Lada VAZ-21215 (1999) manual

VAZ VEHICLES VAZ-21213, VAZ-21214, VAZ-21214-20, VAZ-21215 REPAIR MANUAL[...]

2 Contents Section 1. General data ..........................................................4 Section 2. Engine ..................................................................7 Engine - removal and refitting..........................................12 Cylinder block ..................................................................19 Inspectio[...]

About this manual This Manual provides information on routine maintenance and servicing and is intended for engineers and mechanics of service outlets, garages and workshops. The Manual covers the following models: VAZ-21213 model - an off-road vehicle, three-door body of all-steel unitary construction, with 1.7 litre carburettor engine; VAZ-21214 [...]

Section 1. General Data T able 1-1 TECHNICAL SPECIFICATION Features VAZ-21213 VAZ-21214 VAZ-21214-20 VAZ-21215 General Number of seats 5 5 5 5 Kerb weight, kg 1210 1210 1210 1240 Payload, kg 400 400 400 400 Overall dimensions Fig.1-1 Maximum braking distance at GVW and 80 km/h on horizontal dry flat asphalt road, not greater, meters: • with servi[...]

Features VAZ-21213 VAZ-21214 VAZ-21214-20 VAZ-21215 Power train Clutch single dry plate, diaphragm spring Clutch release mechanism hydraulic, servo spring Transmission 5-speed, synchro units on all forward gears Gear ratio: • first gear 3.67 3.67 3.67 3.67 • second gear 2.10 2.10 2.10 2.10 • third gear 1.36 1.36 1.36 1.36 • fourth gear 1.00[...]

Features VAZ-21213 VAZ-21214 VAZ-21214-20 VAZ-21215 Steering Steering mechanism globoidal worm, double-crest roller, steering ratio 16.4 Steering linkage three links, relay rod and two steering rods, drop arm, idler arm and swing arms Braking system Service braking system: • front brakes disc-type, floating caliper, automatic disc-to-pad clearanc[...]

Section 2. Engine Refer to Fig.2-1 and Fig.2-2 for front and side sectional views of the engine. 7 Fig.2-1. Side sectional view of the engine[...]

8 Fig.2-2. Front sectional view of the engine[...]

Fault diagnosis Symptom/fault Remedy Engine fails to start 1. No fuel to carburettor: - blocked fuel pipes or fuel filter; - clogged carburettor or fuel pump filters; - faulty fuel pump 2. Ignition system fault 3. Carburettor fuel cutoff solenoid fails to open at ignition switch-on: - disconnected, loose or broken wiring to solenoid or solenoid con[...]

Main bearing knocking Typical knocking or thumping noticeable at sudden throttle opening at idle which intensifies with higher crankshaft rate. Excessive endfloat of crankshaft causes sharper irregular knocking, especially noticeable during smooth increase or decrease in crankshaft speed. 1. Early ignition 2. Insufficient pressure oil 3. Loose flyw[...]

Excessive oil consumption 1. Oil leaking through engine gaskets 2. Restricted crankcase ventilation system 3. Worn piston rings 4. Broken piston rings 5. Foul windows of oil scraper rings or foul slots in piston grooves due to wrong oil 6. Worn or damaged valve oil caps 7. Badly worn valve stems or guides Excessive fuel consumption 1. Choke not ful[...]

Engine - removal and refitting Put the vehicle on a lift or over an inspection pit and apply the handbrake. Take out the spare wheel and its supporting pipe. Disconnect the battery leads and withdraw the battery. Unbolt and remove the bonnet. To remove the air cleaner, disconnect its hoses, remove the cover and filter element. Temporarily plug the [...]

Remove the starter motor heat shield, followed by the starter motor, hot air intake complete with the supply hose. Remove from the cylinder head two side brackets together with the front engine mounting rubbers. Unbolt the clutch and withdraw it. Refitting is a reversal of the removal procedure. Draw special attention to the engine-to-transmission [...]

Remove thrust flange 1 (Fig.2-8) of the oil pump drive shaft and take the shaft out of the cylinder block. Using picker Ä.40005/1/7 (kit Ä.40005) drive the sprocket off the crankshaft (Fig.2-9). Undo the connecting rod bolts, remove the big end cap and carefully lift the pistons with the conrods through the cylinders. Mark the piston, connecting [...]

