en_4j2_9r0.pdf part of Daewoo Nubira/Lacetti Service Manual - Daewoo Lacetti.part01.rar, Also known as: Chevrolet Nubira / Lacetti, Chevrolet Optra Optra5, Suzuki Forenza Reno Covers the 1.4L, 1.6L and 1.8L engine. Year 2004 text manual preview

Text preview for : en_4j2_9r0.pdf part of Daewoo Nubira/Lacetti Also known as: Chevrolet Nubira / Lacetti, Chevrolet Optra Optra5, Suzuki Forenza Reno Covers the 1.4L, 1.6L and 1.8L engine. Year 2004

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SECTION : 9R

BODY FRONT END
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9R1 Fastener Tightening Specifications . . . . . . . . . . . 9R1 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9R2 ONVEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9R2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R2 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R2 Anticorrosion Materials . . . . . . . . . . . . . . . . . . . . . 9R2 Front End Sealing . . . . . . . . . . . . . . . . . . . . . . . . . 9R2 Cowl Vent Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R2 Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R3 Hood Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Prop Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Secondary Latch . . . . . . . . . . . . . . . . . . . . . Hood Latch Release Cable . . . . . . . . . . . . . . . . . . Notchback Radiator Grille . . . . . . . . . . . . . . . . . . . Hatchback Radiator Grille . . . . . . . . . . . . . . . . . . . Front Wheel Well Splash Shield . . . . . . . . . . . . . Fender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R3 9R4 9R4 9R5 9R5 9R6 9R6 9R7

GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R10 Body Front End . . . . . . . . . . . . . . . . . . . . . . . . . . 9R10

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application APillar Fender Bolt Fender Bolt (Front of Fascia) Front Bumper FasciatoFender Bolt Hinge Bolts HoodtoHinge Bolts Hood Latch Bolts Hood Release Handle Nuts Lower Fender Bolt Radiator Grille Nuts Splash Shield screws Upper Fender Bolts NSm 10 4 2.5 27 27 8 4 10 4 2 10 LbFt 20 20 LbIn 89 35 22 71 35 89 35 18 89

9R 2IBODY FRONT END

MAINTENANCE AND REPAIR
ONVEHICLE SERVICE LUBRICATION
The hood hinges and the locking mechanisms require periodic lubrication for proper operation. Refer to Section 0B, General Information for the specific types and intervals of lubrication.

FASTENERS
Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. Many aluminum components are used on current models. Aluminum in contact with steel may corrode rapidly if it is not protected by special finishes or isolators. The fasteners used have a special finish which provides adequate protection from corrosion. These special fasteners differ in color in order to easily identify them from the standard metric fasteners, which are medium blue. When replacing fasteners, avoid substituting otherwise similar fasteners in the same location.

ANTICORROSION MATERIALS
In order to provide rust resistance, anticorrosion materials have been applied to the interior surfaces of most of the metal panels. When you service these panels, properly recoat them with a servicetype anticorrosion material if any of the original material has been disturbed.

FRONT END SEALING
All locations where waterleaks may occur are sealed during production with high quality, durable sealers. If it becomes necessary to reseal specific areas, use a high quality sealer of mediumbodied consistency which will retain its flexible characteristics after curing and can be painted, if necessary.

COWL VENT GRILLE
(LeftHand Drive Shown, RightHand Drive Similar) Removal Procedure
1. 2. 3. 4. Raise the hood and support it with the hood prop. Remove the weatherstrip. Remove the wiper arms. Refer to Section 9D, Wipers/Washer Systems. Remove the cowl vent grille screws and the two piece grille.

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BODY FRONT END 9R 3 Installation Procedure
Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 1. Install the twopiece grille and the cowl vent grille screws.

Tighten
2. 3. Tighten the cowl vent grille screws to 4SNSm (35 lb in). Remove the wiper arms. Refer to Section 9D, Wipers/Washer Systems. Install the weatherstrip.

HOOD
Removal Procedure
Notice : Install protective coverings over the fenders and the windshield in order to prevent damage to the paint, the glass and the moldings when you are removing and installing the hood. 1. Raise and support the hood. 2. Mark the position of the hinge to the hood to facilitate alignment during installation. 3. Remove the bolts that retain the hood to both hinges. 4. With the aid of another technician, remove the hood from the hinges.

Installation Procedure
1. With the aid of another technician, position the hood in the location marked during removal.

Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 2. Install the two bolts securing the hood to each hinge.

Tighten
Tighten the hoodtohinge bolts to 27 NSm (20 lbft). 3. Inspect the hood for proper alignment.

HOOD HINGES
Removal Procedure
1. 2. Remove the hood. Refer to "Hood" in this section. Remove the bolts and the hinge.

