Almost all modern sedan-type cars are equipped with a carrier-type body, the VAZ 2101 in this case is no exception. And what does a load-bearing body mean, you ask? This means that the steel box of the body is not only a comfortable container for passengers, driver and their luggage, but also "carries" on itself (and in itself) all the elements, components and assemblies of the car.
The body of the VAZ 2101 perceives not only the static loads of the elements attached to it, it also resists their influence during movement (in dynamics). This property of the car frame is called torsional stiffness, which is about 7300 Nm / deg.
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The condition of its bottom, sills and roof, which are interconnected by the front panel, pillars of door and window openings, and the transverse panel of the luggage compartment, greatly affects this indicator of the strength and rigidity of the body of the VAZ 2101. You can see for yourself the integrity of the geometry, and therefore the general condition of your car, by taking off the dimensions of the body of the VAZ 2101 with your own hands and checking them with the data that contains the instructions for repairing the car.
| 0 | Car base line |
| 1 | Radiator bracket, top |
| 2 | Pendulum arm and steering housing |
| 3 | Center of pedal axis |
| 4 | Steering wheel center axis |
| 5 | Rear Wheel Center Axle |
| 6 | Rear shock absorber mount |
| 7 | Muffler, rear mount |
| 8 | Muffler, front mount |
| 9 | Transverse thrust |
| 10 | Rear wheel center axle |
| 11 | Upper longitudinal rods |
| 12 | Lower longitudinal rods |
| 13 | Front Wheel Center Axle |
| 14 | Front cross member attachment points |
| 15 | Anti-roll bar |
| 16 | Radiator bracket |
| 17 | Center of body axle |
| 18 | Radiator, top mount |
| 19 | Rear engine mount |
| 20 | Hand brake |
| 21 | Cardan shaft support |
| 22 | Rear shock absorber |
| 0 | Horizon |
| 1 | The axis of the bolts of the front stabilizer mounts at the intersection of the axis of the surface of the side members |
| 2 | The axis of the bolts from the bottom of the fasteners of the steering mechanism housing and the "pendulum" bracket |
| 3 | Intersection of technological holes in the front of the bottom with the side members |
| 4 | Intersection of technological holes with the rear holes of the front side members |
| 5 | Axle of the bolts of the longitudinal lower links |
| 6 | Axle of the bolts of the longitudinal upper links |
| 7 | Upper transverse rod bolt |
| 8 | Axle of the rear of those bottom amplifier holes / amplifier surface |
| 9 | Front stabilizer bolt axle |
| 10 | Intersection of position No. 2 with the spar mudguard |
| 11 | Position No. 3 top view |
| 12 | Position No. 4 top view |
| 13 | Position # 5 / outer surface of the body bracket |
| 14 | Position No. 6 / outer surface of the middle spar |
| 15 | Position number 7, top view |
| 16 | Position # 8, the center of those holes in the bottom amplifier |
| 17 | Central longitudinal axis of the body |
What follows from the above? And the fact that body fatigue directly affects not only the control points of attachment of components and assemblies, which are shown by the body diagram of the VAZ 2101 described above, it also manifests itself in the "purity" of the geometry of its side and front openings. The distribution of loads over the body in dynamics is as follows: from the suspension elements in front, vibration and shock pass to the cross member and then to the sub-frame, after which to the area of the mudguards and the front shield, which are already the load-bearing elements of the body. At the back, about the same picture occurs, only in a shorter form, that is, without the involvement of the power unit, immediately from the suspension to the car body.
Vaz 2101 body scheme
As you can imagine, with this type of body and the operation of its suspension, not the least role in the stability and safety of the car is played by what the car frame is made of. It is clear that the more we strengthen the weak points of the body, the harder and more stable it will be, but this is the whole point of the trick question: how much does the body of the VAZ 2101 weigh?