Fit the centre main bearing shells without an oilway into the bearing recesses. Fit into other cylinder bores the bearing shells with an oilway, while into the relevant main bearing caps - the bearing shells without an oilway. Lower the crankshaft into posi- tion, then stick two thrust washers into the rear bearing recesses (Fig.2-12). WARNING. The[...]

Locate the flywheel in position so that the marking (a cut-out) near the rim is against the No 4 cylinder crankpin axis. While holding the flywheel stationary with tool Ä.60330/R, bolt it to the crankshaft flange to the specified torque. Using a ring compressor (tool 67.8125.9502), fit the pistons and connecting rods to the cylinders (Fig.2-17). W[...]

Turn the flywheel so that the mark on the crankshaft sprock- et is against the cylinder block mark (Fig.2-19). Check to see the camshaft bearing housing centering pins are in position (Fig.2-20). Refit the sprocket to the camshaft com- plete with the bearing housing and turn the camshaft so that the timing mark in the sprocket is aligned against th[...]

Adjust the clearance between the camshaft lobes and valve levers. Refit the camshaft cover (Fig.2-23) complete with the gasket and oil seal to the cylinder block, do not tighten the retaining bolts and nuts fully. Using tool 41.7853.4010 centralize the cover against the crankshaft end, then tighten the retaining nuts and bolts to the torques specif[...]

Engine run-in after overhaul After overhaul the engine is bench tested (run-in) at no loads under the following cycle: 750-800 rpm 2 minutes 1000 rpm 3 minutes 1500 rpm 4 minutes 2000 rpm 5 minutes Locate the engine on the test bench, start the engine and make checks with respect to the following items: - evidence of coolant or fuel leaks through m[...]

20 Fig.2-26. Cylinder size class engraved on the cylinder block Fig.2-27. Measuring the cylinder bore with the inside dial gauge: 1 - inside dial gauge; 2 - setting to zero against reference gauge Fig.2-25. Basic sizes of the cylinder block[...]

There is practically no wear in the land 1 area of the cylin- ders. Compare the values measured on the first and other cylin- der lands to see the amount of the cylinder wear. When the maximum wear is over 0.15 mm, rebore the cylin- ders to the nearest oversize; provide 0.03 mm honing allowance on the diameter. Hone the cylinder walls so that the d[...]

The connecting rod small-end features a pressed-in steel- bronze bush. As to the diameter of the bush, the connecting rods are divided into three classes in steps of 0.004 mm (similar to the pistons). The class number (5 in Fig.2-30) is engraved on the big-end cap. The connecting rod small-end and big-end are classified weight-wise (Table 2-1) and [...]

Table 2-1 Connecting rod classification as to small-end and big-end weights Connecting rod weight, g Class Paint mark small-end big-end 519±3 Ä white 186±2 525±3 Ç blue 531±3 ë red 519±3 D black 190±2 525±3 E violet 531±3 F green 519±3 G yellow 194±2 525±3 ç brown 531±3 I orange Selecting piston to cylinder The design clearance betw[...]

Make certain the second compression ring is positioned with the recess facing down (Fig.2-30), while the TOP (or ÇÖêï) mark should face up (the piston crown). Before refitting the oil ring, check to see the joint of the coil expander (spreader ring) is on the side opposite to the ring gap. Inspection Scrape away all traces of carbon from the pi[...]

crankpins. Regrind when the wear is in excess of 0.03 mm, oval- ity is over 0.03 mm, or when scoring and scuffing is obvious. Regrind the journals and crankpins through reducing the diameter to the nearest undersize (Fig.2-36). When regrinding, observe the sizes for the crankshaft fillet as shown in Fig.2-36 for the standard-size crankshaft. The ov[...]

The nominal design clearance is 0.02-0.07 mm for the crankpins and 0.026-0.073 mm for the main bearing journal. When the running clearance is below the maximum value (0.1 mm for the big-end bearing journals and 0.15 mm for the main bearing journals), the bearing shells can be re-used. When the running clearance exceeds the specified maxi- mum, repl[...]

