Text preview for : en_4j2_9s0.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 : 9S

BODY REAR END
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9S­1 Fastener Tightening Specifications . . . . . . . . . . . 9S­1 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . Fuel Filler Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filler Door Remote Handle and Cable . . . . Rear Deck Lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Deck Lid Torque Rods . . . . . . . . . . . . . . . . . Luggage Compartment Lock Cylinder . . . . . . . . Luggage Compartment Lock Striker . . . . . . . . . . 9S­2 9S­2 9S­2 9S­2 9S­4 9S­5 9S­5 9S­6 Weatherstrip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9S­7 Hatchback Weatherstrip . . . . . . . . . . . . . . . . . . . . 9S­7 Hatchback Door . . . . . . . . . . . . . . . . . . . . . . . . . . . 9S­8 Gas Support Assemblies . . . . . . . . . . . . . . . . . . . 9S­8 Hatchback Door Lock Striker . . . . . . . . . . . . . . . . 9S­9 Hatchback Door Lock . . . . . . . . . . . . . . . . . . . . . . 9S­9 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9S­10 Fuel Filler Door . . . . . . . . . . . . . . . . . . . . . . . . . . . 9S­10 Rear Deck Lid (Notchback) . . . . . . . . . . . . . . . . 9S­10 Hatchback Door . . . . . . . . . . . . . . . . . . . . . . . . . . 9S­10

Luggage Compartment Lock . . . . . . . . . . . . . . . . 9S­6

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application Fuel Filler Door Screws Fuel Filler Door Remote Cable Handle Cover Screw Fuel Filler Door Remote Cable Handle Screws Lower B­Pillar Seat Belt Anchor Bolt Luggage Compartment Lock Cylinder Nuts Luggage Compartment Lock Screws Luggage Compartment Lock Striker Bolts Rear Deck Lid Bolts NSm 4 3 10 38 8 6 8 10 Lb­Ft ­ ­ ­ 28 ­ ­ ­ ­ Lb­In 35 27 89 ­ 71 53 71 89

9S ­ 2IBODY REAR END

MAINTENANCE AND REPAIR
ON­VEHICLE SERVICE FUEL FILLER DOOR
Removal Procedure
1. Remove the screws and the fuel filler door.

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 fuel filler door with the screws.

Tighten
Tighten the fuel filler door screws to 4 NSm (35 lb­in).

FUEL FILLER DOOR REMOTE HANDLE AND CABLE
Removal Procedure
1. 2. Open the luggage compartment. Remove the luggage compartment wheelhouse trim panels and the luggage compartment rear trim panel. Refer to Section 9G, Interior Trim. Disconnect the cable from the fuel filler door.

3.

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BODY REAR END 9S ­ 3
4. Remove the lower B­pillar seat belt bolt and the anchor.

5.

Remove the screw and the fuel filler door remote cable handle cover. 6. Remove the screws and the fuel filler door remote cable handle. 7. Disconnect the cable from the handle. 8. Remove the driver's side seat and the rear seats. Refer to Section 9H, Seats. 9. Remove the left side front and rear rocker panels, the left side kick panel, and the left side lower B­ pillar trim panel. Refer to Section 9G, InteriorTrim. 10. Reposition the floor carpet on the left side of the vehicle. 11. Remove the cable.

Installation Procedure
Feed the cable from the luggage compartment to the passenger compartment. 2. Install the floor carpet to its original position. 3. Install the left side front and rear rocker panels, the left side kick panel, and the left side lower B­pillar trim panel. Refer to Section 9G, Interior Trim. 4. Install the driver's side seat and the rear seats. Refer to Section 9H, Seats. 5. Connect the cable to the handle. Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 6. Install the fuel filler door remote cable handle with the screws. 1.

Tighten
Tighten the fuel filler door remote cable handle screws to 10 NSm (89 lb­in). Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 7. Install the fuel filler door remote cable handle cover with the screw.

Tighten
Tighten the fuel filler door remote cable handle cover screw to 3 NSm (27 lb­in).

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9S ­ 4IBODY REAR END
8. Install the lower B­pillar seat belt anchor with the bolt.

Tighten
Tighten the lower B­pillar seat belt anchor bolt to 38 NSm (28 lb­ft).

9. Connect the cable to the fuel filler door. 10. Install the luggage compartment wheelhouse trim panels and the luggage compartment rear trim panel. Refer to Section 9G, Interior Trim. 11. Close the luggage compartment.

REAR DECK LID
Removal Procedure
1. 2. 3. 4. Disconnect the negative battery cable. Disconnect the electrical connector. Remove the electrical harness from the rear deck lid hinge arm. Remove the bolts and the rear deck lid.

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 rear deck lid with the bolts.

Tighten
Tighten the rear deck lid bolts to 10 NSm (89 lb­in). 2. 3. 4. Install the electrical harness to the rear deck lid hinge arm. Connect the electrical connector. Connect the negative battery cable.

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BODY REAR END 9S ­ 5

REAR DECK LID TORQUE RODS
Removal Procedure
1. 2. 3. Raise and support the deck lid in the open position. Pull the torque rods out of the rear mount. Remove the torque rods from the hinge.

Installation Procedure
1. 2. Install the torque rods into the hinge mount. Extend the torque rods to mount them in the rear mounting hole.

LUGGAGE COMPARTMENT LOCK CYLINDER
Removal Procedure
1. 2. 3. 4. Remove the nuts securing the lock cylinder. Disconnect the lock rod. Disconnect the electrical connector. Remove the luggage compartment lock cylinder.

Installation Procedure
1. 2. 3. Install the luggage compartment lock cylinder. Connect the electrical connector. Connect the lock rod.

Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 4. Install the luggage compartment lock cylinder with the nuts.