Strengthening the car frame, we increase its mass, thereby increasing the load on its structural parts. Vicious circle? This is by no means why smart people teach in institutes such a science as resistance to material, having studied which the design engineers rationally selected the thickness of the materials, their ratio of sizes and sections. Ultimately, all these factors helped to obtain a high-strength frame of the VAZ 2101 "at the output".
| 1 | 0.7 mm - hood |
| 2 | 1.0 mm - mud flaps |
| 3 | 1.0 mm - front panel |
| 4 | 0.9 mm - front of floor |
| 5 | 0.9 mm - roof |
| 6 | 0.9 mm - floor, back |
| 7 | 0.7 mm - trunk |
| 8 | 0.7 mm - rear "empennage" |
| 9 | 0.7 mm - door panels outside |
| 10 | 0.9 mm - thresholds |
| 11 | 0.9 mm - front "empennage" |
To save weight and reduce costs, non-load bearing parts (luggage compartment lids and engine compartment lids) are made of thinner metal. The thickness of the steel sheets of which the elements, which are most important for the strength of the body, are composed, is about one millimeter, which is no less (one might say even more) than that of other modern cars of a similar class.
The front and rear "plumage" of the "penny" are welded to the body, which made it possible to introduce them on an equal footing into the load-bearing circuit of the car, which also contributed to a decrease in its weight, which is 955 kilograms.
But this is its total mass, to find out how much the body of the VAZ 2101 weighs, the following layout will help us:
- 140 kilograms - the weight of the power unit with attachments;
- 26 kilograms - gearbox;
- 10 kilograms - driveshaft;
- 52 kilograms - rear axle;
- 7 kilograms - radiator;
- 280 kilograms - the actual weight of the body of the VAZ 2101.
As it is not a particularly impressive figure. And if you multiply it by all cars produced for all years of production (from 1970 to 1988) in the amount of 4.85 million? Agree, here every gram saved plays a significant role!
But it's not that simple. The durability of the body is not at all in the thickness of the metal sheet from which it is made, it depends on how well the anti-corrosion protection is carried out at the manufacturer's plant (in our case, by the owner himself).
As a rule, after welding operations, in front of the spray booth, the body of the VAZ 2101 was subjected to phosphatization, during which its entire surface was subjected to a chemically resistant phosphate film. In addition to this, the result was consolidated with a layer of primer applied by electrophoresis, which allowed the primer layer to create an even coating in the most difficult to reach areas. The bottom of the car, in turn, was covered with a layer of special durable mastic, which reliably protected it from the effects of an aggressive environment.
All of the above, in the coupe, contributed to the fact that the VAZ 2101 became popular not only at one time, but confidently "keeps the brand" of a reliable hard worker to this day.
By the way, the "penny" was one of the first cars of the famous Formula 1 pilot Kimi Raikkonen, whose father was extremely attached to him for his unpretentiousness and reliability.
| Engine | 1.2l, 8-cl. | 1.2l, 8-cl. | 1.3l, 8 cl. |
|---|---|---|---|
| Length, mm | 4073 | 4043 | 4043 |
| Width, mm | 1611 | 1611 | 1611 |
| Height, mm | 1440 | 1440 | 1440 |
| Wheelbase, mm | 2424 | 2424 | 2424 |
| Front track, mm | 1349 | 1349 | 1349 |
| Back track, mm | 1305 | 1305 | 1305 |
| Clearance, mm | 170 | 170 | 170 |
| Minimum trunk volume, l | 325 | 325 | 325 |
| Body type / number of doors | Sedan / 4 | ||
| Engine location | Front, longitudinally | ||
| Engine volume, cm 3 | 1198 | 1198 | 1300 |
| Cylinder type | Inline | ||
| Number of cylinders | 4 | 4 | 4 |
| Piston stroke, mm | 66 | 66 | 66 |
| Cylinder diameter, mm | 76 | 76 | 79 |
| Compression ratio | 8,5 | 8,5 | 8,5 |
| Number of valves per cylinder | 2 | 2 | 2 |
| Supply system | Carburetor | ||
