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 FRONT 4–1SECTION 4FRONTCONTENTS1. FRONT PANEL 4 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.GENERAL DESCRIPTION 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.REPAIR PROCEDURE 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. FRONT WHEELHOUSE 4 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.GENERAL DESCRIPTION 4–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.REPAIR PROCEDURE 4–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. FRONT LONGITUDINAL 4 – 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.GENERAL DESCRIPTION 4–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.REPAIR PROCEDURE 4–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. FRONT PILLAR 4 – 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.GENERAL DESCRIPTION 4–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.REPAIR PROCEDURE 4–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2 FRONT NUBIRA/LACETTI1. FRONT PANEL1–1. GENERAL DESCRIPTION.The front panel is joined to the front wheelhouse andfront longitudinal. It forms the base for the headlampsand other parts and maintains the rigidity of the frontsection of the body. Pay particular attention to twistsand parallelism and check mounting of related partswhen welding Fig. 1 Front Welding Assembly NUBIRA/LACETTI FRONT 4–31–2. REPAIR PROCEDURE1. Remove the related parts.S Hood, radiator grill and front bumper.S Head lamps and fender.S Engine, radiator and related parts.S Aircon condenser and related parts.S Others.Fig. 22. Roughly pull out and straighten the damaged area.S Check the damage to the front wheelhouse and frontlongitudinal before removing the front panel. Use theframe straightener to roughly pull out and repair thedamaged front panel before removing the front panel.Note : Check the fit of the door, taking care not to pullthe damaged area out more than necessary.S Use the horizontal pinch weld clamps and attach the carto the frame straightener at the clamping points secure-ly.3. Keep the body, level.S Jack up the body, and place safety stands at the fourdesignated places of the frame door opening.4. Cut and pry off the front panel.S Center punch around the spot weld imprints.S Use the special spot cutter to drill holes at the spot weldnuggets on the front wheel house and longitudinal.Note : When drilling holes be careful not to drill down tothe front wheelhouse and longitudinal themselves.S Cut off the front panel with an air chisel, leaving the weld-ing flanges intact.S Level and finish the burrs from the pried off spot weldswith disc sander.CAUTION : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grind-ing.Fig. 35. Mold damaged related parts.S Use a hammer and dolly to mold damaged areas of thefront wheelhouse and longitudinal.S Even out the welding flanges with a hammer and dolly.S Fill any holes drilled by welding.Fig. 46. Set the front panel.S Grind both sides of the welding section of the front panelwith a sander to remove the paint and expose the steelplate.CAUTION : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grind-ing.S Clamp both the right and left sides with the vise grips asshown.S Weld the clamped sections for temporary installation.CAUTION : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes. 4–4 FRONT NUBIRA/LACETTIFig. 5Note : Make sure that the right and left front panels arein line with each others.7. Measure the front compartment diagonally.S Measure the front compartment diagonally with a track-ing gauge or convex rule as shown to check it for twistingor bending.S Temporarily assemble the fender, head lamps and hood,then check the clearances and level differences.Fig. 68. Perform the main welding.S Spot weld the front panel as shown.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 weldng condi-tion.S Increase the number of spot by 20% for areas to be spotwelded.Fig. 79. Finish the welding areas.S Use a hammer and dolly to even out the front wheel-house and longitudinal flanges for a close fit with the sur-face of the front panel.10. Apply the undercoat.S Undercoat to the damaged areas of front wheelhouseand longitudinal if necessary.11. Apply the paint.CAUTIONS Ventilate when spraying paint. Most paint contains sub-stances that are harmful if inhaled or swallowed. Rearthe 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 itaway from sparks, flames or cigarettes.12. Coating the anti–rust agents.S Coating the anti–rust agents to the end of front panelside and the door hinge areas.Fig. 813. Install the related parts.S Engine, radiator and related parts. NUBIRA/LACETTI FRONT 4–5S Aircon condenser and related parts.S Head lamps and fenders.S Hood, radiator grill, and bumper.S OthersS Install in the reverse order in which they were removed.Note : After install the all related parts, rub in grease tothe moving parts and replenish cooling liquid, break oil,aircon gas and others.14. Check and adjustS 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 checkproperly. 