Niva 1.7 Instrukcja eng6.pdf

Chapter 8. Bodywork

Fault diagnosis

Cause

Remedy

Dark spots over bodywork

1. Hot water was used for washing (above 80¡)

1. Remove minor blemishes through buffing, respray body in case of major

deterioration

2. Respray body

2. Leaded petrol or other aggressive agents were used for dewaxing

Pink spots over light painted surfaces

Deterioration by coolant

Polish affected areas

Lighter spots over dark painted surfaces

Deterioration by moisture due to prolonged vehicle storage under an air-

tight cover

Buff affected areas, respray body, if applicable

Dull shine

1. Dry cloths were used for cleaning

2. Extended exposure to the sun

3. Aggressive cleaners were used for bodywork washing

1. Buff affected areas, respray body, if applicable

2. Buff affected areas, respray body, if applicable

3. Buff affected areas, respray body, if applicable

Water penetration into passenger compartment

1. Excessive or irregular clearance over door aperture

1. Centralize door and adjust door lock striker position, adjust door aperture

flange

2. Renew seal

3. Put 51--7 sealant under outer seal lug

4. Properly route servo unit hose

2. Crumpled metal structure of door seal

3. Windscreen seal leaking

4. Heater air box drain valve is squeezed by vacuum servo unit hose

Excessive efforts to open door

1. Door lock striker retainer pivot shaft bent

2. Striker retainer worn

3. Door position incorrect

1. Renew pivot

2. Renew retainer

3. Adjust door position

Failure to lock door by key or locking knob

Top end of lock outer control lever butts against exterior handle shoulder

Bend lever top end away of handle shoulder to have 0.5-2.0 mm clearance

Failure to unlock door with exterior handle

Excessive clearance between exterior handle shoulder and top end of

lock exterior linkage

Bend lever top end to handle shoulder to have 0.5-2.0 mm clearance

Failure to lock door

1. Broken or weak spring of lock central shaft or external control lever

2. Loose riveting of external operating lever shaft. On closing the lever lug

fails to engage ratchet due to lever misalignment

1. Renew lock

2. Remove lock and ensure reliable riveting

3. Seized exterior control lever due to dust or grease coking

3. Remove lock, wash and lubricate friction parts with grease Litol 24

Failure to unlock door with interior handle

Insufficient travel of inner control lever due to insufficient operating link

travel

Adjust lock inner control lever

Failure to unlock bonnet from passenger compartment

1. Lock operating link broken

2. Excessive operating link length

1. Renew operating link

2. Adjust operating link length through loop on lock hook

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Cause

Remedy

Failure to lock bonnet

1. Lock spring broken or loose

2. Shorter lock operating link

3. Incorrect position of lock

1. Renew spring

2. Adjust operating link length through loop on lock hook

3. Adjust lock position

Failure to secure sliding glass in position

Spring brake of window lifter broken

Renew window lifter

Excessive efforts or failure to recline front seat back forward or

rearward

1. Excessive friction in seat reclining mechanism

1. Lubricate friction components of seat reclining mechanism and front seat

rails with grease èîë-1

2. Renew worn components, lubricate new ones

3. Renew front seat frame

2. Worn components of seat reclining mechanism

3. Damaged welding joints of front seat frame components

Failure to fix front seat back in reclined position

1. Disconnected control cable of front seat rake adjuster

2. Broken control cable or fractured outer cable of seat back rake adjuster

1. Secure control cable on seat recliner hook, check for proper operation

2. Renew faulty recliner mechanism components, check for proper operation

Failure to adjust front seat back rake

1. Faulty retainer of front seat back rake adjuster knob

1. Renew front seat back rake adjuster knob retainer, check operation of

mechanism

2. Renew front seat back frame

2. Faulty front seat back rake adjuster

Front seat position is difficult to adjust

1. Seized runners in tracks due to poor lubrication

1. Lubricate runners with grease èîë-1

2. Misaligned front seat tracks and runners

2. Adjust front seat runner using adjusting shims under securing bolts

Hot air flow to interior compartment

1. Faulty heater tap linkage

1. Check cable operation, secure outer cable, renew cable, if applicable

2. Heater tap fails to shut off water flow

2. Renew tap

Air to interior compartment is not heated

1. Heater tap inoperative due to faulty tap cable drive

2. Faulty heater tap

1. Check cable operation, secure outer cable, renew cable, if applicable

2. Renew tap

Insufficient air inflow to interior

Inoperative air intake cover cable drive (cover closed)

Check cable operation, secure outer cable, renew cable, when applicable

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Bodywork - repair

Deformed surfaces - repair

Refer to Fig.8-1, Fig.8-2 and Fig.8-3 for body frame design

and relevant cross-sections.

The repair of any damaged body parts is carried out by

means of stretching, ding and dent, straightening, cutting out of

irreparable areas, making of maintenance patches from the body

rejects or metal sheets by shaping them into a suitable part.

Deformed panels are restored, as a rule, manually with the

help of specialized tools (metal hammers, plastic or wooden mal-

lets, various mandrels) and accessories.

Heating up is recommended to contract (settle down) heavily

stretched panel surfaces. Heat up to 600-650¡ (cherry-red colour)

to prevent a sharp belling-out of the panel or degrading of physical

properties. The heated area should not exceed 20 to 30 mm.