| Power, hp / rev. min. | 64/5600 | 64/5600 | 70/5600 |
| Torque | 89/3400 | 89/3400 | 96/3400 |
| Fuel type | AI-92 | AI-92 | AI-92 |
| Drive unit | Rear | Rear | Rear |
| Gearbox type / number of gears | Manual transmission / 4 | Manual transmission / 4 | Manual transmission / 4 |
| Gear ratio of the main pair | 4,3 | 4,1 | 4,1 |
| Front suspension type | Double wishbone | ||
| Rear suspension type | Coil spring | ||
| Steering type | Worm gear | ||
| Fuel tank volume, l | 39 | 39 | 39 |
| Maximum speed, km / h | 140 | 142 | 145 |
| The equipped mass of the car, kg | 955 | 955 | 955 |
| Permissible total weight, kg | 1355 | 1355 | 1355 |
| Tires | 155 SR13 | 165/70 SR13 | 155 SR13 |
| Acceleration time (0-100 km / h), s | 22 | 20 | 18 |
| Fuel consumption in the urban cycle, l | 9,4 | 9,4 | 11 |
| Extra-urban fuel consumption, l | 6,9 | 6,9 | 8 |
| Combined fuel consumption, l | 9,2 | 9,2 | - |
Short description and history
It is the VAZ 2101 that is the oldest model of the Volga Automobile Plant, with which the history of the domestic auto industry began. On April 19, 1970, the first compact car rolled off the assembly line of the plant. The model was based on the 1966 Fiat 124 model. In fact, the first "kopecks" were practically Italian cars, because the technical characteristics of the VAZ 2101 and fait 124 did not differ much from each other: a 1.2-liter engine and an entry-level interior trim. There was practically no difference between the cars.
In the future, domestic auto designers have significantly modified the design of the car for the operating conditions in our country. The ground clearance has been increased because the quality of the road surface did not always allow you to move with convenience and comfort. The body and suspension were significantly strengthened, thereby improving the technical characteristics of the VAZ 2101. Rear disc brakes from fiat were replaced with drum brakes. This was due to their durability and resistance to dust and dirt, which was always enough.
Almost everything has undergone changes, including the design of the engine. The distance between the cylinders was increased (this made it possible to bore the diameter of the cylinders), the camshaft was moved to the cylinder head. In addition to the engine, the clutch, gearbox, and rear suspension have undergone changes. As a result, the vehicle's weight has increased by 90 kg. In total, there were more than 800 changes and differences in the design of the VAZ 2101.
From 1970 to 1986, about three million VAZ 2101 cars were assembled at the plant. 19 years after the car left the assembly line, the first commercial copy took an honorable place in the AvtoVAZ museum.
Tuning VAZ 2101
* Height without load. Download information from the page↓ Comments ↓
Please enable JavaScript to view the comments powered by Disqus.1. Technical data 1.0 Technical data 1.1 Main dimensions of the VAZ-2101 car 1.2 Main dimensions of the VAZ-21011 1.3 Main dimensions of the VAZ-2102 car 1.4 Technical characteristics of cars 1.5 Controls and control devices 1.6 Ignition switch 1.7 Controls for ventilation and heating salon
2. Operation and maintenance 2.0 Operation and maintenance 2.1. Car operation 2.2. Car maintenance
3. Engine 3.0 Engine 3.1 Features of the device 3.2 Possible engine malfunctions, their causes and methods of elimination 3.3 Removal and engine installation 3.4 Engine disassembly 3.5 Engine assembly 3.6 Bench tests of the engine 3.7 Checking the engine on a car 3.8. The block of cylinders 3.9. Pistons and connecting rods 3.10. A crankshaft and a flywheel 3.11. Cylinder head and valve mechanism 3.12. The camshaft and its drive 3.13. Cooling system 3.14. Lubrication system
4. Fuel system 4.0 Fuel system 4.1. Power supply system 4.2. Carburetor
5. Ignition system 5.0 Ignition system 5.1 Setting the ignition moment 5.2 Gap between the contacts of the breaker in the ignition distributor 5.3. Checking ignition devices at the stand 5.4 Possible ignition faults, their causes and methods of elimination