The outer diameter of the replacement guides is 0.2 mm big- ger. Bearing housing 5 with camshaft 6 is fitted to the cylinder head. Valve train. Valves 2 are operated by the cams through levers 4. One end of the lever pushes the valve stem, while the other end rests on the spherical head of adjuster bolt 7 which adjusts the clearance A in the valve [...]

lock nut tightening, until the blade is a firm sliding fit when the lock nut is tightened (Fig.2-42); - after the clearance is adjusted at the cylinder No4 exhaust valve and cylinder No3 intake valve, turn the crankshaft progres- sively to the 180° and adjust the clearances, observing the sequence as shown in Table 2-2. Table 2-2 Valve clearance a[...]

Disconnect the leads from the spark plugs and coolant tem- perature sender, from carburettor idle switch and fuel cutoff sole- noid. Disconnect the choke cable; disconnect the throttle linkage from the intermediate lever on the valve cover. Loosen the clips and disconnect the carburettor supply / return fuel hoses. Secure the hoses in a manner to e[...]

Put spring A.94069/5 on tool Ä.94059, fit tapered wheel A.94078 on spindle Ä.94069 for the exhaust valve seats or wheel Ä.94100 for the inlet valve seats, secure the spindle in a grinder and recut the valve seat (Fig.2-48). The grinding wheel must be off at the moment the grinding wheel contacts the valve seat, otherwise vibration ensued will di[...]

When a new valve fails to take up clearance between the valve guide and the valve rim, renew the valve guides using tool Ä.60153/R (Fig.2-51). Push in the valve guide complete with the circlip to the cylin- der head to their stop. After the valve is pressed into position, ream the valve guide bores using tool Ä.90310/1 (for the inlet valve guides[...]

For lever springs (Fig.2-53) the size Ä (spring unloaded) must be 35 mm, whereas the size Ç (spring loaded 51-73.5 N/ 5.2-7.5 kgf) must be 43 mm. Cylinder head bolts. Multiple use of the cylinder head bolts results in the bolt elongation. Therefore, check the length of the bolt (L) to be 120 mm (less the bolt head length), otherwise renew the bol[...]

Drain the cooling water from the radiator and cylinder block, remove the radiator complete with the hoses and thermostat. Undo the retaining nuts and remove the fan. Remove the valve cover and turn the crankshaft to align the TDC mark in the camshaft sprocket against the timing mark in the bearing housing (Fig.2-21), while the alternator belt pulle[...]

Camshaft bearing housing. Wash and clean the bearing housing, flush clean the oilways. Check the diameters of the holes in the bearings. When the clearance between the camshaft journals and bearing surfaces exceeds 0.2 mm (wear limit), renew the bearing housing. The inner bearing surfaces should be smooth, with no scores; renew the bearing housing [...]

When the level in the expansion tank is below the value spec- ified, while its density is in excess of that required, top up distilled water. When the density is as recommended, top up the correct coolant of the same grade as that in the cooling system. When the coolant density is below the value specified, while the vehicle will be used in cold co[...]

36 Fig.2-61. Checking the water pump belt tension Fig.2-63. Removing the impeller: 1 - puller; 2 - impeller Fig.2-62. Sectional view of the coolant pump: 1 - pulley hub; 2 - shaft; 3 - cover; 4 - impeller; 5 - housing; 6 - thrust ring; 7 - oil seal; 8 - bearing stop screw; 9 - pulley; 10 - blower fan; 11 - cover plate; 12 - fan hub[...]

Water pump drivebelt tension adjustment The belt tension is checked by exerting a hand pressure on the chain between the alternator pulley and pump pulley or between the pump pulley and crankshaft pulley. With proper ten- sion, slack A in the belt (Fig.2-61) at 98 N (10 kgf) must be 10-15 ÏÏ, while at the same pressure the deflection Ç must be w[...]

Gradually heat the water from the starting 73-75 ° ë in incre- ments of approximately 1 ° ë per minute, at constant agitation to ensure homogeneous heating within the container. The value, when the valve travel is 0.1 mm, is deemed as the initial temperature of the main valve opening. The main valve opening temperature is stated on the ther- mo[...]

39 Fig.2-67. Lubrication system: 1 - oil passage to main bearing; 2 - main bearing-to-big-end bearing oil passage; 3 - oil filter relief valve; 4 - paper element; 5 - check valve; 6 - oil pump; 7 - oil pump-to- oil filter oil passage; 8 - oil passage from oil filter to main oil gallery; 9 - oil passage to oil pump gear and ignition distributor; 10 [...]

