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The Daewoo Lacetti is a compact car made by the South Korean automaker GM Daewoo since 2002. The first-generation Lacetti was available as a four-door sedan, a five-door hatchback or a five-door station wagon.
NUBIRA/LACETTI FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 6–1SECTION 6FRAME DOOR OPENING, DOOR AND SIDEPANEL OUTERCONTENTS1. FRAME DOOR OPENING 6 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.GENERAL DESCRIPTION 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.REPAIR PROCEDURE 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. DOOR 6 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.REPAIR PROCEDURE 6–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. SIDE PANEL OUTER 6 – 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.GENERAL DESCRIPTION 6–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.REPAIR PROCEDURE 6–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER NUBIRA/LACETTI1. FRAME DOOR OPENING1–1. GENERAL DESCRIPTIONThe frame door opening consist of frame door area andside outer area. It forms the base for the front, reardoors and other parts and maintains the rigidity of thedoors and roof. The frame door opening area should,depending on the degree of damage, be repaired asmuch as possible rather than repalced.(Repair by pull-ing out)Fig. 1 Frame Door Opening Welding Assembly NUBIRA/LACETTI FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 6–31–2. REPAIR PROCEDURE1. Remove the related parts.S Doors.S Weather strips, pillar trims and related parts.S Carpet.S Seat belt assemblyS Door switch and wiring harness.S Fuel pipe and brake oil pipe.S Other related parts.Note : Pull out and straighten the damaged area toapproximately the original shape.2. Remove the related parts.S Damage may extend to the inner roof frame, the innerframe door opening and the floor. Determine the extentof the damage first, so the frame can be pulled out prop-erly.Note : Use heat–resistant protective cover for protectpainting 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 cutthe new frame door opening so it will overlap by30mm(1.18in.) in the pillar, front and rear.S Cut the damaged area with a hand saw along the boldline as shown.Note : Be careful not to cut the inner panel. This couldresult in extensive repair.Fig. 2S If the damage involves part of the center pillar, cut themas shown.Fig. 3S Center punch around the spot weld imprints on thewelded flange.S Use the special spot cutter to drill holes at the spot weldnuggets.Note : When drilling holes be careful not to drill down tothe 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 orsafety 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 whenwelding, wear an approved welding helmet, glovesand safety shoes.S Use a hammer and dolly to mold damaged areas of theremaining inner panel and even out the welding flanges.S Level and finish the burrs from the pried off spot weldswith disc sander.S Sand off the paint and undercoat from both sides of theflange to be welded.5. Set the new frame door opening.S Grind both sides of the welding section of the preparedframe door opening part with a disk sander to removethe 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 whenwelding, wear an approved welding helmet, glovesand safety shoes. 6–4 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER NUBIRA/LACETTIFig. 4S Remove the vise grips and temporarily install the fenderand doors, then check the clearances, level differencesand outer appearance.6. Perform the main welding.S Weld the front, rear frame door opening and center pillarat the butt joints with a gas or MIG welder.S Spot weld the frame door opening and center pillar asshown.CAUTION : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand 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 spotwelded.Fig. 57. 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 carefulnot to deform them.CAUTION : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grind-ing.S Use a hammer and dolly to even out the spot weldedflanges for a close fit with the surface of the frame dooropening panel.S Fill in deformations and level differences of the weldedareas with solder or putty, then finish.8. Apply the sealer.S Apply the sealer to the matching surfaces of the floorand frame door opening.9. Apply the undercoat.S Undercoat to the front floor.10. Apply the paint.CAUTIONS Ventilate when spraying paint. Most paint contains sub-stances that are harmful if inhaled or swallowed. Readthe paint label before opening paint con tainer.S Avoid contact with skin. Wear an approved respirator,gloves, eye protection and appropriate clothing when NUBIRA/LACETTI FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 6–5painting.S Paint is flammable. Store in a safe place, and keep itaway from sparks, flames or cigarettes.11. Coating the anti–rust agents.S Coating the anti–rust agents to the inside of frame dooropening areas sufficiently.Fig. 612. Install the related parts.S Clean the passenger compartment.S Wiring harness and related parts.S Seat belt assembly and carpet.S Trims and weather strips.S Door and others.S Install in the reverse order in which they were removed.13. Check and adjust.S Check clearances and level differences.S Check the door locking and unlocking condition.S Check for water leaks in the passenger compartment. 