6. Starting and charging system 6.0 Starting and charging system 6.1. Storage battery 6.2. Generator 6.3. Starter
7. Transmission 7.0 Transmission 7.1. Clutch 7.2. A transmission 7.3. Cardan transmission 7.4. Rear axle
8. Running gear 8.0 Running gear 8.1. Forward suspension bracket 8.2. Back suspension bracket 8.3. Shock absorbers 8.4 Possible malfunctions of the chassis, their causes and methods of elimination
9. Steering 9.0 Steering 9.1 Features of the device 9.2. Inspection, check and steering adjustment 9.3. The steering gear 9.4. Drafts and spherical joints of a steering drive 9.5. Pendulum arm bracket 9.6 Possible steering malfunctions
10. Brake system 10.0 Brake system 10.1. Features of the device 10.2. Check and adjustment of brakes 10.3. A bracket of clutch and brake pedals 10.4. The main cylinder 10.5. Forward brakes 10.6. Back brakes 10.7. The regulator of pressure of back brakes 10.8. Parking brake 10.9 Possible brake malfunctions, their causes and remedies
11. Electrical equipment 11.0 Electrical equipment 11.1. Electric equipment diagrams 11.2. Lighting and light signaling 11.3. Sound signals 11.4. Screen wiper 11.5. Heater electric motor 11.6. Control devices
12. Body 12.0 Body 12.1 Features of the device 12.2. Body skeleton repair 12.3. Paints and varnishes 12.4. Anti-corrosion protection of a body 12.5. Doors 12.6. Hood, trunk lid, bumpers 12.7. Body glazing and windscreen washer 12.8 Instrument panel 12.8. Removal and installation 12.9. Seats 12.10. Heater
13. Peculiarities of repair 13.0 Peculiarities of repair 13.1. VAZ-21011 car 13.2 VAZ-21013 cars 13.3. Automobile VAZ-2102 13.4 Automobiles VAZ-21021 and VAZ-21023
14. Appendices 14.0 Appendices 14.1 Tightening torques for threaded connections 14.2 Tools for repair and maintenance of cars 14.3 Used fuels and lubricants and operating fluids 14.4 Basic data for adjustments and control
automend.ru
VAZ 2101 | Dimensions | Zhiguli
Dimensions (edit)
Dimensions of two body options
Sedan, hatchback or station wagon body (Turnier): Mondeo plays the whole keyboard. In width with a value of 1931 millimeters, no differences are found between them. The picture is different in terms of length - the maximum is 4804 millimeters at Turnier, in the other two variants it is 4731 millimeters. In terms of height, each version of the model goes its own way: depending on the design of the chassis, the sedan body has a height in the range of 1420-1460 millimeters, the hatchback body, respectively, 1429-1459 millimeters and Turnier - 1441-1471 millimeters. Turnier's height increases by 40 millimeters with the roof side rail. However, there is complete agreement in the wheelbase: 2754 millimeters is a good indicator for a car of the upper middle class. In addition, Mondeo stands out for its large cabin, which can accommodate five adult passengers.
Even in the rear seats, the three mid-sized Europeans have no fear of space. In addition, Mondeo passengers can travel not only with hand luggage: in the sedan and hatchback bodies, the maximum volume, according to VDA standards, is 500 liters - including the spare wheel. Turnier already has a load capacity of 540 liters along with the spare wheel. When the rear seat is folded back, the hatchback model will enter 1,370 liters to the roof, and the Turnier will swallow even 1,700 liters.
automn.ru
VAZ-2101 Photo. Specifications. Dimensions. The weight. Tires
The Volga Automobile Plant was created in the same way as GAZ in its time - the government of the USSR purchased technologies and a model range of a foreign company and instructed it to train Soviet specialists in the latest methods of work. This time the partner of the Ministry of Industry was the Italian Fiat. At the future plant in Togliatti, it was planned to produce three models: a sedan and a station wagon of the "norm" configuration, as well as a luxury sedan. The Fiat 124 was chosen as the prototype for the "norm".
