Welding rear side members on a VAZ 2114

Cars of the VAZ-2108-09 family are not distinguished by a strong body or durable body iron; the metal rusts especially quickly if it is not treated with anticorrosive. Over time, rust appears on the metal surface, and the rear spar often rots on either side, and cracks appear on it during use. If you drive for a long time with a rotten side member, the rear beam can tear out, which will lead to unpredictable consequences. To avoid a major nuisance or even disaster along the way, it is better to change the spar in advance; this work can be done in a car service center or with your own hands in a garage if you have sufficient experience, the necessary tools and materials.

Rear spar

A burst rear element can lead to complete destruction of the entire car body. If during an accident the part is slightly dented, then it is corrected using a special Swedish body control and straightening stand. In case of serious accidents, straightening the parts is impossible; they are completely replaced. Therefore, it is important to carry out preliminary calculations, since changes in shape and material cause changes in the parameters of the automobile body. The rear element changes completely in situations where the part is deformed after an impact; it is not able to provide strength to the body or perform a shock-absorbing function. To perform such an operation, you need to jack up the car and do the following:

First, those parts that are attached to the spar are dismantled.
Next, the damaged part is stretched as much as possible (it is advisable to achieve the initial classic position).
The protective coating is removed from it, the damaged element is cut off (cutting cutters will be required).
Those places that remain after cutting are treated with a grinder to prevent the corrosion process.

Once the wheel arch, which will be attached to the rear side member, has been prepared, you can begin installing the new part. The fastening points are fixed by spot welding to prevent the part from moving. Welding areas are cleaned with a ground disc and treated with sealant. You can also completely replace the rear part to increase the safety of movement on the vehicle.

Attention! If violations are made during the process of replacing the rear side member, the car will pose a real danger to passengers. We recommend that you entrust the repair of these parts to specialists.

It is not advisable to weld or straighten the rear spar, since rubber wear increases and the condition of the suspension changes.

Preparation for work

Lanzheron photo in a VAZ 2114 car
Considering the long-term use of the VAZ 21099 sedan, the condition of the power frame of the car body may not be the best. Therefore, if you need to replace the rear side member of a VAZ 21099, you need to purchase all the necessary spare parts.

Replacing the rear beam

It is equally important to decide how the replacement will be carried out. If you do everything in a garage, you will need a lift and the necessary equipment

If you are replacing the rear side member yourself, you need to perform a number of preparatory work before lifting the car on the lift.

Seats, carpets and interior floor coverings must be removed. This is done to comply with fire safety and maintain the quality of materials.
Considering the welding work, it is advisable to dismantle (or at least protect with special material) the fuel tank with gasoline residues. And after the car is on the lift, be sure to disconnect the negative terminal from the battery.

Further operations are carried out in the following sequence:

drive the car onto a lift, remove the wheels from the hubs;
release the rear beam with suspension elements, otherwise it will be impossible to carry out work;
clean the rear spar to determine the mounting points.

It should be borne in mind that the spar is usually secured by spot welding, so it is important to locate all such places. For better cleaning, use a wire brush

We clean the welding areas using an angle grinder.

Features of replacing the front spar

Let us highlight several main reasons for wear of the front part:

poor quality road surface;
weakening of the steering mechanism, suspension mountings;
driving at high speed on bad roads

There is a certain algorithm of actions when replacing such a spare part:

Use a power screwdriver to remove the door. Soundproofing material and mats are removed from the interior.
The wing is removed, the front part of the body, as well as the front axle, are fixed.
The spring is tightened, 3 bolts are unscrewed from the upper ball joint, and the upper arm is dismantled.

Advice! If you can’t unscrew the bolts (they are jammed), you can use a grinder.

Next, the stretcher is unscrewed, with the help of which the beam and the front spar are attached, and the engine mudguard is cut off using a grinder.
The front side member, divided into two parts, is separated from the car body.
Dust and traces of corrosion are removed from all attachment points of the front spar, and then the new part is fixed.
The mudguard of the car engine and the lower part are welded, the fender is put in place, and the door is attached.

