Vaz 2109 do-it-yourself body overhaul

In detail: vaz 2109 do-it-yourself body overhaul from a real master for the site my.housecope.com.

This video shows the overhaul of the body of a VAZ 2109 car. An initial inspection of the vehicle body shows that it is in an emergency condition. There is rust and rusted through holes on almost all elements of the car. It is worth noting that even the engine compartment has many damaged parts. Rusty elements were found under the rubber seals, in the spare wheel storage compartment and on the side skirts. Also, after dismantling the wings, it is clear that the metal of the body is damaged there by corrosion.

Before starting repair work, dismantling of all units that block access to the body parts being repaired, the interior trim is disassembled. Further, on the car, the necessary body elements are welded, putty is applied and the gaps are restored. Particular attention is paid to the treatment of hard-to-reach elements (sills, wheel arch liners, arches) with an anti-corrosion compound, which will allow you to extend the service life of the car as long as possible. After cleaning the putty, the process of applying the primer takes place. All work is done very carefully, not a single body part has been missed.

Then the painting process begins. The video shows that the car is painted very professionally, the paint is applied evenly, all elements are painted, including the engine compartment. After the paint has dried, the assembly process begins. With the help of a winch, the engine is mounted, all the actuators are connected. The salon is carefully assembled, the acoustic equipment is connected. The battery is installed, the operation of the lighting equipment is checked. Everything is normal, and we can summarize - the car is ready for use.

Video (click to play).

The video of the body repair of the VAZ 2109 demonstrates how the car is reincarnated. As a result of the work done, the car got a second wind and began to look like new.

Body repair skills may be required "due to" various accidents or corrosion.

In this video we will learn how to overhaul the body of a VAZ 2108, 2109, 21099 (SAMARA). That is, let's start with disassembling the body, after that correct preparation to painting. How to properly cut rusty spots and weld new metal. We will learn how to completely alter, then assemble the salon.

Obviously, this manual is very useful and will allow you to get a visual idea of how to repair the body of 2109.

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Is it possible to process a car after replacing arches and sills in winter?

Fans of domestic cars often stumble upon a problem with the body. For example, they bought a used car of the VAZ 2109 brand.
Outwardly, the car looks pretty decent, but once you look closely at the body and it becomes clear to you that it is rusted, And the body is the main part of the car, everything actually rests on it. However, fixing the body with your own hands is not a difficult task.
Having a minimum of the necessary tools and skills, you can replace a rotten arch, bottom or threshold yourself and without replacing the entire body. Our detailed instructions describe the do-it-yourself body repair of a VAZ 2109 step by step.

Rotten nut vaz 2109

Doors;
Rear trunk lid;
The front fenders are also removable.

Dismantling of doors;
Removing the trunk lid;
Removing the hood cover;
Removing the radiator grill;
Removing both bumpers.

Disconnect the door opening limiter. To do this, use the socket wrench to unscrew the bolts securing the doors to the body pillars;
Unscrew the hinge fasteners, hold the door to avoid skewing. Do-it-yourself body repair of a VAZ 2109 is impossible without dismantling the trunk lid;
Therefore, we remove the upholstery by unscrewing the screws from the inside and snapping off the fastening latches. Disconnect the backlight wiring and remove the harnesses from the internal cavities.
Then we disconnect the stops and unscrew the trunk lid by unscrewing the bolts that attach it to the hinges, then remove it from the car.
Now we remove the hood, we start by marking the locations of the bolts on the brackets relative to the hinges, so that during assembly it is easier to screw it into place.
We disconnect the power wires and dismantle the lighting lamps, be sure to remove the harnesses with wires from the grooves.
Now we unscrew the bolts securing the hood, two on each side, and remove it.

The hood has already been removed, now it is enough to unscrew just a couple of screws on the body that hold the grille.

Using a screwdriver, squeeze the plastic latch and pull the grill towards us, it can be easily removed.

Detaching the radiator grill

The bumpers are made of plastic alloy. When loaded on the bumper, it bends slightly rather than bursting.

Remove the front bumper by unscrewing the fasteners to the bracket and to the body, consisting of a pair of bolts.

Advice: We dismantle the rear bumper with a wrench, pre-lubricate the nuts with a liquid wrench (vd-40) or clean gasoline. In these places, the nuts rust and do not loosen well.

