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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 ROOF, BACK PANEL AND REAR FLOOR PANEL 5–1SECTION 5ROOF, BACK PANEL AND REAR FLOOR PANELCONTENTS1. ROOF 5 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.GENERAL DESCRIPTION 5–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.REPAIR PROCEDURE 5–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. BACK PANEL 5 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.GENERAL DESCRIPTION 5–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.REPAIR PROCEDURE 5–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. REAR FLOOR PANEL 5 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.GENERAL DESCRIPTION 5–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.REPAIR PROCEDURE 5–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 ROOF, BACK PANEL AND REAR FLOOR PANEL NUBIRA/LACETTI1. ROOF1–1. GENERAL DESCRIPTIONDeformation of the roof panel is highly noticeable interms of the vehicle’s outer appearance. Before replac-ing the roof, make sure that the body is horizontal. Be-fore welding the roof panel, adjust the frame door open-ing flanges so that they contact the roof panel. Payparticular attention to twists and parallelism.Fig. 1 NUBIRA/LACETTI ROOF, BACK PANEL AND REAR FLOOR PANEL 5–31–2. REPAIR PROCEDURE1. 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 protectpainting areas, seats, carpets and other parts.S Attach the car to the frame straightener by tightening theunderbody clamps at the horizontal pinch welds.S Before cutting off the roof panel, pull them out so thatthey are restored to the original shape.S Do not pull out more than necessary.S Pull out and straighten the related damaged parts toapproximately their original shape.Note : Make sure that the right and left pillars are parallelwith the windshield surface. Check the door for properopening and closing.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 off the shaded areas of the roof panel.S Cut the roof weld flanges with a hand saw and snips atthe roof panel and roof frames.Fig. 2S Using a chisel, pry off the roof panel along the bold linesas shown.S Center punch around the spot weld imprints of the roofwelded flange.S Drill holes using the spot cutter.S Using a chisel and a disc sander, pry off the weldedflange from the front, rear body pillar and roof panel.S Level and finish the burrs of welded flanges with a discsander.CAUTION : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grind-ing.5. Peel off the sealer.S Peel off the sealer with a steel spatula at the weldingareas of the frame door opening.6. Mold damaged related parts.S Use a hammer and dolly to mold damaged areas of thefront, rear body pillar inner and frame door opening.S Even out the welding flanges with a hammer and dollyfor 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 paneland roof panel with a disc sander to remove the paint andexpose the steel plate.CAUTION : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grind-ing.S Temporarily set the new three frames and roof panel andclamp with the vise grips.Note : Check that the flange surface fit closely. Be care-ful not to twist or deform the roof panel.Fig. 3S Measure the dimensions diagonally at the windshieldarea and rear glass area with a tracking gauge or convexrule as shown to check it for twisting or bending. 5–4 ROOF, BACK PANEL AND REAR FLOOR PANEL NUBIRA/LACETTIFig. 4S Dismantle the new roof panel.S Weld the clamped sections of the roof frames and front,rear body pillar inner for temporary installation.Fig. 5S Set the new roof panel and clamp again.S Temporarily set the windshield and rear glass, andcheck the roof panel for proper installation.S Install the roof molding and check the clearance and out-er appearance.8. Apply the sealer to the roof frames.S Dismantle the new roof panel again.S Apply the sealer to one groove of the rail windshieldheader, two grooves of the support roof panel and onegroove of the frame rear roof panel.S Set and tack weld the roof panel.Fig. 69. Perform the main welding and finish.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.S Use a hammer and dolly to smooth the spot weld areason the windshield and rear glass.S Cut off the irregular and unuseful flanges and even outthe flanges for a close fit with the surface of the roof pan-el. NUBIRA/LACETTI ROOF, BACK PANEL AND REAR FLOOR PANEL 5–5Fig. 710. Apply the sealer.S Apply the sealer to the welded areas.Fig. 811. 