2004 DAEWOO NUBIRA ESP

5–8 ROOF, BACK PANEL AND REAR FLOOR PANEL NUBIRA/LACETTI
S Clamp both the right and left sides with the vise grips as
shown.
S Weld the clamped sections for temporary installation.
CAUTION : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
Fig. 13
7. Measure and check.
S Measure the trunk compartment diagonally to check it
for twisting or bending and its correct position with the
rear bumper installed.
S Temporarily assemble the rear combination lamps and
trunk, then check the clearances and level differences.
8. Perform the main welding.
S Make MIG or gas welds at the butt joints.
S Spot weld the back panel 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. 14
9. Finish the welding areas.S Level the gas or MIG welded areas with disc sander,
then even out high areas with a hammer being careful
not to deform them.
S Use a hammer and dolly to even out the rear side outer
and extension rear floor panel flanges for a close fit with
the surface of the rear panel.
10. Apply the sealer.
S Apply the sealer to the rear side outer joint and around
the rear lamps areas of the rear panel.
S Apply the sealer to the extension rear floor panel and
rear panel joint.
11. Apply the undercoat.
S Undercoat to the joint and overlapped areas of the rear
floor under side.
12. 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.
13. Install the related parts.
S Clean the trunk compartment.
S Install in the reverse order in which they were removed.
14. Check and adjust.
S Check clearances and level differences.
S Check the trunk locking and unlocking condition.
S Check all operation.
S Check for water leaks in the trunk compartment.
Note : Use specified check sheet for operation check
properly.

NUBIRA/LACETTI ROOF, BACK PANEL AND REAR FLOOR PANEL 5–13
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever standing, cutting, or
grinding.
Fig. 22
S Use a hammer and dolly to even out the spot welded
areas for a close fill the flange surface together.
11. Apply the sealer.
S Apply the sealer at the overlapped areas of the rear floor
and extension rear floor, and welded surfaces of the
matching panel and all sealing gaps completely.
12. Apply the undercoat.
S Undercoat to the rear wheelhouse and designated rear
floor.
13. Apply the paintCAUTION
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.
14. Apply the deadner.
S Clean the passenger and trunk compartment.
S Apply the deadner to the surface of rear floor and exten-
sion rear floor.
Fig. 23
15. Install the related parts.
S Install in the reverse order in which they were removed.
16. Check and adjust
S Check clearances and level differences.
S Check the trunk locking and unlocking condition.
S Check all operation.
S Check for water leaks in the trunk compartment.
Note : Use specified check sheet for operation check
properly.

6–4 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER NUBIRA/LACETTI
Fig. 4
S Remove the vise grips and temporarily install the fender
and doors, then check the clearances, level differences
and outer appearance.
6. Perform the main welding.
S Weld the front, rear frame door opening and center pillar
at the butt joints with a gas or MIG welder.
S Spot weld the frame door opening and center 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 welding con-
dition.
S Increase the number of spot by 20% for areas to be spot
welded.Fig. 5
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 frame door
opening panel.
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 floor
and frame door opening.
9. Apply the undercoat.
S Undercoat to the front floor.
10. 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 con tainer.
S Avoid contact with skin. Wear an approved respirator,
gloves, eye protection and appropriate clothing when

6–6 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER NUBIRA/LACETTI
2. DOOR
2–1. REPAIR PROCEDURE
1. Remove the related parts.
S Door trim and related parts.
S Wiring harness and solenoid valve.
S Glass and window lifter.
S Linkage, lock set and handle.
S Others.
Note : Inspection and choose the usable parts.
2. Remove the door.
S Remove the bolt from door check hinge(1) and remove
the four bolts from door assembly(2).
Fig. 7
3. Preparation of the new door.
S Preparation of the new door and check damaged areas.
4. Preinstall the door.
S Fix the four bolts.
S Check and adjust the clearances and level differences
of doors, fender, pillar, roof and side panel outers.
Fig. 8
S Check any deformation.
5. Remove the new door.
S Remove the four bolts from door assembly.
6. 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 t
away from sparks, flames or cigarettes.
7. Coating the anti–rust agents.
S Coating the anti–rust agents to the inside of bottom
areas.
Fig. 9
8. Install the door.
S Install the door with four bolts.
S Install the door check link set in the door and fix the bolt.
S Check clearances and level differences.
9. Install the related parts.
S Handle, linkage and lock set.

6–8 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER NUBIRA/LACETTI
3. SIDE PANEL OUTER
3–1. GENERAL DESCRIPTION
The side panel outer consists of side outer area and
frame door area. The side outer area is a conspicuous
part of the outer appearance of the vehicle. It is espe-cially important for the body line continuing from door.
Therefore, pay particular attention to it when conducting
work. This part must be aligned with the rear door, trunk
lid, rear glass and other parts.
Fig. 10 Side Panel Outer Welding Assembly (NOTCHBACK)

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)

7–2 FENDER, HOOD, TAILGATE AND TRUNK LID NUBIRA/LACETTI
1. FENDER
1–1. REPAIR PROCEDURE
1. Remove the related parts.
S Front bumper and mud guard.
.
2. Remove the fender
.
3. Preparation of the new fender.
S Preparation of the new fender and check damaged
areas.
.
4. 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.
5. Apply the mastic sealer.
S Apply the mastic sealer to the mounting bolts.
Fig. 1
6. Preinstall the fender.
S Fasten to the wheelhouse at two places with bolts. Close
the hood and check the front and rear clearances and
level differences of the hood and door.
Fig. 2
7. Tighten fully.
S After checking and adjusting the mounting position,
tighten all bolts fully.
.
8. Install the related parts.
S Install in the reverse order in which they were removed.
.
9. Check clearance
S Check clearance of front bumper.

NUBIRA/LACETTI FENDER, HOOD, TAILGATE AND TRUNK LID 7–3
2. HOOD
2–1. REPAIR PROCEDURE
1. Remove the related parts.
2. Remove the hood.
S Remove the hood mounting bolts from two hinge bows.
Fig. 3
3. Preparation of the new hood.
S Preparation of the new hood and check damaged areas.
.
4. 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.
.
5. Preinstall the hood.
S Fasten to the hood hinges bows at two places with four
bolts, carefully.
Fig. 4
S Close the hood and check the front and rear clearancesand level difference of hood. fender and head lamps.
Fig. 5
6. Tighten fully.
S After checking and adjusting the mounting position,
tighten all bolts fully.
.
7. Install the related parts.
S Install in the reverse order in which they were removed.
.
8. Check and adjust.
S Check clearances and level differences.
S Check the hood locking and unlocking condition.