We begin the repair by dismantling the rotten, deformed and rusted parts.

Problem spots in the car:

Our car (which we are repairing in this article) has a completely rotten floor along with jacks and stiffeners. The jack had to be installed under the engine beam.
The floor in the back also rotted. The bottom was practically absent. The wings also required replacement.
The front hood is covered with rust, all the floor and gas tank mountings are missing, as well as the spare wheel mount. The front spar has burst in the area of the gearbox. And in the floor of the trunk above the muffler, a huge hole has formed.
The corners of the doors are corroded.

We have prepared the tool necessary for body repair, we are starting the installation.

We start with the engine compartment: drain the coolant, then remove the radiator. We take out the "TV", if it is completely rotten, then you can tear it off, and then cut off the flanges to which the TV was welded with a grinder.
We cut off completely the tail panel, and the wings. Using welding and patches, we weld holes in the mudguards (if any), insert flanges made of new metal, to which we will subsequently weld the “TV”.

In more detail, you can watch the body repair by typing in the search for a VAZ 2109 body repair video.

We install and weld new reinforcements for mudguards using roofing iron for this purpose.
Then we adjust the new details: front and rear fenders, TV, sill and hood. We fasten these elements with self-tapping screws. This is where a set of drills comes in handy.
Now the welding process is ahead. We start welding after all the parts (TV, fenders) are mounted on self-tapping screws.

Tip: I advise you to paint the TV in advance, after fixing it in place, it will not work well to paint it.

We restore the geometry of the car body.
To do this, we drive the car onto a tipper machine. The procedure is performed using a slipway, on which the car is attached.
Special fasteners provide reliability, and the power struts provide a special leveling force. It is recommended that this part be done in a workshop.

We weld the patches to the front and rear floors using a welding machine. We digest all the jacks, joints and amplifiers of the bottom.
Using a rotary grinder, cover the cavities of the machine with an anti-corrosion mixture.

In the photo, the digested bottom of the VAZ 2109

In our case, the arches are completely rotten. Experts recommend not to suffer, but simply to purchase and install new arches.

But it is also quite possible to make a repair. Resin mixed with used oil makes an excellent coat for arches, but rust will creep underneath it in the future.
The choice of anti-corrosion mixture depends on your budget and experience with the material. The VAZ 2109 video (body repair) will show you in detail how the polishing processes proceed, using various means, the list of which is due to the age of your car.
Considering that all machines are in service today for more than 6 years, polishing is carried out in two stages.

At the first stage, pastes containing coarse-grained mechanical additives are used, then pastes that do not contain abrasive substances are applied, beforehand, the car should be thoroughly washed and dried.
The main body repair tool in our case is a polishing wheel, the work is done separately for each part.

Body painting is the final stage. It is produced one hundred percent or independently, if there is a spray gun and skills in working with it. The body shines as good as new, the price of repair with your own hands is many times lower than a hundred work.

Considering the current opportunities in terms of buying spare parts, materials, tools, as well as the relative simplicity of the VAZ 2109 car design, doing body repairs with your own hands is not the most difficult task. Many do bodywork on their own, not inferior in quality to specialized workshops.

What are the weak points of the body of the domestic nine? Let's try to find out.

If rotten or deformed elements of the car body are found, they must be removed and appropriate measures taken to restore the integrity of these areas.

The most vulnerable parts of the VAZ 2109 body include:

Front floor, side skirts with amplifiers, doors, fenders and underbody of the rear part of the body;
The hood has relative endurance, but begins to lose its former properties over time. The area above the battery is especially affected. Here, most often, the owners of the nine notice the formation of rust;
A notable problem that many drivers face is the floor of the fuel tank;
Reflectors optics, muffler also cannot boast of a long life without the appearance of signs of rust.

To get rid of the problem of rust formation on the body, you need to do some work. On your own or with the help of specialists, decide for yourself.In the process of body repair, it is often necessary to raise the car on a jack. If the areas for the jack are rusted, use the sub-boom to lift the vehicle.Often, the body is repaired on its own in the event that small areas have suffered, dents or holes have formed due to rust. In addition to geometry correction, painting and polishing are performed.