VAZ-2101 - drift video
VAZ-2101 - tuning video
Soviet specialists, assembled from different factories, began to get acquainted with the car in 1966, a whole year before the start of construction of the plant in Togliatti (and even before Fiat 124 became the "Car of the Year" in Europe). Whether they liked the car or not is unknown. Only documented remarks have come down to us: a weak body and a small clearance by the standards of the Soviet off-road; disc brakes are afraid of dirt and other claims of the same type. More than 800 changes were made together with Italian engineers, and not only to strengthen and increase survivability.
The design of the engine camshafts was replaced with a more modern one, the rear suspension was improved for better handling; the front seats were made folding into a berth, the door handles were replaced with injury-safe ones - by the way, unified with luxury (Fiat put different handles on different versions, which is less technologically advanced). The future VAZ-2101 was named Fiat 124R (from the word "Russia"). It is believed that Fiat residents were also pleased with the valuable experience of testing their models in extremely harsh conditions.
Police VAZ-2101
The VAZ-2101 became the first car in the USSR to receive a digital 4-digit designation according to the rules of a new industry document - the standard OH 025270-66. Critics of the historic decision to build a VAZ say that the odious pro-Italian project pulled away human and financial resources from other factories, which is why the good developments of the relatives of ZAZ, GAZ and AZLK, which were more suitable for the conditions of the USSR, were not implemented, and the factories themselves plunged into long stagnation. On the other hand, without the VAZ-2101, the industry would not have been able to satisfy the huge demand for passenger cars for a long time. The volume of production of cars in Togliatti several times exceeded the production of any other plant, and still there was a two-year queue for them.
"Edinichka" became the first Soviet car that could easily start up in cold weather, with normal interior heating and comfortable seats. On the highway, you could talk in the cabin without raising your voice, and drive twice the distance without getting tired. The first Soviet antifreeze, the famous A40 antifreeze, was specially developed for the new model, and an all-Soviet network of service stations was created (this was a mandatory requirement of Fiat). The Italians also transferred technologies for the production of finishing materials that did not fade in the sun. The advantage of the VAZ-2101 over other Soviet cars turned out to be so obvious that many technical solutions were quickly adopted at other factories. The entire industry of the country received an opportunity to leap forward, it remains only to use it.
The quality of workmanship has also risen to new heights and has held on for over 10 years. "Ones" of the early series drove without problems for decades without changing the oil, battery, clutch and brake pads, without showing signs of rust. Therefore, they called the car respectfully - "the first", or "unit", and the nickname "kopeck" appeared only in the 1990s. In addition, the VAZ-2101 can be considered a long-liver of the conveyor. Considering that all subsequent models of the classic family are, in fact, only its modifications, it lasted more than 40 years in production.
Technical characteristics of the VAZ-2101 Zhiguli
Body type: 4-door sedan (5-seater)
VAZ-2101 engine
Volume: 1.2 l - Maximum power, hp / kW at rpm: 64/47 at 5600 - Maximum torque, N.m at rpm: 89 at 3400
Volume: 1.3 l - Maximum power, hp / kW at rpm: 69/51 at 5600 - Maximum torque, N.m at rpm: 96 at 3400
Maximum speed VAZ-2101
Checkpoint: 4-speed mechanical Gasoline: AI-92
Overall dimensions of the VAZ-2101
Length: 4073 mm - Width: 1611 mm - Height: 1382 mm - Ground clearance: 170 mm - Wheelbase: 2424 mm - Back / front track, mm: 1305/1349
What to pour oil into a VAZ-2101 engine
5W-30, 5W-40, 10W-40, 15W-40
Tire size VAZ-2101
