
with a 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 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.

4–4 FRONTNUBIRA/LACETTI
Fig. 5
Note : Make sure that the right and left front panels are
in line with each others.
7. Measure the front compartment diagonally.
S Measure the front compartment diagonally with a track-
ing gauge or convex rule as shown to check it for twisting
or bending.
S Temporarily assemble the fender, head lamps and hood,
then check the clearances and level differences.
Fig. 6
8. Perform the main welding.
S Spot weld the front 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 weldng condi-
tion.
S Increase the number of spot by 20% for areas to be spot
welded.
Fig. 7
9. Finish the welding areas.
S Use a hammer and dolly to even out the front wheel-
house and longitudinal flanges for a close fit with the sur-
face of the front panel.
10. Apply the undercoat.
S Undercoat to the damaged areas of front wheelhouse
and longitudinal if necessary.
11. Apply the paint.
CAUTION
S Ventilate when spraying paint. Most paint contains sub-
stances that are harmful if inhaled or swallowed. Rear
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 door hinge areas.
Fig. 8
13. Install the related parts.
S Engine, radiator and related parts.

4–6 FRONTNUBIRA/LACETTI
2. FRONT WHEELHOUSE
2–1. GENERAL DESCRIPTION
The front wheelhouse component is constructed as a
unit with the locator shockabsorber. Therefore, replace-
ment of the component affects the front wheel align-ment. When assembling it, either use a jig or follow di-
mensions on the body repair chart for positioning. It
must be welded carefully.
Fig. 9 Front Wheelhouse Welding Assembly

NUBIRA/LACETTIFRONT 4–7
2–2. REPAIR PROCEDURE
1. Remove the related parts.
S Parts on passenger side of dash panel lower which are
especially flammable.
S Instrument panel, wiring harness, related parts and oth-
ers.
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 Do not pull out more than necessary.
S Pull out and straighten the damaged areas of the rear
wheelhouse and dash panel lower, front filar and other
parts.
Note : Check the condition of the door and hinges.
Fig. 10
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.
Fig. 11
S Using a chisel, pry off the welded flange from the front
body puller and wheelhouse.
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 wheelhouse.
S Center punch around the spot weld imprints on the longi-
tudinal and rear wheelhouse.
S Use the special spot cutter to drill holes at the spot weld
nuggets on the center punched areas.
S Cut off the front wheelhouse with an air chisel, leaving
the welding flanges intact.
S Level and finish the burrs from the pried off spot welds
with disc sander.
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or
grindng.