2004 DAEWOO LACETTI roof rack

POSITION OF CONNECTORS AND GROUNDSW2–3
2) CONNECTOR INFORMATION
Connector
Number
Te r m i n a l
NumberColorConnecting Wiring
HarnessConnector Position
C10121 PinWhiteBody
Engine Fuse BlockEngine Fuse Block
C10211 P i nWhiteBody
Engine Fuse BlockEngine Fuse Block
C10310 PinWhiteEngine
Engine Fuse BlockEngine Fuse Block
C10424 PinWhiteFront
Engine Fuse BlockEngine Fuse Block
C1054 PinWhiteBody
Engine Fuse BlockEngine Fuse Block
C10620 PinWhiteEngine
Engine Fuse BlockEngine Fuse Block
C1072 PinWhiteABS
Engine Fuse BlockEngine Fuse Block
C10824 PinBlackBody
EngineLeft Engine Fuse Block
C1094 PinWhiteEngine
FrontUnder Engine Fuse Block
C11012 PinWhiteABS
BodyBelow Engine Fuse Block
C 1112 PinBlackABS
FrontBelow Engine Fuse Block
C1122 PinBlackFront – HornCenter Cross Member Panel
C11316 PinBlackBody
FrontBehind ECM Bracket
C20176 PinBlackI.P
I.P Fuse BlockI.P Fuse Block
C20289 PinWhiteI.P
BodyLeft CO–Driver Leg Room
C2048 PinWhiteRoof
Body (W/O Rain Sensor)Left CO–Driver Leg Room
C20414 PinWhiteRoof
Body(W/ Rain Sensor)Left CO–Driver Leg Room
C20622 PinWhiteI.P
TCMUpper Driver Leg Room
C2076 PinWhiteAir Bag
I.PUpper Left Driver Leg Room
C20815 PinWhiteI.P
FAT CBehind Glove Box
C20920 PinBlackFAT C
FAT C . A u xBetween Heater Core and
Evaporator Core
C2106 PinWhiteI.P
ConsoleBelow Console Box
C3018 PinWhiteAir Bag
BodyFront SDM
C3024 PinBlackRR. ABS
BodyCenter Rear Cross Member
C35133 PinGrayBody
Front Light DoorUnder CO–Driver A Pillar
C36133 PinGrayBody
Front Right DoorUnder Driver A Pillar
C37112 PinWhiteBody
Rear Light DoorUnder Left B Pillar
C38112 PinWhiteBody
Rear Right DoorUnder Right B Pillar
C401 (N/B)8 PinWhiteTrunk
BodyInside Right Trunk Side Cover
C401 (H/B)6 PinWhiteTrunk
BodyInside Right Trunk Side Cover
C4026 PinWhiteTrunk LID
BodyInside Right Trunk Side Cover
C4036 PinWhiteT/Gate. EXT. – BodyInside Left C Pillar
C4048 PinWhiteT/Gate. EXT. – BodyInside Left C Pillar
C4058 PinWhiteT/Gate. EXT. – T/GateBeside Left Rear Wiper Motor
C4066 PinWhiteT/Gate. EXT. – T/GateBeside Left Rear Wiper Motor
3) GROUND INFORMATION
Ground Number
Wiring HarnessGround Position
G101FrontBehind Left Head Lamp
G102FrontBehind Right Head Lamp
G103BatteryLeft Battery
G104EngineUnder Start Motor
G105BatteryUnder Start Motor
G106ABSBelow EBCM
G107Engine(MR–140/HV–240)Under Start Motor
G201I.PLeft I/P Fuse Block
G202Air BagBehind Left Audio Bracket
G203I.PBehind Left Audio Bracket
G205RoofUpper Driver Leg Room
G301BodyBelow Driver Cross Member Floor Panel
G302BodyBelow Left C Pillar
G303BodyBelow Left CO–Driver Leg Room
G401TrunkCenter Trunk Lower Back Panel
G402T/Gate. EXT.Inside Driver C Pillar
4) SPLICE PACK INFORMATION
Splice Pack Number
ColorWiring HarnessGround Position
S101BlackEngine(MR–140/HV–240)Upper Transmission
S202BlackI.PBehind Cluster
S203RedI.PBehind Audio Mounting
S204MagentaI.PBehind Audio Mounting
S205OrangeTCM (MR–140/HV–240)Upper Driver Leg Room
S301BlueBodyLeft CO–Driver Leg Room
S302BrownBodyLeft CO–Driver Leg Room