165/70 / R13; 165/80 / R13
Environmental class VAZ-2101
Fuel consumption VAZ-2101
City 9.4 l; track 6.9 l; mixed 9.2 l / 100km
Carrying capacity of the VAZ-2101
Weight VAZ-2101
Curb vehicle weight: 955 kg - Gross vehicle weight: 1355 kg
Tank volume VAZ-2101
39 liters
Trunk volume VAZ-2101
325 Liters
VAZ-2101 do-it-yourself tuning photo
Do-it-yourself tuning of the VAZ-2101 salon
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| Car parameters | VAZ car model | |||
| 2101 | 21011 | 21018 | 21019 | |
| rotary | ||||
| Total information | ||||
| Number of seats, including the driver's seat | ||||
| Carrying capacity, kg | ||||
| Curb weight, kg | ||||
| Front axle weight, kg: | ||||
| equipped car | ||||
| Rear axle weight, kg: | ||||
| equipped car | ||||
| Vehicle clearance at full load and normal tire pressure, mm: | ||||
| to the cross member of the front suspension | ||||
| to the rear axle beam | ||||
| The smallest turning radius (along the axis of the track of the front outer wheel), m | ||||
| Maximum travel speed in top gear, km / h: | ||||
| with full vehicle weight | ||||
| 160 | ||||
| Acceleration time from standstill with gear shifting to a speed of 100 km / h, s: | ||||
| with full vehicle weight | ||||
| with driver and one passenger | ||||
| The maximum rise with a length of at least double the length of the car, overcome without acceleration with the full mass of the car,% | ||||
| Braking distance at full vehicle weight at a speed of 80 km / h, m | ||||
| Engine | ||||
| Engine model: | VAZ 311 | VAZ 411 | ||
| Cylinder diameter and piston stroke, mm: | ||||
| Working volume, l: | ||||
| Compression ratio | ||||
| Rated power in accordance with GOST 14846 (net) at a crankshaft speed of 5600 min, h.p. | 70 | |||
| Maximum torque in accordance with GOST 14846 (net) at a crankshaft rotation speed of 3400 min, kgf - m | ||||
| The order of the cylinders | ||||
| Transmission | ||||
| Clutch | Single disc with central pressure spring |
|||
| Transmission | mechanical, three-way, four-stage |
|||
| gear ratios: | ||||
| fourth | ||||
| reverse | ||||
| Cardan transmission | two shafts with an intermediate elastic support, connected to the gearbox with an elastic coupling. Two rigid universal joints at the ends of the rear shaft have needle bearings |
|||
| main gear | conical, hypoid |
|||
| ratio | 3,9 | 3,9 | ||
| Chassis | ||||
| Front wheel suspension | independent, on wishbones, with coil springs, telescopic hydraulic shock absorbers and anti-roll bar |
|||
| Rear wheel suspension | dependent, rigid beam connected to the body with one transverse and four longitudinal rods, with coil springs and with hydraulic telescopic shock absorbers |
|||
| disc stamped |
||||
| rim size | 1 W -330 (4.50-13) |
|||
| chamber diagonal | 6.15-13(155-330) |
|||
| chamber radial | ||||
| Role-based management | ||||
| Steering gear reducer | globoidal worm with two-ridge roller |
|||
| ratio | ||||
| Steering drive | three-link, consists of one middle and two lateral symmetrical rods. bipod, swing arm and swing arms |
|||
| Brakes | ||||
| Service brakes: | ||||
| front | disk |
|||
| drum with self-centering pads and rear brake pressure regulator |
||||
| Service brake drive | foot hydraulic, double-circuit |
|||
| Parking brake | manual, with a cable drive on the rear brake pads |
|||
| Electrical equipment | ||||
| Electrical system | one wire, the negative pole of the power supplies is connected to ground |
|||
| Rated voltage, V | ||||
| Accumulator battery | 6 ST-55. capacity 55 A. h at 20-hour discharge mode |
|||
| Generator | G -221, alternating current with built-in rectifier, recoil current 42 A at 5000 min - " | |||
| Starter | ST-221, with electromagnetic traction relay and freewheel clutch | |||
| Spark plug | A17DV | |||
| Body | ||||
| Body type | Sedan, all-metal, load-bearing, four-door |
|||
VAZ 2101 and VAZ 2102, data on the geometry of the body and control points VAZ 2101, 2102 (Zhiguli) repair methods, welding points of body parts, everything is taken from the factory documentation.