4–6 FRONT NUBIRA/LACETTI2. FRONT WHEELHOUSE2–1. GENERAL DESCRIPTIONThe front wheelhouse component is constructed as aunit with the locator shockabsorber. Therefore, replace-ment of the component affects the front wheel align-ment. When assembling it, either use a jig or follow di-mensions on the body repair chart for positioning. Itmust be welded carefully.Fig. 9 Front Wheelhouse Welding Assembly NUBIRA/LACETTI FRONT 4–72–2. REPAIR PROCEDURE1. Remove the related parts.S Parts on passenger side of dash panel lower which areespecially flammable.S Instrument panel, wiring harness, related parts and oth-ers.2. Roughly pull out and straighten the damaged area toapproximately the original shape.S Attach the car to the frame straightener by tightening theunderbody clamps at the horizontal pinch weld 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 rearwheelhouse and dash panel lower, front filar and otherparts.Note : Check the condition of the door and hinges.Fig. 103. Remove the brace wheelhouse.S Center punch around the spot weld imprints.S Use the special spot cutter to drill holes at the spot weldnuggets on the brace wheelhouse.S Remove the MIG weld areas with a disc sander.CAUTION : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grind-ing.Fig. 11S Using a chisel, pry off the welded flange from the frontbody puller and wheelhouse.4. Peel off the undercoat and sealer.S Heat the undercoat and sealer at the welding areas ofthe wheelhouse and longitudinal with a gas torch andpeel off the undercoat and sealer with a steel spatula.5. Cut and pry off the front wheelhouse.S Center punch around the spot weld imprints on the longi-tudinal and rear wheelhouse.S Use the special spot cutter to drill holes at the spot weldnuggets on the center punched areas.S Cut off the front wheelhouse with an air chisel, leavingthe welding flanges intact.S Level and finish the burrs from the pried off spot weldswith disc sander.CAUTION : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, orgrindng. 4–8 FRONT NUBIRA/LACETTIFig. 12NOTE :S If damage has occurred only front side, cut the damagedsection of the front wheelhouse, trim the new panel to fitthe remaining section, then butt weld both parts at theinner ends.6. Mold damaged related parts.S Fill any holes drilled by welding.S Use a hammer and dolly to mold damaged areas of thefront 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, rearwheelhouse and front longitudinal with a disc sander toremove the paint and expose the steel plate.CAUTION : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grind-ing.S Clamp to the front longitudinal with vise grips and squillvises.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 whenwelding, 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 checkthe 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. 13CAUTION : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.S Increase the number of spot by 20% for areas to be spotwelded.10. Apply the sealer tape.S Apply the sealer tape to the hinge and brace wheelhousematching area as shown. NUBIRA/LACETTI FRONT 4–9Fig. 1411. Weld the brace wheelhouse.S Spot weld the brace wheelhouse as shown.S Make MIG or gas welds at the door hinge areas.Fig. 1512. 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 withthe surface of the front wheelhouse.13. Apply the sealerS Apply the sealer to the matching and overlapped sur-face.14. Apply the undercoat.S Undercoat to the inside of the front, rear wheelhouseand longitudinal.15. 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 whenpanting.S Paint is flammable. Store in a safe place, and keep itaway from sparks, flames or cigarettes.16. Coating the anti–rust agents.S Coating the anti–rust agents to the end of front panelside 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 tothe moving parts and replenish cooling liquid, break oil,aircon gas and others.18. Check and adjustS 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 checkproperly. 4–10 FRONT NUBIRA/LACETTI3. FRONT LONGITUDINAL3–1. GENERAL DESCRIPTION The front longitudinal is joined to the wheelhouse andfront panel, it forms the base for the front suspension,engine, transmission and others. Therefore, replace-ment of the component affects the front wheel align-ment and maintains the rigidity of the front section.When assembling it, either use a jig or follow dimen-sions on the body repair chart for positioning. It must bewelded carefully.Fig. 16 Front Longitudinal Welding Assembly . shockabsorber. Therefore, replace-ment of the component affects the front wheel align-ment. When assembling it, either use a jig or follow di-mensions on the body. a hammer and dolly to even out the front wheel-house and longitudinal flanges for a close fit with the sur-face of the front panel.10. Apply the undercoat.S