Before repairing the carburetor unit, it is recommended to stock up on a repair kit, a can of carburetor cleaner and an acetone (solvent) bath for rinsing parts.

During the repair work, the following items may need to be replaced:

idle jet solenoid valve;
carburetor cover gaskets;
fuel valve;
springs, diaphragms, nozzles and their seals in the accelerating pump;
main fuel jets and their emulsion tubes.

The need for overhaul of a power unit on a VAZ 2109 usually arises after its long-term operation, as a result of which there is an increased depletion of the resource of parts.

The VAZ 2109 engine often requires overhaul after a long service life

Most often, the front of work involves the replacement of the following elements:

gaskets (oil pan, front and rear covers, cylinder head, intake and exhaust manifolds) and crankshaft oil seal;
pistons and piston rings;
connecting rod and main bearings;
valve mechanism;
distributor or ignition module;
fuel injectors;
spark plugs, etc.

In addition, it is necessary to clean the parts, as well as boring or honing the cylinders, and grinding the crankshaft.

After removing the cylinder head, it must be washed with acetone, the combustion chamber must be cleaned of carbon deposits. Parts such as the camshaft and the valve group are cleaned in the same way.

In the process of inspecting the state of the elements of the cylinder head, the need for replacement may be identified:

valves;
springs;
guide bushings;
valve tappets and shims;
cylinder head mounting bolts;
intake and exhaust manifold gaskets.

Additionally, it may be necessary to replace the camshaft.If it was found that there is an unevenness in the mating plane of the head, you can try to lapping. But experts recommend replacing it if the cylinder head is leaking.

There are several ways to fix a radiator leak in the engine cooling system. Among the quick but temporary solutions, the most popular are:

the use of sealing additives that are added to the coolant and clog the breakdown site;
hole putty by "cold welding".

In the photo, the radiator of the VAZ 2109 internal combustion engine cooling system, the elimination of the leak of which is solved in 2 ways

A completely satisfactory result is demonstrated by epoxy paste, with which the problem area is sealed from the outside. However, it is still better to resort to more reliable methods: brazing and argon welding.

As a rule, when repairing the clutch, they change: the release bearing, the clutch basket, the driven disc. Also, replacement may require a fork or clutch cable. As for the gearbox, after its disassembly, the axles, drive rod, lever and springs, rods, roller bearings, magnet, oil seals, gears, etc. are subject to main replacement. Minor damage can be repaired with ordinary sandpaper.

To repair the steering rack on the "nine", you need to buy special keys for disassembling it (if they are not available), as well as a repair kit, which consists of: a support sleeve with O-rings, roller and ball bearings, a retaining ring, an anther, a rack stop, a spring, thrust nut. The steering rack boot is also changing.

Although the design of the VAZ 2109 suspension is well adapted to bad roads and even off-road conditions, the repair of its elements is required quite often.

Typically, undercarriage rebuilding work involves repair and replacement:

hub bearings;
shock absorbers;
springs;
levers;
rubber bushings;
anti-roll bar;
ball bearings.

The development of stretch marks for the front suspension struts of the VAZ 2109 is solved by replacing with new ones

The most common front suspension problems are:

Wear of silent blocks: dismantling of levers, pressing out old ones, pressing in new silent blocks.
Development of ball joints: replacement, it may also be necessary to replace only damaged anthers of the ball joints.
Anti-roll arm wear: complete replacement or replacement of only side struts.
Failure of the hub bearing: replacement on the removed hub.
Development of front struts stretch marks: replacement with new ones.
Defective shock absorbers, subsidence or damage to the springs.

A striking factor indicating a possible malfunction of the suspension struts is the characteristic knock on a bumpy road. Both the assembled struts (shock absorber plus the spring) and the assembly elements separately can be replaced. The racks are disassembled using special spring pullers. Compression buffers, rubber pads, shock absorber rod covers are being changed. Replacing the shock absorbers and springs themselves is carried out in pairs (together the rear and together the front). Disassembling shock absorbers in case of wear is not recommended, as this may affect their factory performance. In addition, shock absorbers are often non-separable.

The brake system of the VAZ "nine" presupposes the presence of two circuits, as well as a vacuum booster, which rarely fails, but in such a case it must only be replaced or repaired using professional equipment. As for the rest of the brake system components, everything can be done in a garage.