Removal and refitting. When only the oil pump requires recon- ditioning, remove it from the vehicle (Refer to section «Engine - removal and refitting»), place it on the turning stand, drain the oil from the sump, turn over the engine and remove the sump. Undo the oil pump bolts and remove the pump complete with the intake manifold assembly. Refit[...]

Oil pump shaft and drive gears Check to see there is no denting or scuffing of the shaft bear- ing journals or eccentric cam surfaces. No pitting of the oil pump gears or ignition distributor is per- mitted, if this is the case, renew the gears and shaft. Oil pump shaft bushes. Check the inner diameter of the bushes, their proper fitting, make cert[...]

Crankcase emission ventilation system Flushing the system. For flushing disconnect vent hoses 4 and 5 (Fig. 2-75) from the manifolds, remove flame arrester 3 from discharge hose 5, remove cover 6 of oil separator 7 and wash them in petrol or kerosine. Flush and blow dry with compressed air the carburettor man- ifold to draw crankcase emission on th[...]

Fuel system Air cleaner and temperature regulator Removal and refitting. To remove the air cleaner, release spring retainers 14 (Fig. 2-76) and undo nut 7 securing air clean- er cover 8. Remove the cover and lift out filter element 10. Undo the nuts holding housing 13 to the carburettor. Disconnect hose 2, then remove the air cleaner and temperatur[...]

44 Fig.2-78. Fuel tank and fuel pipeline associated components 1 - fuel tank; 2 - hoses, fuel vapour separator and fuel tank; 3 - fuel vapour separator; 4 - filler pipe; 5 - cap; 6 - hose, fuel tank and filler pipe; 7 - hose, fuel vapour sepa - rator and fuel tank cover; 8 - fuel level sender; 9 - connection hoses; 10 - grommet; 11 - return flow li[...]

Check and renew any worn components. Always fit new pump gaskets, remember to lubricate the gaskets with a thin layer of grease before refitting them to the pump. Refitting pump to engine. For correct fitting, use two out of three gaskets as stated below: «Ä» gasket of 0.27-0.33 mm; «Ç» gasket of 0.70-0.80 mm «ë» gasket of 1.10-1.30 mm. Re[...]

Carburettor General description The engine is fitted with the 21073-1107010 carburettor (Fig.2-81) of emulsion, twin progressive throttle type. The carbu- rettor features a balanced float barrel, a system of drawing crankcase emission on the throttle body, a part throttle channel heater and secondary barrel locking. The carburettor has two main fue[...]

Table 2-2 21073-1107010 CARBURETTOR Parameters Primary barrel Secondary barrel Barrel diameter, mm 32 32 Venturi diameter,mm 24 24 Main jet system: • fuel jet marking* 107.5 117.5 • air jet marking 150 135 Emulsion tube, type ZD ZC Idling and air correction systems, primary barrel: • fuel jet marking 39 – • conventional flow,** air jet 14[...]

48 Fig.2-82. Main metering system: 1 - main air jets and emulsion tubes; 2 - atomizers, primary and secondary barrels; 3 - balance orifice; 4 - fuel filter; 5 - return pipe with calibrated orifice to petrol tank; 6 - needle valve; 7 - float; 8 - secondary throttle valve; 9 - main fuel jets; 10 - primary throttle valve Fig.2-83. Idling and air corre[...]

Main metering system. Fuel through gauze filter 4 (Fig. 2- 82) and needle valve 6 is fed to the float chamber. From the float chamber fuel flows through main fuel jets 9 to the emulsion wells to be mixed with air, escaping from emulsion tubes 1 which are built as one piece with the main air jets. Through atomizers 2 the air-fuel mixture flows to th[...]

engine speed. Inner profiles 4.1 and 4.2 operate choke lever 6 allowing choke opening to a certain amount at intermediate posi- tions of lever 4. Rotation of choke lever 4 anticlockwise causes the wider slot to release choke lever 6 stud; the choke is held in a fully closed position by return spring 7. At the same time the primary throttle is opene[...]

When the crankshaft speed goes down as low as 1900 rpm on the overrun, the control unit re-triggers the fuel cutoff solenoid to feed fuel through the idle jet, and the engine gradually shifts to idling. Secondary barrel locking. The secondary throttle can open only with the open choke when lever 5 edge (Fig.2-81) does not rest against pin 2 of the [...]