Every car owner must know what the front and rear side members in a car are intended for. A similar tubular structure with a rectangular cross-section takes on the main loads. The maximum of them exist in automobile side members, since they are associated with traction and lifting force. In older car models, designers used rigid longitudinal frames. When assessing the technical characteristics of the spar, it should be noted that this part is important for the car and, if deformed, can have a negative impact on the main characteristics of the car. Collisions and strong impacts lead to deformation of the side members and the appearance of cracks on them.

Damage has a serious impact on the integrity of the entire vehicle: main components, engine, suspension, doors, wings, and other parts. If the wing or car door is damaged, the deformed rear and front side members can “float”, that is, disrupt the geometry of the entire suspension. The car stops “obeying” its owner, and the rate of wear of car tires increases.

During crash tests, some modern Chinese cars demonstrated a sharp separation of the side members from the floor in the cabin. In Chinese models, welding a deformed spar is a waste of time and money. It’s better to immediately go to a service station and entrust your car to professionals who will replace the worn-out part. A significant impact negatively affects the subsequent use of the vehicle and casts doubt on the possibility of safe operation.

You can learn how to pull out the spars from the following video:

When repairs are required

For all VAZ models, the body was made of black or low-carbon steel of class 08Yu, 08KP. The parts were not galvanized, but were coated with a polymer anti-corrosion composition; the film protected the bottom from moisture for up to 6 months, then natural oxidation processes began. After the purchase, drivers had to carry out thorough anti-corrosion treatment of the metal.

Repair or complete over-welding of the bottom of the VAZ 2114 will be required in the following cases:

It is impossible to jack up the car; the jacks fall through.
The floor in the car became uneven, the metal sagged from corrosion.
The driver's seat cannot be adjusted; when the doors are closed, increased gaps appear.
Noticeable areas of corrosion on the sills and wheel arches. If you lift the car onto an overpass and check it with an awl, the anti-corrosion layer from the bottom will fall off, and traces of rust will be clearly visible.

What is a spar, what does it look like, and where is it installed?

A spar is a structural unit of a car that looks like a rectangular pipe, that is, a metal profile with a rectangular cross-section.

The part passes through the front and rear of the body, acting as a support. Depending on the body design, an option with side members between the bumpers is possible.

This unit can be composite (assembled from several elements) or integral.

In the classic configuration, two spars are installed (left and right).

Example, left front side member of a VAZ 2110.

Each element is divided into three parts - middle, front and back. The main difference is the location.

Thus, the spar installed at the front and left is positioned at a level lower than the spar at the rear and the same unit, but only the wing.

The nodes are parallel to each other, but there may be cases where they are located at a minimum angle.

Spar on Nissan Bluebird HU14 SR20VE.

The starting material for production is aluminum or titanium. Sometimes component layers are used to add to the fortress structure. The cross section of the spar has the shape of the letter “P”. At the same time, in places of maximum load the cross-section is larger.

The main advantage of the part is its exceptional strength. These units are able to withstand maximum loads - the weight of the car, luggage, mass of units, and so on.

In addition, the side members cope with all the impacts that they receive when the wheels get into holes or in the event of an accident.

Structurally, these units form a U-shaped staircase frame laid on its side.

This type of design is an integral part of many SUVs and trucks.

As for passenger cars, the ladder principle is not applied in them. To visually see the detail, just look under the bottom of the vehicle.

Body structure of the VAZ 2108, location of the side members.

Classification

There are composite parts similar to a set of iron elements. There are also solid ones, produced by milling or stamping.

The standard design assumes:

Each has three main parts: middle, back, front. Most often, individual elements are installed in parallel, but in some designs a small angle is assumed.

They are mandatory components of every car, no matter what type of body it has. To produce this type of spare part, aluminum or titanium alloys and composite materials are used. The channel, which is the main section in this part, has a U-shaped appearance.

Automotive engineers can install the frame at the rear, at the front of the vehicle, or throughout the entire vehicle body.

Due to the significant pressure, durable materials and alloys are needed during manufacturing. Pressure is exerted on this element by the weight of passengers, the engine, and other automobile parts. It is also subject to the load transmitted during driving from the wheels of the vehicle. Passenger cars require a load-bearing body structure, SUVs are equipped with ladder frames.

Purpose and tasks

The spar is literally the power part of the car. The purpose of the unit varies depending on the type of vehicle:

In trucks and 4x4 cars, side members are the main unit that is part of the frame;

In passenger vehicles, the task of the part is to strengthen the bottom of the car and the lower part of the trunk.