6–6 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER NUBIRA/LACETTI2. DOOR2–1. REPAIR PROCEDURE1. 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 removethe four bolts from door assembly(2).Fig. 73. 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 differencesof doors, fender, pillar, roof and side panel outers.Fig. 8S Check any deformation.5. Remove the new door.S Remove the four bolts from door assembly.6. Apply the paint.CAUTIONS Ventilate when spraying paint. Most paint contains sub-stances that are harmful if inhaled or swallowed. Readthe paint label before opening paint container.S Avoid contact with skin. Wear an approved respirator,gloves, eye protection and appropriate clothing whenpainting.S Paint is flammable. Store in a safe place, and keep taway from sparks, flames or cigarettes.7. Coating the anti–rust agents.S Coating the anti–rust agents to the inside of bottomareas.Fig. 98. 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. NUBIRA/LACETTI FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 6–7S Glass and window lifter.S Solenoid valve and wiring harness.S Install door trim and others.Note : Before install the door trim and related parts, rubin grease to the moving parts and check all operation.10. Check and adjust.S Check clearance and level differences.S Check the door locking and unlocking condition.S Check for water leaks in the passenger compartment.S Install door trim and others. 6–8 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER NUBIRA/LACETTI3. SIDE PANEL OUTER3–1. GENERAL DESCRIPTION The side panel outer consists of side outer area andframe door area. The side outer area is a conspicuouspart 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 conductingwork. This part must be aligned with the rear door, trunklid, rear glass and other parts.Fig. 10 Side Panel Outer Welding Assembly (NOTCHBACK) NUBIRA/LACETTI FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 6–9Fig. 11 Side Panel Outer Welding Assembly (HATCHBACK) 6–10 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER NUBIRA/LACETTI3–2. REPAIR PROCEDURE1. 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 thefuel system. Keep open flame away from the fuelsystem. If necessary, remove the fuel tank and offlines.2. Pull out and straighten the damaged area to approxi-mately the original shape.S Attach the car to the frame straightener by tightening theunderbody clamps at the four designated support points.S Before cutting off the damaged sections, pull them outso 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 rearside 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 framedoor opening) along the bold lines as shown with a hand-saw and snips carefully.Fig. 12S Center punch around the spot weld imprints with the rearpanel, side panel inner and arch area.S Use the special spot cutter to drill holes at the spot weldnuggets on the rear side outer panel.Note : When drilling holes be careful not to drill down tothe side panel inner and rear panel themselves.S Cut the panel from the body with an air chisel, leaving thewelding flanges at the side inner panel, wheelhouse in-ner and back panel intact.S Level and finish the burrs from the pried off spot weldswith a hammer, dolly and disc sander.CAUTION : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grind-ing.Fig. 134. Mold damaged related parts.S Fill any holes drilled by welding.CAUTION : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.S Use a hammer and dolly to mold damaged areas of theremaining inner panel and even out the welding flanges.S Sand off the paint and undercoat from both sides of theflange to be welded.5. Set the new side panel outer.S Cut the new side panel outer so it will overlap by30mm(1.18in.) in the frame door opening area with ahand saw.Fig. 14S Grind both sides of the welding section of the preparedside panel outer with a disk sander to remove the paintand expose the steel plate.S Clamp the new panel in place with the vise grips. . damage, be repaired asmuch as possible rather than repalced.(Repair by pull-ing out)Fig. 1 Frame Door Opening Welding Assembly NUBIRA/LACETTI FRAME DOOR. Determine the extentof the damage first, so the frame can be pulled out prop-erly.Note : Use heat–resistant protective cover for protectpainting areas,