8.2. Repair of a framework and hinged knots

Features of repair of a framework
In use the body can sustain various damage (dents, cracks, destructions from corrosion etc.) therefore the volume and ways of performance of recovery work depend on a damage rate and on existence of technological means of carrying out repair.
At small damages align the damaged panels with use of the leveling tool (leveling hammers, shovels, mandrels, supports etc.), without resorting to the thermal influence destroying anticorrosive protection of a body.
Use editing with heating for an osazhivaniye (tightening) of strongly stretched surfaces of panels.
Eliminate small roughnesses with filling, epoxies of cold hardening, solders.
At large damages replace the damaged body panels with repair knots and details. At the same time the damaged panels cut out, and on their place establish new by means of electro-or gas weldings.

Replacement of a motionless glazing

Fig. 8.1. Installation of glasses: 1 – glass of a wind window; 2 – sidewall glass; 3 – sidewall glass sealant; 4 – back door glass; 5 – back door sealant; 6 – windshield sealant; 7 – back door; 8 – back door sealant; 9 – sealant of a forward door; 10 – the door is forward


The windshield of 1 (fig. 8.1) fastens in a window opening by means of a rubber sealant 3.
1. Press the top part of a windshield from within a body. Not to break glass, the assistant has to support glass at the time of its exit from an aperture.
2. Before installation of glass check a condition of an aperture and if necessary clear it of the remains of old mastic and wipe with gasoline.
3. If the removed sealant in good shape, it it is possible to use, previously having cleared and having wiped.
4. Before installation of glass remove the dashboard to provide access to the lower part of an aperture.
5. Put on a sealant glass.
6. Enclose an assembly cord in a sealant groove, having brought its ends out of a groove in the middle of the lower part of glass (as an assembly cord it is possible to use a strong rope with a diameter no more than 7 mm).
7. Apply glass outside to an aperture, having brought an assembly ledge of a sealant on the lower part for an aperture flange to salon together with the ends of an assembly cord.
8. Evenly extending a cord from a groove in both parties and getting thereby an assembly ledge for an aperture flange, insert glass into an aperture. At the same time the assistant has to press outside of the car glass to an aperture in places where there is a cord. In the course of installation it is possible to strike slightly with a palm glass for its more dense prileganiye to an aperture.
9. Similar to removal and installation of a windshield remove and establish glass of a sidewall and glass of a door of a back.

Removal and installation of side doors
Remove a door with the assistant and only if damages do not manage to be corrected on the established door. Order of removal of forward and back doors identical.

Fig. 8.2. Fragments of sections of a body: 1 – door limiter; 2 – limiter axis; 3 – motionless link of a loop of a door; 4 – mobile link of a loop of a door; 5 – a bolt of fastening of a loop to a body; 6 – a bolt of fastening of a loop to a door; 7 – bolt; 8 – washer; 9 – the nut is lamellar; 10 – protection cover; 11 – screw of fastening of the protection cover; 12 – cowl; 13 – mobile loop of a cowl; 14 – a bolt of fastening of a loop to a cowl; 15 – a bolt of fastening of a loop of a cowl to a body; 16 – the washer is spring; 17 – cowl emphasis; 18 – cowl emphasis spring; 19 – forward wing


1. Open a door and beat out axis 2 (fig. 8.2) of the limiter of a door.
2. If the door is removed not for replacement, outline contours of bolts of the 5th fastening of a door to a body rack. It will facilitate adjustment of provision of a door at installation.
3. Turn off bolts of the 5th fastening of loops of a door to a body rack. At the same time the assistant has to hold a door.
4. Remove a door.
5. Establish a door upside-down. Then check and if necessary adjust the provision of a door.

Adjustment of provision of side doors
1. For adjustment in the horizontal plane weaken an inhaling of bolts 5 and move a door so that vertical gaps between a door and a body were identical. Then tighten bolts 5.
2. For adjustment in the vertical plane and at a vystupaniye or sticking of a door concerning a surface of a body weaken an inhaling of bolts of the 6th fastening of loops to a door and move a door so that horizontal gaps between a door and a body were identical or that the surface of a door was aflush with a body surface. Then tighten bolts 6.