In the first and second cases, the U-shaped unit takes on the weight of the body, components and passengers of the vehicle.

Design advantages

Each design has advantages. Thus, “angular” spars allow the wheel to turn at a larger angle, and devices with vertical bending allow the vehicle’s center of gravity to be lowered and the bottom level to be lowered.

Parts with horizontal bending are structural elements that also make it possible to lower the level of the bottom, increasing safety in the event of a side impact.

To increase rigidity, the spars are strengthened with cross members. The latter come in different profiles - in the form of the letter K, X, or be straight.

This type of crossbar is made of a special profile made of reliable and deformation-resistant metal.

To increase reliability in freight transport, cross members and side members are combined with special rivets, and in passenger transport - by welding.

An important point is the fixation of the body on the frame, which occurs using special brackets.

Considering the spar design as a whole, it is worth highlighting the following advantages:

Minimum weight and torsional rigidity;
High level of controllability and dynamics, as well as minimal fuel consumption due to the low mass of the unit;
Greatest passive safety. The latter is possible thanks to special zones that “absorb” excess energy and increase the level of comfort.

Toyota Mark II front side members.

Worth about:

If one node breaks down, the integrity and connections of the structural elements are disrupted. This is due to the fact that the load is distributed evenly over the area;
Difficulty in repair. In case of serious deformations, the only solution is to replace the unit.

Basic malfunctions and problems associated with side members, solutions

During operation, the following problems are possible:

Deformation (curvature) due to exposure to loads over long periods of time. It is worth remembering that the spars are made of metal, which gets tired and damaged over time.
If you get into an accident, the part may be severely damaged. In such situations, many car parameters are violated. So, in the event of an accident, it is possible that the suspension or power unit may shift in relation to the body part, the location of the wings or doors may change, the geometry of the body will be deformed, obvious cracks may appear on the outside, and so on.

If there is obvious damage (cracks appearing) in the part, the integrity of the structure is also destroyed.

That is why after an accident it is worth making sure that there is no deformation of the components. In practice, in 90% of cases after an accident, the front side members have to be repaired.

The method of restoration is determined taking into account the severity of the problem and damage to the damper section. So, the spar, which is part of the frame, is easy to change. If the assembly is part of the supporting body, then restoration work may be useless.

The possibility of repair depends on the degree of deformation:

If the damage is minimal, the assembly is pulled out on a special stand, after which the parameters of the part are checked;

If the deformation is severe, the best option is replacement. If you try to make corrections to a distorted part, you may change the structure and reduce the strength of the structure. The result is deterioration in body characteristics.

There may be situations where the replacement is not complete. In this case, new parts are attached by welding. The use of couplings to connect structures is prohibited.

We must not forget that the main function of the spar is to strengthen the body, so during the repair process maximum attention is paid to strength.

On the other hand, excessive strengthening of the unit leads to a decrease in shock-absorbing functions, which is unacceptable.

So when repairing, you should take this parameter into account and try not to overestimate the level of rigidity.

Matters of the heart

Over the 22-year conveyor life of the Nizhny Novgorod “one and a half”, quite a few different engines managed to work in its engine compartment, starting with gasoline Rover 20T4 / V8 MPI, DCC EDZ (Chrysler 2.4 DOHC), ZMZ, UMP and ending with diesel engines GAZ-560 (Steyr), ZMZ-514 and Cummins ISF 2.8. And these are only mass-produced units, and how many more experimental, experimental and converted versions were generated both by the plant itself and by countless private service stations and tuning studios...

Acting empirically, in the late 1990s, experts came to the conclusion that one of the most optimal engine options for GAZ passenger cars and light commercial vehicles is the product of the Japanese company Toyota. Numerous tuning shops operating at the Gorky Automobile Plant at that time, "Celeste"), began to re-equip Volgas, Sobols and GAZelles on individual orders, installing more powerful 6-cylinder Toyota engines on them. One of the most famous in this area was, which still exists today, however, tuning GAZ cars has not been its main business for a long time.