Undo shaft 19, extract ball 17 with the spring, remove choke lever 18, detach the choke lever spring. When applicable, undo choke retaining screws, withdraw plate 14 and spindle 16. Dismantle the diaphragm-type choke control unit, having removed cover 8 complete with adjusting screw 7. Lift out spring 6 and diaphragm 5 with the rod. Dismantle the c[...]

Float components. Wash the components in petrol and examine them. The floats must have no damages. Check to see there are no damages on the needle valve sealing face and seat which can result in the valve leakage. The valve must easily oper- ate in its socket, the ball should not stick. The float weight should not exceed 6.23 gram. Renew any damage[...]

Part throttle enrichment unit (economizer). The diaphragm must be integral and have no damages. Renew the diaphragm complete with the pushrod when the pushrod length (the head included) is less than 6.0 mm. Carburettor - reassembly Reassembly of the carburettor is a reverse of the dismantling procedure. Special attention should be drawn to the foll[...]

throttle must be fully closed. If not, adjust the pedal and throttle by means of end piece 10 at front rod 1 end. Secure the end of throttle linkage cable 3 so that with knob 5 pulled, the choke is fully closed, while with knob 5 pushed in - fully open. Engine idle adjustment. This is to be done via idle mixture adjustment screw 2 (Fig.2-91) and th[...]

Exhaust system Exhaust gases escape from the engine through the exhaust manifold, front exhaust pipe (downpipe) 2 (Fig.2-93), centre (front) silencer 7 and main (rear) silencer 6. Gasket 1 is fitted between the exhaust manifold and down- pipe. The silencer pipes are connected through their flared ends by means of clasps 4 with taper rings. Downpipe[...]

The design of the clutch is shown on fig. 3-1. The clutch release fork 11 (fig. 3-1) can be of two types: with a leaf or wire spring. Chapter 3. Power train Clutch 57 Fig. 3-1. Clutch assembly: 1 - bleeder; 2 - central diaphragm spring; 3 - diaphragm spring rivet; 4 - pressure plate; 5 - clutch disc; 6 - flywheel; 7 - clutch bellhousing; 8 - bellho[...]

Fault diagnosis Diagnosis Remedy Incomplete clutch release (clutch spin) 1. Excessive gaps in clutch release drive 2. Buckling of clutch disc (camming action more than 0.5 mm) 3. Roughness on clutch disc friction linings 4. Jammed rivets or broken clutch disc friction linings 5. Jammed clutch disc hub on primary shaft splines 6. Broken thrust flang[...]

Bleeding the clutch hydraulic system Air in the clutch hydraulic system is indicated by incomplete clutch release, and also by "sponginess" and "failure" of clutch pedal. To expel air from the hydraulic drive: - clean the tank and the bleeder from dust and dirt; - check the liquid level in the hydraulic system tank and top up if[...]

Clutch assembly - removal and refitting Removal. First remove the gearbox (see "Gearbox"). Undo the bolts and remove the clutch cover in assembly with the pressure plate. Do not lift this unit by holding the pressure plate thrust flange. Refitting is a reversal of removal, providing the following: - inspect the bearing on the crankshaft e[...]

Clutch inspection The inspection of the clutch is carried out on a bench, which simulates the engine flywheel and has a metal intermediate ring 4 (fig. 3-5) with thickness of 8.2 mm simulating the clutch disc. Having fixed the clutch cover, make four release strokes equal to 8-9 mm. The release stroke of 8 mm should correspond to the travel of the [...]

62 Fig. 3-8. Master cylinder components: 1 - body; 2 - sealing; 3 - plug; 4 - gasket; 5 - union; 6 - retaining washer;7 - cap; 8 - circlip; 9 - pushrod piston; 10 - sealing ring; 11 - master cylinder piston; 12 - spring Fig. 3-7. Straightening the clutch disc Fig. 3-9. Slave cylinder components: 1 - body; 2 - bleeder; 3 - cap; 4 - pushrod; 5 - seal[...]

Master and slave cylinders - dismantling, inspection, repair and reassembly Master cylinder. Turn out plug 3 (fig. 3-8), remove protective rubber cap 7 and circlip 8. This will allow to withdraw from the cylinder body piston 9, sealing ring 10, floating piston 11 with sealing ring and piston return spring 12. Cylinder mirror and the outer surface o[...]

