2004 DAEWOO LACETTI wheel

4–8 FRONTNUBIRA/LACETTI
Fig. 12
NOTE :
S If damage has occurred only front side, cut the damaged
section of the front wheelhouse, trim the new panel to fit
the remaining section, then butt weld both parts at the
inner ends.
6. Mold damaged related parts.
S Fill any holes drilled by welding.
S Use a hammer and dolly to mold damaged areas of the
front longitudinal, rear wheelhouse and other panels.
S Even out the welding flanges with a hammer and dolly.
7. Set the new front wheelhouse panel.
S Grind both sides of the welding section of the front, rear
wheelhouse and front longitudinal 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 Clamp to the front longitudinal with vise grips and squill
vises.
S Clamp the front panel with vise grips.
Note : Use of jigs is recommended.
S Weld the clamped sections for temporary installation.
CAUTION : To prevent eye injury and burns when
welding, wear an approved welding helmet, glovesand safety shoes.
8. Measure the front compartment diagonally.
S Measure the front compartment diagonally with a track-
ing gauge or convex rule to check it for twisting or bend-
ing.
S Temporarily assemble the fender and hood, then check
the clearances and level differences.
9. Perform the main welding.
S Weld as much as possible with the jig still mounted.
S Perform a trial welding first, and check the welding con-
dition.
S Perform the welding.
Fig. 13
CAUTION : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
S Increase the number of spot by 20% for areas to be spot
welded.
10. Apply the sealer tape.
S Apply the sealer tape to the hinge and brace wheelhouse
matching area as shown.

NUBIRA/LACETTIFRONT 4–9
Fig. 14
11. Weld the brace wheelhouse.
S Spot weld the brace wheelhouse as shown.
S Make MIG or gas welds at the door hinge areas.
Fig. 15
12. Finish the welding areas.
S Use a hammer and dolly to even out the rear wheel-
house and front longitudinal flanges for a close fit with
the surface of the front 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
panting.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 Wiring harness, instrument panel and related parts.
S Parts of the passenger compartment.
S Parts to be installed when install the front panel.
S Others.
S Install in the reverse order in which they were removed..
Note : After install the all related parts, rub in grease to
the moving parts and replenish cooling liquid, break oil,
aircon gas and others.
18. Check and adjust
S Measure the front wheel alignment.
S Check clearances and level differences.
S Check the hood locking and unlocking condition.
S Adjust the head lamp aim.
S Check all operation.
S Check for gas, oil and liquid leaks.
Note : Use specified check sheet for operation check
properly.

4–10 FRONTNUBIRA/LACETTI
3. FRONT LONGITUDINAL
3–1. GENERAL DESCRIPTION
The front longitudinal is joined to the wheelhouse and
front panel, it forms the base for the front suspension,
engine, transmission and others. Therefore, replace-ment of the component affects the front wheel align-
ment and maintains the rigidity of the front section.
When assembling it, either use a jig or follow dimen-
sions on the body repair chart for positioning. It must be
welded carefully.
Fig. 16 Front Longitudinal Welding Assembly

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 4–15
4–2. REPAIR PROCEDURE
1. Remove the related parts.
S Hood, radiator grill and front bumper.
S Door and fender.
S Wiper, cowl and windshield.
S Weatherstrip and pillar trims.
S Instrument panel and wiring harness.
S Carpet and others.
2. Roughly pull out and straighten the damaged area.
S Check the damage to the wheelhouse and roof before
removing the brace wheelhouse and front pillar and de-
termine the extent of the damage.
S Use the frame straightener to roughly pull out and repair
the damaged front pillar before removing the brace
wheelhouse and front panel.
Note : Pull out until the pillar is lined up with the surface
of the windshield and do not pull out more than neces-
sary.
Fig. 23
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.
S Using a chisel, pry off the welded flange from the front
body pillar and wheelhouse.
Fig. 24
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 pillar.
S Cut off the front pillar along the bold lines as shown in the
figure below with a handsaw and snips carefully.
Note : Be careful not to cut the inner section.
Fig. 25
S Center punch around the spot weld imprints with the rear
wheelhouse, front body pillar inner, rein– forcement front
body pillar inner and floor panel side.
S Use the special spot cutter to drill holes at the spot weld
nuggets on the front pillar.
Note : When drilling holes be careful not to drill down to
the front body pillar inner, reinforcement front body pillar
inner and floor panel side themselves.
S Pry off the remaining flanges from the body with an air
chisel and leaving the welding flanges.
S Level and finish the burrs from the pried off spot welds
with a hammer, dolly and disc sander.

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 5–11
3–2. REPAIR PROCEDURE
1. Remove the related parts.
S Parts to be removed when removing the back panel.
S Rear seat belt and rear seat.
S Muffler, fuel tank and related parts.
S Chassis 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. Roughly pull out and straighten the damaged area.
S Check the damage and roughly pull out and re pair the
related back panel, side panel, wheel house inner, rear
longitudinal and other damaged parts with the frame
straightener before remov ing the extension rear floor
panel, rear floor pane and back panel.
S Attach the car to the frame straightener by tightening the
underbody clamps located at the jack up designated
points on the bottom of the frame door opening.
Note : Measure in reference to the dimensions on the
body repair chart.
3. Cut and pry off the back panel.
S The back panel to be cut and pried off when removing
the back panel.
4. Cut and pry off the rear floor and extension rear floor
panel.
S Cut off the rear floor and extension rear floor with a gas
torch or air chisel leaving the spot welded flanges of the
rear longitudinal along the bold line in the figure below.
Note : Cut the rear floor 15mm(0.59in.) from welded
flange of the cross member rear seat.
S Center punch around the spot weld imprints with the rear
longitudinal, extension rear longitudinal and web plate.
S Use the special spot cutter to drill holes at the spot weld
nuggets on the center punched areas.
Fig. 17
Fig. 18
Note : When drilling holes be careful not to drill down to
the rear longitudinal, extension rear longitudinal and
web plate themselves.
S Cut and pry off the remaining rear floor and extension
rear floor panel with an air chisel, leaving the welding
flanges intact.
S Level and finish the burrs from the pried off spot welds
with disc sander and repair all cracks, holes or other de-
fects by welding also repair the rear longitudinal and ex-
tension rear longitudinal if necessary.
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
Fig. 19
5. Peel off the undercoat and sealer.
S Heat the undercoat and sealer at the welding areas with
a gas torch and peel off the undercoat and sealer with
a steel spatula.
6. Mold damaged related parts.
S Use a hammer and dolly to mold damaged areas of the
rear longitudinal and extension rear longitudinal.
S Even out the welding flanges with a hammer and dolly.
S Fill any holes drilled by welding.