Body parts
1 - front panel;
2 - front spar;
3 - headlamp casing;
4 - front wing;
5 - the hood;
6 - bulkhead;
7 - air intake box;
8 - sidewall;
9 - wind window frame;
10 - the lower cross member of the panel
devices;
11 - roof panel;
12 - rear window frame panel;
13 - side roof panel;
14 - rear partition frame with shelf;
15 - rear panel;
16 - the lower cross member of the rear;
17 - trunk lid;
18 - rear wing;
19 - rear floor spar;
20 - rear wheel arch;
21 - trunk floor;
22 - cross member of the trunk floor;
23 - rear cross member of the floor;
24 - front floor;
25 - front strut amplifier;
26 - mudguard;
27 - a rack of a mudguard
Main body sections (body side view)
The main sections of the body (top view of the body)
The main dimensions of the body VAZ 2101, 2102 (Zhiguli) for checking the attachment points of the units:
0 - baseline;
1 - top mount for the radiator;
2 - fastening of the steering gear housing and the pendulum arm;
3 - axis of the brake and clutch pedals;
4 - the center of the steering mechanism;
5 - the center of the rear wheel;
6 - mount the rear suspension shock absorbers;
7 - rear attachment of the muffler;
8 - front attachment of the muffler;
9 - fastening the transverse rod of the rear suspension;
10 - rear wheel axle;
11 - fastening of the upper longitudinal rods of the rear suspension;
12 - fastening of the lower longitudinal rods of the rear suspension;
13 - the center of the front wheel;
14 - attachment points of the front suspension cross member;
15 - mount the anti-roll bar;
16 - bottom mount of the radiator;
17 - vehicle axis;
18 - upper radiator mount;
19 - rear mount of the power unit;
20 - hand brake mount;
21 - fastening the cardan shaft support;
22 - mount the rear suspension shock absorbers
A significant part of body repair work falls on emergency vehicles, which, in most cases, require checking the geometry of the attachment points of the components and assemblies of the vehicle chassis.
Check points for checking the floor of the body VAZ 2101, 2102 (Zhiguli)
1 - intersection of the axes of the front anti-roll bar mounting bolts with the surfaces of the side members;
2 - the center of the axes of the lower bolts of the steering gear housing and the pendulum arm bracket;
3 - intersection of the centers of the front technological openings of the side members of the front floor with the surfaces of the side members;
4 - intersection of the rear technological openings of the front floor side members with the side member surfaces;
5 - the center of the axes of the bolts of the lower longitudinal rods;
6 - the center of the axes of the bolts of the upper longitudinal rods;
7 - intersection of the axis of the transverse rod mounting bolt with the body bracket;
8 - intersection of the center of the rear technological hole of the central amplifier of the rear floor with the surface of the amplifier;
9 - the center of the axes of the front bolts of the anti-roll bar;
10 - intersection of the centers of the axes of the lower bolts of the steering gear housing and the pendulum arm bracket with the surfaces of the side members mudguards;
11 - the center of the front technological openings of the side members of the front floor;
12 - the center of the rear technological openings of the side members of the front floor;
13 - intersection of the axes of the bolts of the lower longitudinal rods with the outer surfaces of the body brackets;
14 - intersection of the axes of the bolts of the upper longitudinal rods with the outer surfaces of the middle spars;
15 - intersection of the axis of the transverse rod mounting bolt with the body bracket;
16 - the center of the rear technological hole of the rear floor amplifier;
17 - longitudinal axis of the vehicle;
0 - reference line
Using the control points of the body floor, it is possible, without dismantling the chassis components and assemblies, to check the position of the floor elements at the installation.
Control dimensions of door openings
The diagonal dimensions of the front and rear door openings shown in the figure should be respectively 1273 ± 2 mm and 983 ± 2 mm.
The distance between the posts from the centers of the links of the upper fixed hinges to the opposite posts of the openings, in the center of the door locks, should be equal: for the front door opening 889 ± 2 mm, for the rear door - 819 ± 2 mm. From the centers of the links of the lower fixed hinges to the opposite pillars of the door openings, in the center of the lock latches, the distances must correspond: for the front door opening - 926 ± 2 mm, for the rear door - 863 ± 2 mm.