Contracting of surfaces is carried out as described below:

- using a carbon electrode of a semi-automatic welder or a

gas burner, heat up the metal sheet starting from outside to cen-

tre of the damaged area and restore the original shape by ham-

mering out the heated sections with a wooden mallet or a ham-

mer and facilitating the job with a flat block and anvil;

- proceed with alternative heating and settling until you

achieve the desired quality of the panel surface.

Panel irregularities can be rectified by means of polyester

fillers, thermosetting plastics, cold set epoxy resins or soldering.

Bodywork damages - repair

Most repair on vehicles, especially after road accidents, falls

on bodywork. In the large part repair involves geometry inspec-

tion of attachment points of diverse vehicle units and ancillaries.

The main reference sizes for inspection are shown in Fig.8-4.

The bodywork damages can vary greatly thus demanding

specific remedial actions in each particular case. Maximum use

of panel ding and dent is recommended. Where applicable, avoid

heat treatment of metal to preserve the factory welding and body-

work rustproof protection. The exposed body panel should be lift-

ed off only when it is absolutely necessary in order to locate the

damaged area, to straighten or align the bodywork.

In the event of major body damage it is advisable to remove

all interior trim to facilitate measurement, examination or fitting of

hydraulic and screw jacks to rectify any crosslays or damages.

All projections of exposed panels or detachable parts against

the adjoining panels must be properly realigned and readjusted.

Fig.8-1. Bodywork:

1 - front bonnet reinforcement; 2 - bonnet panel; 3 - diagonal bonnet reinforcements; 4 - rear bonnet reinforcement; 5 - roof panel; 6 - rear end cross-member; 7 - outer

tailgate panel; 8 - inner tailgate panel; 9 - side panel; 10 - outer front door panel; 11 - inner door panel; 12 - door bar; 13 - front door extension; 14 - front wing; 15 - front

panel

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Fig.8-2. Body components:

1 - front wing; 2 - battery tray; 3 - top bulkhead reinforcement; 4 - instrument panel crossbar; 5 - centre pillar; 6 - outer rear wheel arch; 7 - inner bodyside panel; 8 - rear

floor cross-member; 9 - roof panel; 10 - windscreen frame; 11 - bracket for wheel mudflap; 12 - roof reinforcements; 13 - rear pillar; 14 - rear floor panel; 15 - rear cross-

piece; 16 - brackets of door trim bow; 17 - inner arch, rear wheel; 18 - floor-to-bodyside panel connection; 19 - floor cross-member under rear seat; 20 - floor front panel;

21 - floor cross-member under front seat; 22 - side panel, front end; 23 - splash guard, front wing; 24 - bulkhead; 25 - front chassis arm; 26 - front panel

Fig.8-3. Main bodywork cross-sections

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Polyester fillers of Çåìïðîïîë-È or -0085 type offer a

reliable adhesion with the panels stripped to the bare metal. They

consists of two components: unsaturated polyester resin and a

hardener serving as a fast curing catalyst. The ambient tempera-

ture in the workshop should not be below 18¡. The mixture of

polyester filler must be used within ten minutes since it usually

takes sixty minutes for the filler to harden well through. The thick-

ness of the filler layer should be a maximum of 2 mm.

Thermosetting plastic is produced as a powder. Its elastic

properties, required for application on a metal panel, develop at

150-160¡. The surface to be treated must be thoroughly cleaned

of rust, scale, loose paint and other impurities. Thermoplastic

adheres better to rough metal surfaces. Before applying thermo-

plastic, heat up the affected area to 170-180¡ and apply a first

layer of powder which is to be smoothed down by a metal roller.

Then apply a second layer and further ones until all surface imper-

fections are fully covered. Each layer is rolled down to achieve a

monolithic layer of plastic mass. Use your usual treating methods

when the layer is hardened well through.

Use solders of ó 18-2 type or ó 25-2 type to

straighten the areas which were earlier filled with solder, to build-

up edges and to eliminate undesirable gaps.

Severely damaged panels are replaced with new ones using

electric inert gas welding.

Front wing - removal and refitting

With minor damages (small dent, scratches, etc.), straighten

and paint the wing without removing it from the vehicle. Inspect

the condition of inner anti-corrosion coating, restore it when nec-

essary.

Always renew the wing in case of major damages or splits.

Remove the bumper, bonnet and front door.

Fig.8-4. Anchorages of vehicle units and assemblies:

0 - datum lines; 1 - centre of steering mechanism; 2 - brake and clutch pedal axis; 3 - steering wheel shaft axis; 4 - attachment of rear suspension shock-absorbers; 5 -

rear wheel axis; 6 - attachment of front pipe, main silencer; 7 - rear attachment of main silencer; 8 - bottom radiator attachment; 9 - top radiator attachment; 10 - front sus-

pension cross-member attachment; 11 - differential centre; 12 - wheel centre; 13 - front anti-roll bar attachment; 14 - rear power unit mounting attachment; 15 - transfer case

attachment; 16 - attachment of handbrake lever bracket; 17 - front attachment of rear suspension trailing arms; 18 - rear attachment of rear suspension trailing arms; 19 -

rear suspension shock-absorber attachment; 20 - attachment of rear suspension trailing arms; 21 - front attachment of main silencer; 22 - attachment of exhaust pipe

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