The most common problem is the wear of the rubber parts of the main and working brake cylinders. Dismantling them is not difficult, and for repair, an affordable repair kit is bought, which includes all the necessary seals and oil seals. In second place in terms of the frequency of breakdowns is the rear brake pressure regulator, the so-called "sorcerer".Its malfunction is indicated by the emerging tendency to skid the rear of the car during braking. As a rule, the regulator is replaced as an assembly.

Repair of the VAZ 2109 brake system, in addition to the vacuum booster, can be done on your own

Brake hoses and pipes are also at risk of damage. In case of breakage or leakage, these elements are replaced with new ones. There may be an uneven development of the rear brake drums and front brake discs (risks, grooves, etc.), which requires either grinding (grooving) of the friction surfaces, or replacing these system elements. Also, refurbishment work may include repairing the calipers, replacing the parking brake cable, springs and rear brake levers, replacing the brake fluid reservoir and the brake pedal bushing.

A frequent occurrence in the case of a VAZ 2109 is a starter failure, when only a click is heard when the ignition key is turned. Most likely, this is a traction relay. If the relay is collapsible, then usually it is enough to open it, clean the "pyataks" and assemble in the reverse order. A non-dismountable relay will require the skills of soldering or buying a new assembly part.

In addition to the traction relay, replacement or restoration work may require:

Two types of generator were installed on the VAZ 2109: 37.3701 and 94.3701. Usually, for a complete overhaul of the generator, a repair kit is required, consisting of: a diode bridge, bearings, a brush assembly, a relay-regulator and a capacitor. In addition, it may be necessary to replace the pulley, repair or replace the armature, stator, rotor.

When operating the VAZ 21099, the vehicle body is exposed to various negative factors, which necessitates its repair at a service station or by hand. Bodywork includes a wide range of operations, including painting the car, restoring the geometry and repairing the bodywork.

Before repairing the body of a VAZ 21099, it is necessary to assess its technical condition and determine what body work needs to be done, whether it is advisable to carry out them from an economic point of view.

To do this, visually inspect the body surface for:

dents;
chips;
scratches;
peeling of the paint layer;
the presence of rust (pay special attention to the sills, wheel arches and underbody).

The problem of any car of the Togliatti assembly, including the VAZ 21099, is the poor quality of the metal, the low, insufficient level of anti-corrosion treatment of the main elements of the body structure.

In the event that the car has been in an accident, the geometry of the body is checked. It is impossible to do this with your own hands, you need a special stand, which is available only to specialized service stations, after which the factory geometry of the bearing elements is restored.

Then we decide on the budget. Body repair can be major or local, partial. For VAZ 21099, in the event of rust and peeling of the paint layer, a major overhaul of the body is recommended, because a local one is a temporary solution, a postponement of the sentence. It is better to invest once and do everything, including with your own hands, than to restore it gradually, which leads to a decrease in the performance of the car, the appearance of hidden defects and more significant financial costs as a result. After all, the build quality of domestic cars is extremely low, and an attempt to create a sedan on the basis of a station wagon was a very dubious design decision, which is confirmed by the practice of operating the VAZ 21099.

Overhaul of the body involves a complete disassembly of the car. It is necessary to remove everything from the car, from the power plant to the interior trim, and drill out the contact welding places. This will allow you to detect hidden defects and carry out repairs in the most efficient and less costly manner.

When disassembling, take the "Operation manual for the VAZ 21099" as a basis. Damage can be varied, but most of all complaints are about:

the bottom, especially the left side, the driver's seat, is often subject to particularly intense corrosion in Togliatti-assembled cars;

trunk niches;

rear side members;

thresholds and threshold amplifiers;

wheel arches (due to design features, pay close attention to the rear).

If the rust is deep, there are cracks in the structure, and parts are prone to corrosion, including through, and deep deformation, then a body overhaul will not do without welding. It is necessary to weld problem areas. In most cases, replacement parts are required. To do this, you can use a grinder, cut off places and structural elements that are prone to through corrosion. In some cases, you have to buy a new bottom or limit yourself to a trough without a tunnel, it’s cheaper.It is advisable to restore the body geometry after the complete disassembly of the VAZ 21099, but in a conventional garage, it is impossible to do this with your own hands without special equipment.