Reference linear dimensions between the central pillars of the VAZ 2101, 2102 (Zhiguli)
Control dimensions of the body: openings of the wind window and hood VAZ 2101, 2102 (Zhiguli)
Control body dimensions: rear window openings and trunk lid VAZ 2101, 2102 (Zhiguli)
The diagonal dimensions of the window openings should be: for the wind window 1375 ± 4 mm, for the rear window - 1322 4–2 mm.
The distance between the flanges of the window openings along the vehicle axis should be equal, respectively, for the windshield 537 3 mm, for the rear - 509 3 mm.
Diagonal dimensions should be equal for the bonnet opening 1547 ± 4 mm, for the trunk lid - 1446 4-2 mm. The width of the openings along the vehicle axis must correspond to: for the bonnet opening 876 ± 4 mm and for the trunk lid - 601 ± 1 mm.
The difference in the diagonal dimensions of the opening of the wind window, as well as the openings of the rear window, hood, trunk lid of one body should not exceed 2 mm.
The non-uniformity of the gap (taper) is not more than 1.5 mm, the protrusion of the front surfaces, relatively stationary, by no more than 2 mm.
Front fender welding spots
Rear fender welding spots
Welding lines for roof and bulkhead panels
Welding lines for roof and rear panels
The dots represent the resistance welding seams. The arrows indicate the points of gas welding.
Repair of deformed surfaces
Deformed surfaces are repaired by mechanical or thermal action on the metal, as well as by filling dents with fast-hardening plastics or solder.
The dented plumage is straightened, as a rule, by hand using a special tool (metal, plastic, wooden hammers and various mandrels) and devices.
Heat straightening is used to shrink highly stretched panel surfaces. To prevent sudden swelling and deterioration of mechanical properties, the panels are heated to 600–650 ° C (cherry red color). The diameter of the heated spot should be no more than 20–30 mm.
Shrink the surface as follows:
- gas welding, from the periphery to the center of the defective area, heat the metal and with the blows of a wooden mallet and hammer upset the heated places using a flat support or an anvil;
- Repeat the heating and settling operations until a flat panel surface is obtained.
Irregularities in panels can be leveled with polyester fillers, thermoplastics, cold curing epoxy mastics and solder.
Polyester putties form a secure bond with panels that have been brushed to metal. They are two-component materials: unsaturated polyester resin and a hardener, which catalyzes the quick hardening of the mixture, regardless of the thickness of the putty layer. Drying time at 20 ° C - 15–20 minutes. Therefore, the duration of the putty application is reduced and there is no need to apply it in several layers.
Thermoplastic is available in powder form. Thermoplastic acquires the elastic properties required for its application to the metal surface of the panel at 150–160 ° C.
The surface to be filled must be thoroughly cleaned of rust, scale, old paint and other contaminants.
For better adhesion, it is recommended to roughen the surface with an abrasive tool. To apply thermoplastic, the area to be leveled is heated to 170–180 ° C and the first thin layer of powder is applied, which is rolled with a metal roller. Then a second layer is applied and so on, until the unevenness is filled. Each layer is rolled to obtain a monolithic layer of plastic mass. After hardening, the layer is cleaned and leveled with a metal circle.
Corroded areas of body panels can be repaired with cold curing epoxy mastics, which are highly adhesive, durable and can be easily applied to damaged areas. The composition of mastics includes hardeners, plasticizers (to increase the plasticity of the resin and the impact strength of the cured epoxy composition), fillers (to reduce the shrinkage of the resin and bring the coefficients of thermal expansion of the resin and metal closer together).
POSSu 18 or POSSu 20 solders are used to level areas previously filled with solder, build up the edges of parts and to eliminate the gap. To prevent corrosion, it is better to use an acid-free soldering method.
In case of significant damage, the panels are replaced with new ones, using resistance welding and electric welding in a shielded gas environment.
Most often, when repairing the frame, replacing the wings, front and rear panels is required. The methods for replacing and repairing these parts can be taken as a basis for the repair of other parts of the skeleton, while knowledge of the location of the welds is necessary.
