2004 DAEWOO LACETTI Section 6

NUBIRA/LACETTI FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 6–3
1–2. REPAIR PROCEDURE
1. Remove the related parts.
S Doors.
S Weather strips, pillar trims and related parts.
S Carpet.
S Seat belt assembly
S Door switch and wiring harness.
S Fuel pipe and brake oil pipe.
S Other related parts.
Note : Pull out and straighten the damaged area to
approximately the original shape.
2. Remove the related parts.
S Damage may extend to the inner roof frame, the inner
frame door opening and the floor. Determine the extent
of the damage first, so the frame can be pulled out prop-
erly.
Note : Use heat–resistant protective cover for protect
painting areas, seats, carpets and other parts.
S Pull out and straighten the damaged areas.
S Do not pull out more than necessary.
3. Cut and pry off the frame door opening.
S Check the damage on the frame door opening, then cut
the new frame door opening so it will overlap by
30mm(1.18in.) in the pillar, front and rear.
S Cut the damaged area with a hand saw along the bold
line as shown.
Note : Be careful not to cut the inner panel. This could
result in extensive repair.
Fig. 2
S If the damage involves part of the center pillar, cut them
as shown.
Fig. 3
S Center punch around the spot weld imprints on the
welded flange.
S Use the special spot cutter to drill holes at the spot weld
nuggets.
Note : When drilling holes be careful not to drill down to
the inner panel..
S Pry off the frame door opening panel with an air chisel,
leaving the welding flanges intact.
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
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 Level and finish the burrs from the pried off spot welds
with disc sander.
S Sand off the paint and undercoat from both sides of the
flange to be welded.
5. Set the new frame door opening.
S Grind both sides of the welding section of the prepared
frame door opening part with a disk sander 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.
CAUTION : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.

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.

NUBIRA/LACETTI FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 6–11
Fig. 15
S Tack weld the clamped section for temporary installa-
tion.
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 trunk
lid and doors, then check the clearances, level differ-
ences and outer appearance.
6. 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 and wheel arch of the side panel
outer 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 welding con-
dition.
S Increase the number of spot by 20% for areas to be spot
welded.
Fig. 16
Fig. 17
7. 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 side panel
outer.
S Fill in deformations and level differences of the welded
areas with solder or putty, then finish.
8. Apply the sealer.
S Apply the sealer to the matching surfaces of the web
plate, back panel lower, rear combination lamp area and
side panel outer.
9. Apply the undercoat.
S Undercoat to the rear wheelhouse and designated rear
floor.
10. Apply the paint.
CAUTION
S Ventilate when spraying paint. Most paint contains sub-
stances that are harmful if inhaled or swallowed.
S 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.
11. Coating the anti–rust agents.
S Coating the anti–rust agents to the inside of frame door
opening areas sufficiently.
12. Apply the deadner.
S Apply the deadner to the inside of side panel outer cen-
ter.(Left side only)

NUBIRA/LACETTI FENDER, HOOD, TAILGATE AND TRUNK LID 7–1
SECTION 7
FENDER, HOOD, TAILGATE AND TRUNK LID
CONTENTS
1. FENDER 7 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.REPAIR PROCEDURE7–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. HOOD 7 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.REPAIR PROCEDURE7–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. TAILGATE(HATCHBACK) 7 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.REPAIR PROCEDURE7–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. TRUNK LID (NOTCHBACK) 7 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.REPAIR PROCEDURE7–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NUBIRA/LACETTIBODY DIMENSION 8–1
SECTION 8
BODY DIMENSION
CONTENTS
1. BODY DRAWING 8 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.UNDER BODY8–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.FRONT PANEL8–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.ENGINE ROOM8–8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.BACK PANEL LOWER8–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5.SIDE OUTER8–11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. REPAIR DRAWING 8 – 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.FRAME DOOR OPENING8–13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.WINDSHIELD AND REAR GLASS8–15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. GAP CHART 8 – 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NUBIRA/LACETTI SEALING, CAULKING AND DEADNER 9–1
SECTION 9
SEALING, CAULKING AND DEADNER
CONTENTS
1. SEALING & CAULKING 9 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. DEADNER 9 – 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.GENERAL DESCRIPTION9–14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.REPAIR PROCEDURE9–14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NUBIRA/LACETTIRUST PREVENTION 10–1
SECTION 10
RUST PREVENTION
CONTENTS
1. ZINC TREATED STEEL PLATE REPAIR 10 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. RUST PREVENTIVE PROCEDURE 10 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.GENERAL INFORMATION10–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.AREA COVERED BY ANTI–RUST AGENTS 10–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.UNDERCOATING DIAGRAM10–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11
BODY–FRAME REPAIR EQUIPMENT
CONTENTS
1. SCHEMATIC DIAGRAM OF STRAIGHTENING JIG 11–2. . . . . . . . . . . . . . . . . .
2. EXAMPLE: STRAIGHTENING BODY–DAMAGE 11–5. . . . . . . . . . . . . . . . . . . .