Tighten
Tighten the luggage compartment lock cylinder nut to 8 NSm (71 lb­in).

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9S ­ 6IBODY REAR END

LUGGAGE COMPARTMENT LOCK STRIKER
Removal Procedure
1. 2. 3. 4. 5. Open the luggage compartment. Remove the luggage compartment rear lower cover. Refer to Section 9G, Interior Trim. Remove the bolts securing the lock striker. Pull the lock striker out. Disconnect the lock release cable from the lock striker.

Installation Procedure
1. Connect the lock release cable. 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 lock striker with the bolts.

Tighten
Tighten the luggage compartment lock striker bolts to 8 NSm (71 lb­in). 3. Install the luggage compartment rear lower cover. Refer to Section 9G, Interior Trim.

LUGGAGE COMPARTMENT LOCK
Removal Procedure
1. 2. 3. 4. 5. Disconnect the negative battery cable. Remove the luggage compartment lock cover. Disconnect the electrical connector. Remove the screws and the luggage compartment lock. Disconnect the lock rod.

Installation Procedure
1. Connect the lock rod. 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 luggage compartment lock with the screws.

Tighten
3. 4. 5. Tighten the luggage compartment lock screws to 6 NSm (53 lb­in). Connect the electrical connector. Install the luggage compartment lock cover. Connect the negative battery cable.

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BODY REAR END 9S ­ 7

WEATHERSTRIP
Removal Procedure
1. 2. Open the luggage compartment lid. Remove the weatherstrip from around the gutter.

Installation Procedure
1. 2. 3. Install the weatherstrip onto the gutter flange. Inspect the weatherstrip. Make sure that the clinch is completely seated onto the flange. Using a water hose without a nozzle, test the rear deck lid to make sure that no leaks are present. S S If there are no leaks present, no further repair is required. If leaks are present, continue with the remainder of the installation procedure.

HATCHBACK WEATHERSTRIP
Removal Procedure
1. 2. 3. Open the luggage compartment lid. Remove the luggage compartment rear quarter and rear trim panels. Refer to Section 9G, Interior Trim. Remove the weatherstrip from around the gutter.

J4D39S01

Installation Procedure
1. 2. 3. 4. Install the weatherstrip onto the gutter flange. Inspect the weatherstrip. Make sure that the clinch is completely seated onto the flange. Using a water hose without a nozzle, test the rear deck lid to make sure that no leaks are present. Install the luggage compartment rear quarter and rear trim panels. Refer to Section 9G, Interior Trim.

J4D39S01

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9S ­ 8IBODY REAR END

HATCHBACK DOOR
Removal Procedure
1. 2. 3. Open and suitably support the hatchback door. Disconnect the hatchback door grommet, the electrical connector, and the washer hose. Remove the gas support assemblies from the hatchback door and the body. Refer to "Gas Support Assemblies" in this section. With the aid of another technician, remove the bolts and the hatchback door from the hinges.

4.
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Installation Procedure
1. With the aid of another technician, install the hatchback door to the hinges with the bolts.

Tighten
Tighten the hatchback door hinge bolts to 20 NSm (15 lb­ft). 2. Install the gas support assemblies to the hatchback door and the body. Refer to "Gas Support Assemblies" in this section. Connect the hatchback door electrical connector, the washer hose, and the grommet. Close the hatchback door.

3.
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4.

GAS SUPPORT ASSEMBLIES
Removal Procedure
1. 2. Open and suitably support the hatchback door. Unscrew and remove the gas support assembly from the hatchback door and the body.

Installation Procedure
1. Install the gas support assembly onto the hatchback door and the body.

Tighten
2. Tighten the gas support assembly studs to 8 NSm (71 lb­in). Close the hatchback door.

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BODY REAR END 9S ­ 9

HATCHBACK DOOR LOCK STRIKER
Removal Procedure
1. 2. 3. 4. Open the hatchback door. Remove the luggage compartment rear trim panel. Refer to Section 9G, Interior Trim. Remove the screws that secure the lock striker. Disconnect the cable from the lock striker.

Installation Procedure
1. 2. Connect the cable to the lock striker. Install the lock striker with the screws.

Tighten
3. 4. Tighten the hatchback door lock striker screws to 20 NSm (15 lb­ft). Install the luggage compartment rear trim panel. Refer to Section 9G, Interior Trim. Close the hatchback door.

HATCHBACK DOOR LOCK
Removal Procedure
1. 2. 3. 4. Open the hatchback door. Remove the hatchback door lower garnish molding. Refer to Section 9G, Interior Trim. Remove the screws and the hatchback lock. Disconnect the lock rods and the electrical connector.

J4D39S04

Installation Procedure
1. 2. Connect the lock rods and the electrical connector. Install the hatchback lock with the screws.

Tighten
3. 4. Tighten the hatchback door lock screws to 6 NSm (53 lb­in). Install the hatchback door lower garnish molding. Refer to Section 9G, Interior Trim. Close the hatchback door.

J4D39S04

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9S ­ 10IBODY REAR END

GENERAL DESCRIPTION AND SYSTEM OPERATION
FUEL FILLER DOOR
The fuel filler door attaches to the fuel tank pocket on the right side of the vehicle. The door is opened by pulling on the fuel filler door remote handle located on the floor in front of the driver's seat.

is hemmed around the perimeter and bonded together with structural adhesive. The deck lid torque rods assist in the opening of the rear deck lid and hold it in the open position.

HATCHBACK DOOR
The Hatchback door consists of the rear hatch glass within a steel frame. The steel frame is made of an inner and an outer panel hemmed around the perimeter, and bonded together with structural adhesive. The gas support assemblies assist in the opening of the hatchback door, and can hold the door open.

REAR DECK LID (NOTCHBACK)
The rear deck lid consists of an inner and outer panel that

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