2004 DAEWOO LACETTI Lamp

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.

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 4–13
Note : After install the all related parts, rub in grease o
the moving parts and replenish cooling liquid, break oil,
aircon gas and others.
14. Check and adjust
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.
S Check for water leaks in the passenger compartment.
Note : Use specified check sheet for operation check
properly.

4–16 FRONTNUBIRA/LACETTI
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind–
ing.
6. 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.
7. Set the new front pillar.
S Align the new part with the top section, then cut it with
a hand saw.
S Cut the floor panel side joint area so it will overlap by
30mm(1.18in.) in the floor panel side with a hand saw.
S Grind both sides of the welding section with a disk sand-
er to remove the paint and expose the steel plate.
S Clamp the new panel in place with the vise grips.
S Tack weld the clamped section for temporary installa-
tion.
Fig. 26
Fig. 27
CAUTION : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
S Remove the vise grips and temporarily install the fender
and doors, then check the clearances, level differences
and outer appearance.
8. Perform the main welding.
S Weld the frame door opening area and pillar at the butt
joints with a gas or MIG welder.
S Spot weld the flanges of the front pillar 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 weld ing con-
dition.
S Increase the number of spot by 20% for areas to be spot
welded.

NUBIRA/LACETTI ROOF, BACK PANEL AND REAR FLOOR PANEL 5–3
1–2. REPAIR PROCEDURE
1. Remove the related parts.
S Room lamp, door weatherstrip and pillar trims.
S Headlining and wiring harness.
S Wiper, cowl and windshield.
S Rear glass and others.
2. Pull out and straighten the damaged area to approxi-
mately the original shape.
Note : Use heat–resistant protective cover for protect
painting areas, seats, carpets and other parts.
S Attach the car to the frame straightener by tightening the
underbody clamps at the horizontal pinch welds.
S Before cutting off the roof panel, 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 related damaged parts to
approximately their original shape.
Note : Make sure that the right and left pillars are parallel
with the windshield surface. Check the door for proper
opening and closing.
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 off the shaded areas of the roof panel.
S Cut the roof weld flanges with a hand saw and snips at
the roof panel and roof frames.
Fig. 2
S Using a chisel, pry off the roof panel along the bold lines
as shown.
S Center punch around the spot weld imprints of the roof
welded flange.
S Drill holes using the spot cutter.
S Using a chisel and a disc sander, pry off the welded
flange from the front, rear body pillar and roof panel.
S Level and finish the burrs of welded flanges with a disc
sander.CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
5. Peel off the sealer.
S Peel off the sealer with a steel spatula at the welding
areas of the frame door opening.
6. Mold damaged related parts.
S Use a hammer and dolly to mold damaged areas of the
front, rear body pillar inner and frame door opening.
S Even out the welding flanges with a hammer and dolly
for close fit with the roof panel welding flange.
S Fill any holes drilled by welding.
7. Set the new panels.
S Grind both sides of the welding section of the rail wind-
shield header, support roof panel, frame rear roof panel
and roof panel 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 Temporarily set the new three frames and roof panel and
clamp with the vise grips.
Note : Check that the flange surface fit closely. Be care-
ful not to twist or deform the roof panel.
Fig. 3
S Measure the dimensions diagonally at the windshield
area and rear glass area with a tracking gauge or convex
rule as shown to check it for twisting or bending.

5–4 ROOF, BACK PANEL AND REAR FLOOR PANEL NUBIRA/LACETTI
Fig. 4
S Dismantle the new roof panel.
S Weld the clamped sections of the roof frames and front,
rear body pillar inner for temporary installation.
Fig. 5
S Set the new roof panel and clamp again.
S Temporarily set the windshield and rear glass, and
check the roof panel for proper installation.
S Install the roof molding and check the clearance and out-
er appearance.
8. Apply the sealer to the roof frames.
S Dismantle the new roof panel again.
S Apply the sealer to one groove of the rail windshieldheader, two grooves of the support roof panel and one
groove of the frame rear roof panel.
S Set and tack weld the roof panel.
Fig. 6
9. Perform the main welding and finish.
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.
S Use a hammer and dolly to smooth the spot weld areas
on the windshield and rear glass.
S Cut off the irregular and unuseful flanges and even out
the flanges for a close fit with the surface of the roof pan-
el.