Gearbox The design of the gearbox is shown on fig. 3-12, 3-26, 3-34. Fault diagnosis Diagnosis Remedy Noise in gearbox 1. Noise in bearings 2. Worn teeth on gears and syn- chro units 3. Low oil level in gearbox 4. Axial shaft movement Difficulty in engaging gears 1. Incomplete clutch release 2. Jammed gearshift lever ball- joint 3. Deformed gearshi[...]

65 Fig. 3-12. Gearbox: 1 - input shaft; 2 - front cover with guide sleeve; 3 - input shaft oil seal; 4 - spring washer; 5 - bearing set collar; 6 - gearbox housing; 7 - breather; 8 - output shaft needle bearing; 9 - synchro spring thrust washer; 10 - 4th speed synchro unit crown; 11 - 3rd/4th synchro unit sleeve; 12 - 3rd/4th synchro unit hub; 13 -[...]

Dismantling and reassembly Dismantling. Wash the gearbox and place it on a bench. Drain oil and remove the bottom cover with the lining. Remove the clutch release fork, and the coupling in assem- bly with the bearing and the spring from the guide sleeve in the gearbox front cover. Remove the clutch bellhousing with the lining and the front cover to[...]

Turn out the 3rd/4th gearshift fork fastening bolt. Install lock 41.7816. 4068 on the input shaft or simultaneously engage both gears. This will prevent the turning of the input, output and inter- mediate shafts and will allow to do the subsequent operations on dismantling. ATTENTION. Since 1997, on the rear end of the gearbox output shaft the desi[...]

68 Fig. 3-24. Removing the 5th synchro unit hub/reverse driven gear: 1 - intermediate shaft; 2 - reverse driven gear; 3 - reverse idler gear shaft; 4 - 5th synchro unit hub; 5 - output shaft; 6 - 1st/2nd selector rod; 7 - 3rd/4th selector rod Fig. 3-22. Removing the 5th speed/reverse selector rod: 1 - 5th/reverse selector rod; 2 - 5th/reverse fork;[...]

Simultaneously remove the reverse idler gear 1 (fig. 3-23) from the shaft, gear 3 in assembly with the coupling and fork 4 from the output shaft. With the help of a special mandrel (like a screwdriver) remove the 5th synchro unit hub together with reverse driven gear 2 from key 4 (fig. 3-24). With the help of a special mandrel (like a screwdriver) [...]

With the help of a special mandrel (like a screwdriver) take out the input shaft together with the bearing and the synchro unit ring (fig. 3-28) and remove the needle bearing from the front end of the output shaft. Punch out the output shaft from the idler bearing, take out the idler bearing and, having inclined as shown on fig. 3-29, take out from[...]

- note visually the location of parts relative to risk A (fig. 3-34), made on the directing plate, so that to reassemble the parts in the same order; - having undone the nuts from the fastening bolts, separate the parts of the gear selector mechanism and remove lever 9, ball socket 4 and rubber sealing rings 15. The reassembly of the gearbox is car[...]

On surfaces mating with the clutch housing, with the rear and bottom covers there should be no damages that may cause oil leak. Insignificant damages should be smoothed with a file. If parts are badly damaged or worn, renew them. Check the condition of the front cover and ensure that the input shaft does not touch it when rotating. If the shaft and[...]

should be no roughness or scuffings on the rolling surfaces of the shaft front end. Check the condition of needle rolling surface in the opening of the primary shaft. Examine the intermediate shaft, no chipping or excessive wear of teeth is allowed. The surface of the reverse gear shaft should be absolutely smooth, with no traces of jamming. The mo[...]

Spontaneous gear or differential lock disengagement 1. Worn teeth on gears and cou- plings 2. Weak detent spring or detent component wear 3. Incomplete gear engagement and differential lock due to drive system component damage or due to dents on gears, clutches or splines Oil leak 1. Damaged sealings 2. Loose nuts and pins fixing cov- ers to casing[...]

- refit and tighten the flange fastening bolts on the transfer box and the layshaft; if the bolts fit perfectly in the apertures of the flanges, the centering is carried out correctly, otherwise the flanges should be re-aligned. Dismantle and reassembly Dismantle. Wash the transfer box and drain oil. Place the transfer box on a bench for dismantle [...]

