2004 DAEWOO LACETTI Points

NUBIRA/LACETTI ROOF, BACK PANEL AND REAR FLOOR PANEL 5–7
2–2. REPAIR PROCEDURE
1. Remove the related parts.
S Rear and trunk trims
S Trunk lid lock and related parts.
S Rear combination lamps and wiring harness.
S Rear bumper and related parts.
S Other related parts.
Fig. 10
2. Roughly pull out and straighten the damaged area.
S Check the damage and roughly pull out and repair the
related side panel inner, rear floor, rear longitudinal and
other damaged parts with the frame straightener before
removing the 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.
3. Cut and pry off the rear panel.
S Center punch around the spot weld imprints with the rear
side outer and extension rear floor panel.
S Use the special spot cutter to drill holes at the spot weld
nuggets on the rear side outer and extension rear floor
panel.
Note : When drilling holes be careful not to drill down to
the side outer and extension rear floor panel them–
selves.
S Cut off the rear panel with an air chisel, leaving the weld-
ing flanges intact.
S Level and finish the burrs from the fried off spot welds
with disc sander and repair all cracks, holes or other de-
fects by welding also repair the floor panel if necessary.
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
Fig. 11
NOTE:
S I f damage has occurred only on one side, cut the dam-
aged section of the rear panel, trim the new panel to fit
the remaining section, then butt weld both parts at the
inner ends.
S Where damage has not extended into the rear side outer
panel, cut the rear panel from the body on either panel.
Fig. 12
4. Peel off the undercoat and sealer.
S Heat the undercoat and sealer at the welding areas of
the rear side outer panel and extension rear floor with a
gas torch and peel off the undercoat and sealer with a
steel spatula.
5. Mold damaged related parts.
S Use a hammer and dolly to mold damaged areas of the
rear side outer and extension rear floor panel.
S Even out the welding flanges with a hammer and dolly.
S Fill any holes drilled by welding.
6. Set the new rear panel.
S Grind both sides of the welding section of the rear 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.

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.

6–10 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER NUBIRA/LACETTI
3–2. REPAIR PROCEDURE
1. Remove the related parts.
S Rear and trunk trims.
S Rear combination lamps and wiring harness.
S Rear bumper and related parts.
S Rear seat and rear seat belt.
S Chassis and fuel 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. Pull out and straighten the damaged area to approxi-
mately the original shape.
S Attach the car to the frame straightener by tightening the
underbody clamps at the four designated support 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
side outer panel, side inner panel and wheelhouse inner.
Note : Check the rear door locking and unlocking condi-
tion.
3. Cut and pry off the side panel outer.
S Cut at the rear pillar and side outer(rear side of frame
door opening) along the bold lines as shown with a hand-
saw and snips carefully.
Fig. 12
S Center punch around the spot weld imprints with the rear
panel, side panel inner and arch area.
S Use the special spot cutter to drill holes at the spot weld
nuggets on the rear side outer panel.
Note : When drilling holes be careful not to drill down to
the side panel inner and rear panel themselves.
S Cut the panel from the body with an air chisel, leaving the
welding flanges at the side inner panel, wheelhouse in-
ner and back panel intact.S Level and finish the burrs from the pried off spot welds
with a hammer, dolly and disc sander.
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
Fig. 13
4. 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 Use a hammer and dolly to mold damaged areas of the
remaining inner panel and even out the welding flanges.
S Sand off the paint and undercoat from both sides of the
flange to be welded.
5. Set the new side panel outer.
S Cut the new side panel outer so it will overlap by
30mm(1.18in.) in the frame door opening area with a
hand saw.
Fig. 14
S Grind both sides of the welding section of the prepared
side panel outer with a disk sander to remove the paint
and expose the steel plate.
S Clamp the new panel in place with the vise grips.