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9R 4IBODY FRONT END Installation Procedure
Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 1. Install the hinge with the bolts.

Tighten
2. Tighten the hinge bolts to 27 NSm (20 lbft). Install the hood. Refer to "Hood" in this section.

HOOD PROP ROD
Removal Procedure
1. 2. Support the hood in the open position. Remove the hood prop rod by gently prying the base from the radiator support.

Installation Procedure
1. Install the hood prop rod by snapping the base back into the radiator support.

HOOD SECONDARY LATCH
(LeftHand Drive Shown, RightHand Drive Similar) Removal Procedure
1. 2. 3. Open the hood. Mark the position of the hood latch on the radiator support to facilitate alignment during installation. Remove the bolts and the hood latch.

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BODY FRONT END 9R 5 Installation Procedure
Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 1. Position the hood latch in the location marked during removal. 2. Install the hood latch with the bolts.

Tighten
Tighten the hood latch bolts to 8 NSm (71 lbin).

HOOD LATCH RELEASE CABLE
(LeftHand Drive Shown, RightHand Drive Similar) Removal Procedure
1. 2. 3. 4. 5. Remove the screws and the hood release handle from the instrument panel. Open the hood. Remove the bolts and the hood latch release. Remove the cable from the hood latch release assembly. Remove the cable from the engine compartment.

Installation Procedure
Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 1. Install the radiator grille with the screws. 2. Install the cable into the hood latch release handle. 3. Install the hood release handle on the instrument panel with the screws.

Tighten
4. 5. Tighten the hood release handle screws to 4 NSm (35 lbin). Install the cable to the hood latch release assembly. Install the hood latch release assembly with the bolts.

Tighten
Tighten the hood latch bolts to 8 NSm (71 lbin).

NOTCHBACK RADIATOR GRILLE
Removal Procedure
1. 2. Open the hood. Remove the screws and clips at lower area of the radiator grille.

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9R 6IBODY FRONT END Installation Procedure
1. Install the radiator grille with the screws and clips.

HATCHBACK RADIATOR GRILLE
Removal Procedure
1. 2. 3. Open the hood. Remove the screws. Pree the clips with the screw driver.

Installation Procedure
1. Install the radiator grille with the screws.

FRONT WHEEL WELL SPLASH SHIELD
Removal Procedure
1. 2. 3. 4. Raise and suitably support the vehicle. Remove the front wheel. Refer to Section 2E, Tires and Wheels. Remove the front mud guard. Refer to Section 9M, Exterior Trim. Remove the screws and the front wheel well splash shield.

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BODY FRONT END 9R 7

Installation Procedure
1. Install the screws and the front wheel well splash shield.

Tighten
Tighten the front wheel well splash shield screws to 2 NSm (18 lbin). 2. 3. 4. Install the front mud guard. Refer to Section 9M, Exterior Trim. Install the front wheel. Refer to Section 2E, Tires and Wheels. Lower the vehicle.

FENDER
Removal Procedure
1. 2. 3. Remove the front wheel well splash shield. Refer to "Front Wheel Well Splash Shield" in this section. Reposition the front headlamp. Remove the bolts securing the front fascia to the fender.

4. 5. 6.

Reposition the front fascia. Remove the fender bolts behind the front fascia. Remove the bolts at the base of the fender.

7.

Open the front door and remove the bolt at the base of the Apillar.

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9R 8IBODY FRONT END
8. 9. Reposition the cowl vent grille weatherstrip. Remove the upper fender bolts and the fender.

Installation Procedure
Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 1. Install the fender with the upper fender bolts.

Tighten
Tighten the upper fender bolts to 10 NSm (89 lbin).

2. 3.

Reposition the cowl vent grille weatherstrip to its original position. Install the bolt at the base of the Apillar.

Tighten
Tighten the Apillar fender bolt to 10 NSm (89 lbin).

4.

Install the bolts at the base of the fender.

Tighten
5. Tighten the lower fender bolts to 10 NSm (89 lbin). Install the front fender bolts behind the front fascia.

Tighten
Tighten the front fender bolts to 10 NSm (89 lbin).

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BODY FRONT END 9R 9
6. 7. Install the front fascia to its original position. Install the bolts securing the front fascia to the fender.

Tighten
8. 9. Tighten the front fasciatofender bolts to 2.5 NSm (22 lbin). Install the front headlamp to its original position. Install the front wheel well splash shield. Refer to "Front Wheel Well Splash Shield" in this section.

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9R 10IBODY FRONT END

GENERAL DESCRIPTION AND SYSTEM OPERATION
BODY FRONT END
This vehicle has a unitized body with a frame assembly supporting the engine and the transaxle. The fender panels and the radiator support are also integral parts of the body.

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