S40/V40
1. General information
2. Operation and maintenance of the car
3. Design and technical characteristics of engines
4. Repair of the engine
5. Transmission
6. Brake system
7. Forward suspension bracket and steering
8. Back suspension bracket
9. Control system of the Fenix 5.1 engine
10. Electric equipment. Conducting and components
11. Body
11.1. General information
11.2. Control sizes of a body
11.3. Ways of connection of details at restoration of operational qualities of a body
11.4. Repair of a body
11.4.1. Repair of sidewalls of a body
11.4.2. Repair of a front of a body
11.4.3. Repair of a back part of a body ("sedan")
11.5. Removal and installation of elements of a body of the car
12. Schemes of electric equipment
 



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11.4.1. Repair of sidewalls of a body

At repair of sidewalls of a body the following works can be carried out:

Fig. 11.27. Ways of connection when replacing door panels


1) replacement of panels of doors (fig. 11.27), for what:
— to a welding point soshlifuyta on the strengthening element and a door arch;
— to a soshlifuyta of an edge of the door panel;
— remove the door panel;
— grind and align the interfaced surfaces;
— apply glue on places of a zavaltsovka and on inside of the details of the door panel and a frame of a door put for welding;
— adjust the door panel, put welding clamps;
— bend edges;
— weld on the strengthening element contact spot welding;
— weld edge of the panel a prikhvatochny seam;
— weld electrorivets at a door arch;
— condense edge of a door;

Fig. 11.28. Ways of connection when replacing of the strengthening elements


2) replacement of the strengthening element and threshold (fig. 11.28), for what:
— replace the strengthening element assembled;
— from the outer side the threshold of a door connects to a Torpedo sidewall under a loop, and at a rack In — at a bend;
— weld continuous seams;
— weld contact spot welding at a doorway and at the lower edge of the panel of a floor;
— weld a threshold electrorivets from below up;

Fig. 11.29. The body details forming a rack And


3) replacement of a rack And (a general view in fig. 11.29) and the strengthening element, for what:
— cut out the damaged part;
— adjust the interfaced surfaces;
— apply welding primer;
— drill openings for electrorivets;
— adjust and fix the strengthening Torpedo sidewall element;
— prepare for welding by electrorivets sites on which it is impossible to execute contact spot welding;
— adjust a rack And;
— cut the edges;

Fig. 11.30. Ways of connection of the replaced details


— weld (fig. 11.30);
— around a loop and fastening of the limiter of opening of a door execute welding by electrorivets;

Fig. 11.31. Ways of connection of the strengthening element of the top longeron


4) installation of the strengthening element of the top longeron (fig. 11.31), for what:
— fix the strengthening element of the top longeron;
— weld the strengthening element of the top longeron;

Fig. 11.32. The body details forming a rack In: 1 — a sidewall; 2 — a rack In; 3 — the amplifier of a rack In; 4 — the internal panel of a beam of a roof; 5, 6 — internal panels are resistant In (top and lower respectively)


5) replacement of knot of a rack In (consisting of five components, fig. 11.32), for what:
— previously cut off the replacing part of a beam of a roof from a rack In;
— cut off the replacing part of a sidewall of a body, so that it could define the provision of a rack In;

Fig. 11.33. A way of cutting of a rack In on
the repaired body under welding: And = 30 mm; In = 30 mm; With = 30 mm


— on the car remove a rack In (from above — as shown in fig. 11.33, from below — on welding connection);
— establish a rack In inside sidewalls of a body;
— fix a body sidewall on the car;
— weld a rack In on the internal panel of a threshold a prikhvatochny seam;
— remove a body sidewall, leave a rack In on the place;
— cut off both panels at a roof beam, weld a continuous seam;

Fig. 11.34. Ways of connection when replacing a rack In


— weld the lower section of a rack electrorivets (fig. 11.34);
— apply glue on a rack In;

       NOTE
Before installation of external section of a rack In it it has to be prepared for pasting by epoxy glue.

— put a glue layer on the site of 70 mm from a roof beam to 130 mm from fastening of the top loop;
— put a body sidewall over the strengthening rack element In;
— adjust and cut off a joint, weld continuous a seam;
— cut off and weld threshold joints;
— weld the lower part of a threshold on a threshold beam electrorivets;
— execute other welded seams contact spot welding;
— put an internal part of a rack In, weld contact spot welding;
— weld the top joint a continuous seam;
— grind welded seams.

       NOTE
Do not forget to rearrange a plate with a carving in a lock clamp cell!

       PREVENTION
Do not place a welding joint at the stuck together site.

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11.4. Repair of a body
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11.4.2. Repair of a front of a body