5–132WELECTRICAL WIRING DIAGRAMS
3) W/ RAIN SENSOR & AIR CONDITIONER : NOTCH BACKa. CONNECTOR INFORMATION
CONNECTOR(NO.)
(PIN NO. COLOR)
CONNECTING, WIRING HARNESSCONNECTOR POSITION
C113 (16 Pin, Black)Body
FrontBehind ECM Bracket
C201 (76 Pin, Black)I.P
I.P Fuse BlockI.P Fuse Block
C202 (89 Pin, White)I.P
BodyLeft CO–Driver Leg Room
C204 (14 Pin, White)Roof
Body (W/ Rain Sensor)Left CO–Driver Leg Room
C204 (8 Pin, White)Roof
Body (W/O Rain Sensor)Left CO–Driver Leg Room
G101FrontBehind Left Head Lamp
G205RoofInside CO–Driver A Pillar
G303BodyBelow Left CO–Driver Leg Room
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION

5–140WELECTRICAL WIRING DIAGRAMS
7) W/ RAIN SENSOR & FATC : NOTCH BACKa. CONNECTOR INFORMATION
CONNECTOR(NO.)
(PIN NO. COLOR)
CONNECTING, WIRING HARNESSCONNECTOR POSITION
C113 (16 Pin, Black)Body
FrontBehind ECM Bracket
C201 (76 Pin, Black)I.P
I.P Fuse BlockI.P Fuse Block
C202 (89 Pin, White)I.P
BodyLeft CO–Driver Leg Room
C204 (14 Pin, White)Roof
Body (W/ Rain Sensor)Left CO–Driver Leg Room
C204 (8 Pin, White)Roof
Body (W/O Rain Sensor)Left CO–Driver Leg Room
C208 (15 Pin, White)I.P
FAT CBehind Glove Box
C209 (20 Pin, Black)FAT C
FAT C . A u xBetween Heater Core and Evaporator Core
S204 (Magenta)I.PBehind Audio Mounting
G101FrontBehind Left Head Lamp
G205RoofInside CO–Driver A Pillar
G303BodyBelow Left CO–Driver Leg Room
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION

5–172WELECTRICAL WIRING DIAGRAMS
2) HATCH BACKa. CONNECTOR INFORMATION
CONNECTOR(NO.)
(PIN NO. COLOR)
CONNECTING, WIRING HARNESSCONNECTOR POSITION
C101 (21 Pin, White)Body
Engine Fuse BlockEngine Fuse Block
C102 (11 Pin, White)Body
Engine Fuse BlockEngine Fuse Block
C105 (4 Pin, White)Body
Engine Fuse BlockEngine Fuse Block
C201 (76 Pin, Black)I.P
I.P Fuse BlockI.P Fuse Block
C202 (89 Pin, White)I.P
BodyLeft CO–Driver Leg Room
C204 (8 Pin, White)Roof – Body (W/O Rain Sensor)Left CO
Driver Leg Room
C204 (14 Pin, White)Roof – Body (W/ Rain Sensor)Left CO
Driver Leg Room
C351 (33 Pin, Gray)Body
Front Light DoorUnder CO–Driver A Pillar
C361 (33 Pin, Gray)Body
Front Right DoorUnder Driver A Pillar
C371 (12 Pin, White)Body
Rear Light DoorUnder Left B Pillar
C381 (12 Pin, White)Body
Rear Right DoorUnder Right B Pillar
S203 (Red)I.PBehind Audio Mounting
S204 (Magenta)I.PBehind Audio Mounting
G203I.PBehind Left Audio Bracket
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION

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.

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.