Removal and installation of a cowl, adjustment of its situation
1. Open a cowl.
2. Disconnect a hose from a washer reservoir.
3. Disconnect a spring 18 (see fig. 8.2) from an emphasis of the 17th cowl and remove an emphasis.
4. Turn out two bolts of the 15th fastening of loops of a cowl to a body.
5. Remove a cowl 12 with a mobile loop 13.
6. Establish a cowl upside-down.
7. Adjust the provision of a cowl on height, width and length, moving a cowl concerning loops and changing provisions of rubber buffers. The cowl is moved after weakening of an inhaling of bolts 14. At the closed cowl lock correctly established and adjusted cowl has uniform gaps and does not act (or does not sink down) over the surfaces of forward wings.

Removal and installation of a door of a back, adjustment of its situation

Fig. 8.3. Installation of a door of a back: 1 – clamp; 2 – plate; 3 – level; 4 – the nut is square; 5 – M6-6gkh16 screw; 6 – screw 5х16; 7 – back door; 8 – back door loop; 9 – M8-6gkh20 bolt


The door of the 7th back (fig. 8.3) is hung on a body by means of the loops 8 welded on the internal panel of a door of a back. In a mobile part of a loop there are two openings through which the door by means of bolts 9 fastens to a body.
1. Disconnect wires from a back door glass heating element.

Fig. 1.15. Back door pneumosprings: 1 – pneumospring; 2 – finger; 3 – the nut is welded.


2. Turn away a finger 2 (see fig. 1.15) fastenings of a pneumospring on a back door, previously having established a reliable emphasis under a door.
3. Turn off four bolts 9 (see fig. 8.3) which are under a back part of an upholstery of a ceiling.
4. Remove a door.
5. Establish a door upside-down.
6. By movement of a door concerning a body at the released bolts 9 adjust the provision of a door with providing a uniform gap of 6 mm (see fig. 8.3) between a door and a roof.
7. Carry out adjustment of installation of a door of a back on width by means of clamps 1.

Removal and installation of the protection cover of a forward wing
The casing 10 (see fig. 8.2) protects an internal cavity of a forward wing from corrosion, dust, dirt and so forth. The casing fastens on a body in nine points: five points on a flange of an arch of a forward wing, four points on a body.
1. Remove a forward wheel.
2. Unscrew the screws located on a flange of a forward wing.
3. Unscrew the screw of a forward point of fastening, two screws in a back part of an aperture of a wheel and one screw in the top part of an aperture.
4. Bring the protection cover out of a wheel aperture.
5. Establish a casing upside-down.

Removal and installation of forward wings
Each forward wing fastens in ten points: the top part covered in six points, the forward lower part covered in two points, a back part in two points (one in the middle, another from below).
1. Remove the protection cover of a wing.
2. Remove the side repeater of the index of turn.
3. Turn off bolts 7 (see fig. 8.2) fastenings of a lobby lower, average back and lower back parts of a forward wing. For access to an average bolt in a back part of a wing open a forward side door.
4. Turn off a bolt of a side point of fastening of the forward buffer.
5. Turn off six bolts of the 7th top fastening of a wing, for access to them open a cowl.
6. Remove a wing.
7. Establish a wing upside-down. At the same time surely provide necessary gaps on wing joints with a cowl, a door, the forward index of turn and the buffer.

Removal and installation of facing of a radiator

Fig. 8.4. Installation of a radiator, forward and back buffers: 1 – facing of a radiator; 2 – the nut is lamellar; 3 – the bolt self-cutting; 4 – washer; 5 – the buffer is forward; 6 – the bolt self-cutting; 7 – washer; 8 – the nut is lamellar; 9 – the bolt self-cutting; 10 – washer; 11 – the nut is lamellar; 12 – the buffer is back.


Facing of 1 radiator (fig. 8.4) fastens on a body four plastic clamps fixed on facing of a radiator and two bolts 3.
1. Remove the forward buffer.
2. Turn out two bolts 3.
3. Bring short moustaches of four clamps out of gearing.
4. Remove facing of a radiator.
5. Establish facing upside-down.

Removal and installation of the forward buffer
1. Turn off two self-cutting bolts 6 (see fig. 8.4), located from the right and left side in niches of forward wheels.
2. Shift the buffer forward, having overcome friction force ("zakusyvaniye") about a traverse, and remove the buffer.
3. Install the buffer upside-down.

Removal and installation of the back buffer
1. Turn off two self-cutting bolts 9 (see fig. 8.4), located from the right and left side under a car floor.
2. Shift the buffer back, having overcome friction force ("zakusyvaniye") about a cross-piece No. 4, and remove the buffer.
3. Install the buffer upside-down.