But if in any search engine on the Internet today you type the query “Toyota engine for GAZelle”, many companies that continue the work of Technoservice will appear in the list of results. But if 10-15 years ago the Japanese power units installed on gas cars cost incredible amounts of money, today components come from Japan in the form of used “contract parts”. In addition, the engines were installed mainly on new GAZ cars, which required certification and registration. And today, engine changes are often carried out on used cars only under a re-equipment certificate.

The latter circumstance became possible thanks to Order No. 20152 of the Ministry of Internal Affairs of Russia dated March 17, 2011, according to which the verification of engine numbers of vehicles with a gross weight of up to 5 tons in the traffic police was canceled. This point still causes numerous disputes and various legal consequences in the traffic police. But this is already a question of the imperfection of legislation and the lack of uniformity in law enforcement.

Classifying an engine as a numberless part has freed up the hands of vehicle tuning companies, and the “registration” of alternative engines under the hood of GAZelles has recently been gaining popularity. With the assistance of Nizhny Novgorod, I watched the process of converting a GAZelle from a basic power unit to an alternative one and even took a ride in one of the “one and a half” with the heart of a samurai.

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The VAZ-2109 is a car that is not distinguished by a strong body; iron quickly succumbs to corrosion, and almost all body parts rust. Replacing the front spar is required when its metal is rotten in different places; the part is also replaced if it is severely deformed after an impact (accident).

Final processing

Primer, anti-corrosion treatment, installation of new sound insulation and installation of the interior with electrical connections are the final stage of work on the bottom. For external treatment, you will need bitumen mastic or anticorrosive Body 930. The product has a budget cost and is highly resistant. The mastic forms a dense but elastic protective layer that does not allow moisture to pass through and protects the iron. Final work step by step:

Clean weld seams.
Treat welding areas with a primer containing zinc.
Cover the inner surface with mastic and install new sound insulation.

Purpose of the spar

The spar is a load-bearing body element, which is a beam, serves as the basis for fastening the components and components of the car, and also plays the role of a shock absorber, softening the impact, absorbing deformation. The “nine” is equipped with paired front and rear spars; these body elements experience significant load.

If a car can move without problems with a dented fender and a rusty door, then the car should not be driven with a deformed front spar (PL). If this part is damaged, quite serious problems may arise:

tires will quickly begin to be eaten away;
the car is poorly controlled;
the body loses strength and collapses.

If the condition of the spar is not the most critical, it can be welded, the geometry can be corrected on a special stand (slipway); in case of severe deformation or if there are cracks, the body element should be replaced. But it should immediately be noted that it is very difficult to do such work with your own hands - here it is important to accurately install the part, you must use welding. If the body element is installed incorrectly, the geometry of the body will be disrupted and the work will have to be redone.

Replacement procedure

We drill out the attachment points of the power element, and if this fails, then the remaining points need to be cut off using a chisel and a hammer.
After dismantling the old spar, it is necessary to thoroughly clean the area for the replacement part purchased, install it and, if necessary, adjust it to the required size.
A new part is being prepared for welding. This must be done in the same places where factory welding was used. A minimum of three welding points will be required for initial fixation.
The prepared part is secured to the place to be installed using removable clamps.
We sequentially weld the spar to the body according to previously prepared marks, after which we evaluate the correctness of the design.
The final stage of installation is the final welding of the part. In this case, the structure is strengthened by applying additional strength elements.
After completion of the work, the welding areas must be processed by cleaning with a grinding machine. Finishing is mandatory.

This stage involves thoroughly cleaning the welding areas from scale and other foreign contaminants. The surface is thoroughly degreased, coated with primer and anticorrosive. Epoxy resin can be applied to the weld areas to permanently protect them from spot corrosion. The final step is to reinstall the suspension parts and secure the beam. The interior elements are installed, the car is completely cleaned, put on wheels and rolled out of the garage.

The body will have to be thoroughly disassembled

Despite its apparent simplicity, before starting work, you need to assess your own capabilities. After all, redoing it is more difficult than doing everything right in the first place. Mistakes that can be made during poor-quality installation can lead not only to the rejection of the new spar, but also to a violation of the geometric shape of the car or its incorrect behavior while driving. Thus, replacing the rear side members is a process that can be done independently, but a responsible approach to the work is required.