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 itaway from sparks, flames or cigarettes.12. Apply the deadner.S Apply the deadner to the front inside of roof panel asshown.13. Install the related parts.S Windshield and rear glass.S Cowl, wiper and related parts.S Wiring harness and headlining.S Pillar trims, door weatherstrip and others.S Install in the reverse order in which they were removed.14. Check and adjust.S Clean the passenger compartment.S Check the windshield and rear glass for water leaks.S Wiring harness and headlining. 5–6 ROOF, BACK PANEL AND REAR FLOOR PANEL NUBIRA/LACETTI2. BACK PANEL2–1. GENERAL DESCRIPTIONThe back panel is joined to the side panel outer, rearextension longitudinal and extension rear floor. It formsthe base for the rear combination lamps and other partsand maintains the rigidity of the rear body. Pay particu-lar attention to twists and parallelism and check mount-ing of related parts when welding.Fig. 9 Back Panel Welding Assembly NUBIRA/LACETTI ROOF, BACK PANEL AND REAR FLOOR PANEL 5–72–2. REPAIR PROCEDURE1. Remove the related parts.S Rear and trunk trimsS Trunk lid lock and related parts.S Rear combination lamps and wiring harness.S Rear bumper and related parts.S Other related parts.Fig. 102. Roughly pull out and straighten the damaged area.S Check the damage and roughly pull out and repair therelated side panel inner, rear floor, rear longitudinal andother damaged parts with the frame straightener beforeremoving the back panel.S Attach the car to the frame straightener by tightening theunderbody clamps located at the jack up designatedpoints 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 rearside outer and extension rear floor panel.S Use the special spot cutter to drill holes at the spot weldnuggets on the rear side outer and extension rear floorpanel.Note : When drilling holes be careful not to drill down tothe 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 weldswith 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 orsafety glasses whenever sanding, cutting, or grind-ing.Fig. 11NOTE:S I f damage has occurred only on one side, cut the dam-aged section of the rear panel, trim the new panel to fitthe remaining section, then butt weld both parts at theinner ends.S Where damage has not extended into the rear side outerpanel, cut the rear panel from the body on either panel.Fig. 124. Peel off the undercoat and sealer.S Heat the undercoat and sealer at the welding areas ofthe rear side outer panel and extension rear floor with agas torch and peel off the undercoat and sealer with asteel spatula.5. Mold damaged related parts.S Use a hammer and dolly to mold damaged areas of therear 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 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. 5–8 ROOF, BACK PANEL AND REAR FLOOR PANEL NUBIRA/LACETTIS 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.Fig. 137. Measure and check.S Measure the trunk compartment diagonally to check itfor twisting or bending and its correct position with therear bumper installed.S Temporarily assemble the rear combination lamps andtrunk, 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 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. 149. Finish the welding areas.S Level the gas or MIG welded areas with disc sander,then even out high areas with a hammer being carefulnot to deform them.S Use a hammer and dolly to even out the rear side outerand extension rear floor panel flanges for a close fit withthe surface of the rear panel.10. Apply the sealer.S Apply the sealer to the rear side outer joint and aroundthe rear lamps areas of the rear panel.S Apply the sealer to the extension rear floor panel andrear panel joint.11. Apply the undercoat.S Undercoat to the joint and overlapped areas of the rearfloor under side.12. 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 itaway 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 checkproperly. NUBIRA/LACETTI ROOF, BACK PANEL AND REAR FLOOR PANEL 5–93. REAR FLOOR PANEL3–1. GENERAL DESCRIPTIONThe rear floor panel is the base of the rear body and it iscritical for the rigidity of the rear body. During replace-ment, refer to the body dimension chart or body repairchart and determine the position to set the rear floorproperly.Be sure that the rear floor is not bent or deformed. Weldsecurely to maintain the rigidity of the rear body.2Fig. 15 Rear Floor Welding Assembly (NOTCHBACK) 5–10 ROOF, BACK PANEL AND REAR FLOOR PANEL NUBIRA/LACETTI413197 79113314Fig. 16 Rear Floor Welding Assembly (HATCHBACK) . appearance. Before replac-ing the roof, make sure that the body is horizontal. Be-fore welding the roof panel, adjust the frame door open-ing flanges so that. grind-ing.S Temporarily set the new three frames and roof panel andclamp with the vise grips.Note : Check that the flange surface fit closely. Be care-ful