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The problem of failure of the VAZ 2108/2109 side member is not a pleasant situation, but this does not mean that it cannot be corrected. There are two ways to fix the problem: replacement or welding, DIY repair or in a workshop. You will learn further how to make the right choice.

The cost of the front side members of the VAZ-2109

The right front spar is very similar in design to the left one, but the parts are not interchangeable, they seem to be a mirror image of each other. Body parts for the “nine” are sold in almost every specialized auto store; you can buy a front spar for an average price of 1,800 to 2,200 rubles.

You can also purchase a PL repair insert; it can be useful if the entire body part does not change and needs to be repaired. The average cost of an insert on the right or left side is 800-1000 rubles, like the spars themselves, the repair inserts from the “nine” are identical and fit on models 2108, 21099, 2113-14-15. There are no side member reinforcements as such for the front part of the body on the VAZ-2108-09-099; rigidity is added to it by the lower radiator frame (“TV”), which is a connector and is welded in front between the left and right load-bearing parts of the body, and the front wing mudguards.

Preparatory work

If you nevertheless decide to repair the spar on a VAZ yourself, first you will need to acquire the following tools for the job:

welding machine;
metal hacksaw or plasma cutter;
grinding machine;
metal spatula.

Since spar replacement and repair are carried out using the same technology, the set of tools will also be the same. First you will need to dismantle all electrical equipment, parts, engine components and chassis.

The next stage is heating the parts. But first you will need to get rid of the old coating, remove the sealant, sound insulation and primer. Now you can cut off the heated spar. Please note that if the wheel arch is also being replaced, there is no need to separate it first.

Please note that it is better to purchase spars complete with other parts. This way you will be sure that they will fit each other perfectly and will not spend so much time installing them.

The main reasons for the destruction of the front spar

As noted above, the submarine bends from impact and rusts over time. The following also have a destructive effect on this body element:

constant engine vibrations, especially if the engine or gearbox mounts are loose;
driving a car on bad roads;
extreme driving.

Since the side members are practically the skeleton of the body, a large load falls on them. All vibrations and shocks are transmitted to these elements; as a result, the body parts cannot withstand, become deformed, and cracks appear on them.

What to do if the spars are rotten

Unfortunately, the quality of the metal from which our cars are made meets the highest standards. Because of this, the body does not withstand high humidity, which is quite common in our latitudes. The side members mounted under the car body also suffer.

Sources

https://avtomobil-vaz.ru/zamena-zadnego-lonzherona-2109/
https://avtobrands.ru/perednij-lonzheron-vaz-2109-zamena-remont-stoimost-rabot/
https://AutomobilGroup.ru/instruktsiya/zamena-lonzherona-foto-instruktsiya-pomenyat-lonzheron/
https://AvtoChehol.su/remont-i-obsluzhivanie/zamena-lonzherona-vaz-2109.html
https://mashinaa.ru/avtovaz/vaz-2109/6187-lonzheron-vaz-2109-remont-zamena.html
https://avtorazbor59.ru/stati/zamena-lonzherona-vaz-2109.html
https://prometey96.ru/ustrojstvo/lonzheron-vaz-2109.html
https://avtobrands.ru/osobennosti-zameny-zadnih-lonzheronov-vaz-2109-stoimost-remonta-v-avtoservise/
https://automanyak.com/remont-i-zapchasti/podrobno-pro-lonzheron-vaz-2109.html

How to replace the front spar on a Nine

Replacing the front side members 2108-09 must be done on a slipway; in a regular car service without special equipment, it is very difficult to perform such work, and in some cases it is simply impossible. Before starting body repairs, it is necessary to partially disassemble the car, remove from the car:

front optics and bumper;
hood;
radiator grille;
expansion tank;
radiator;
front wing (on the side where the submarine changes);

If the car's hardware is sufficiently rusty that you have to additionally change (repair) other body elements, you may have to remove the gearbox and engine. The body repair itself is performed in the following order:

the old spar is cut off (usually using a grinder or a gas cutter) so that the new part “falls” into place better, a beveled cut is made;
the new submarine is cleaned of transportation soil;
At the seat, rust, dust and dirt are removed from the metal; a grinder is used for this. A good result can be achieved by using a sandblasting machine; to remove traces of corrosion, a rust converter is needed;
The new spar is butt welded, first tackling it in several places. Before final welding, the geometry of the body is checked; if the work is not done on a stand, the correct installation of the part is verified using control points:
after welding work, the metal surface is cleaned again, degreased, the weld seam is treated with mastic, and primer is applied;
After the primer has completely dried, the replaced body part is painted in the color of the body, and the car is assembled.

As a rule, one body element on a car is rarely changed; along with the submarine, a new “TV”, upper radiator frame, and panels (mud flaps) of the front wings have to be installed. And the front spar on the nine is not always completely changed; most often it is cut off along the “glass”.

Carrying out repair and welding work

Repairing the underbody of a VAZ 2115 is quite difficult. Under the bottom of the car there is a fuel system, brake system and muffler pipes. When replacing an entire part, these systems must be completely removed and reinstalled after welding. Experienced tinsmiths recommend not dismantling the muffler elements, but cutting them out, after repairing the bottom, boiling the part and installing it in place.

If the underbody is partially repaired, there will be no need to remove the fuel and brake system pipes. When cutting out entirely, it is recommended to cut out the bottom not along the factory welding line, but leaving an allowance of 1-2 cm. The new element is welded with an overlapping seam, which increases the rigidity of the body and the durability of the weld seam.

The cost of replacing the front side member of a VAZ-2108-09 in a car service center

Since replacing a submarine is not an easy job even for an average car service center, not all craftsmen undertake it, especially since not everyone is eager to begin restoring the body of a used Nine. Mostly, small auto repair shops carry out minor and medium body repairs, while large auto repair centers do not want to deal with domestic cars at all. Prices for body work from auto repair companies and private owners are most often approximate; often the final cost of the repairman is announced closer to the end of the repair. The fact is that “pitfalls” may unexpectedly appear, and as a result of their identification, the work is delayed and becomes more complex.

Some car service centers indicate two values in the price list at once - the upper and lower limits; in large cities or the capital, they charge from 3,500 to 9,000 rubles for replacing the front side member; usually, work from private repairmen in garages costs less. Often, along with the submarine, it is necessary to change the wing splash guard, sills, and repair the bottom; some auto repair shops note in their prices that the cost of repairs in the price list is indicated without painting.

Repair of the front side member of the VAZ-2109

The main reasons why submarines have to be repaired are the appearance of cracks on the body element. In some cases, the spar bursts in a circle, the metal rots through and through, if the part itself is not yet in a completely deplorable state, patches are put on it, and the iron is strengthened using spot welding. If the spar is pulled away as a result of an accident, it is pulled out on a stand. You can try to pull out the submarine without a slipway; in garage or field conditions, craftsmen carry out a similar operation using a strong metal chain, a hand winch and some kind of support, for example, wood.

In this case, the rear beam must be fixed so that the car does not move forward; it should be pulled carefully, constantly checking for deformation of the rear axle. If the beam bends due to excessive force, it will have to be replaced. Only professionals can say whether it is worth repairing a car after damage to the spar; in some cases it is easier to sell the car for spare parts than to restore it.

Replacement procedure if you decide to do it yourself

Raise the entire car on a rack lift, or just the damaged side.
The VAZ 2109 spar is attached using spot welding, it must be drilled out. Anything that cannot be drilled out, cut off with a grinder.
If some elements of the part are inaccessible to you, then remove the suspension (the wheels will have to be removed in any case).
If, after all that has been done, you still cannot remove the spar, cut it off with a chisel.
Let's try on a new part. If it is larger, then we will cut off the excess part.
In the new case, we make holes in the places where you will weld it.
We attach the part to the body by welding.
We clean the welded points with a grinding machine.
We prime the new part and paint it in several layers.
If desired, you can carry out anti-corrosion treatment.

I have the same story, but it’s done simpler: if the car doesn’t pull anywhere and it goes smoothly, then we cook at the junction of 3 layers of the spar (this is at the very edge in the lower part of it), then seal from the outside and from the inside. Although sometimes I doubt the correctness, it still doesn’t let me down, pah, pah, pah.

Are there any problems with the VAZ 2110 pump? No problem. All you need to do is read this article. Then you will know how to replace it, how to distinguish a high-quality water pump from a bad one, how much the cheapest pump costs.

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