76 Fig. 3-36. Transfer box operating system: 1 - differential locking clutch yoke; 2 - differential locking clutch; 3 - yoke stop bolt; 4 - boot; 5 - lever spring; 6 - differential locking fork rod; 7 - front axle case cover; 8 - lock washer; 9 - lever shaft bush; 10 - lever shaft; 11 - differential locking lever; 12 - gear shift fork rod; 13 - gea[...]

Remove the bearing setting rings from the front and rear drive shafts. Take the front axle drive shaft 11 (see fig. 3-35) out from the casing together with bearing 8, thrust ring and oil deflec- tor 9. Take the rear axle drive shaft out from the rear cover 31 together with bearing 36, thrust ring and oil deflector. Remove cover 21 from the input sh[...]

Remove front cover 4 (fig. 3-40) with the differential, fit the differential bearing setting ring and take out the bearing in assembly with the differential from the front cover. Remove the setting rings from the bearings of the drive- and intermediate shafts and remove both input- and layshafts from the transfer box casing. Grip the input shaft in[...]

- remove circlips 8 (see fig. 3-42) and spring washer 14, then press out the differential pinion shaft and remove the differential pinions and the drive shaft gears with support washers. Press out worn or damaged oil seals from the front axle case, from the front bearing cover and from the rear cover. Undo the nuts from the axle support pad and rem[...]

After reassembly, top-up oil in the transfer box to the lower edge of the filler neck. Inspection Prior to inspection, all parts of the transfer box should be carefully cleaned with a brush and a scraper, and then washed. Blow the parts with a jet of compressed air. Especially carefully wash and blow the bearings, but do not let them to rotate quic[...]

Noise and vibration of propeller shafts 1. Deformation of front or rear pro- peller shaft 2. Propeller shafts out-of-balance 3. Worn or damaged centering bush on layshaft flexible coupling flange 4. Worn U-joint 5. Loose grease seal retainer on spline joint of front or rear pro- peller shaft 6. Insufficient greasing of spline joints Lubrication lea[...]

Spline joint. Check the gap in the spline joint of the sliding yoke of the forward and rear shafts. The maximum allowable backlash on the spline middle diameter is 0.30 mm. Check for the plug in yoke 5 (fig. 3-48), inspect retainer 7 and seal 6 of the sliding yoke. If necessary, renew the seal, and the retainer if damaged. U-joint. Inspect the bear[...]

Using two feeler gauges 2, with 4 and 3 blades of different thickness accordingly, determine which will tightly fit in the clear- ance H between the base of the bearing and the yoke groove end face, and install a circlip of the same thickness. Note. One feeler gauge has blades with thickness of 1.45; 1.48; 1.52; 1.56 mm, the other one - 1.60; 1.64;[...]

Rear axle The design of the rear axle is shown on fig. 3-54. Fault diagnosis Diagnosis Remedy Excessive noise from the rear wheels 1. Loose wheel fastening 2. Worn or failed axle shaft ball bearing Constant excessive noise at rear axle operation 1. Deformed rear axle beam, damaged axle shaft bearings 2. Damaged axle shafts and intolerable runout 3.[...]

Check the beam deformation by attaching a try square to the outer (fig. 3-56) and side (fig. 3-57) surfaces of the flange A.70172; if the beam is not deformed, the try square will fit per- fectly. Size of deformation is checked by a probe. If a 0.2 mm gauge passes through on any of the flanges, the beam should be straightened. Using a try square (f[...]

If deformation exceeds this size, straighten the beam, follow- ing the procedure given below. After straightening, carefully wash the beam, clean the mag- netic plug, put it in place and check the following: - quality of weld seams and leak-proofness of the beam; - the beam breather and the beam should be clean inside (no burrs, chippings or oil re[...]

graphite greasing or ãëñ-15. After refitting, check the operation of axle shafts during an actual road test. Inspection Inspect the parts composing a complete set, and make sure that: - bearing is not worn and is not damaged; if the axial gap exceeds 0.7 mm, renew the bearing; - stop ring and bearing are not shifted in relation to the initial po[...]

After press-fitting, ensure, that the ring does not shift under the axial load of 19.6 kN (2000 kgf). To do this, place the axle shaft assembly on a special fixture (fig. 3-63), and grip the stop ring in special vice. Attach the leg of indicator 1 with scale interval of 0.01 mm to the axle shaft flange. Set the arrow to "0" and apply the [...]

Test 2. Accelerate the vehicle approximately up to 100 km/h, place the gear shift lever in neutral, switch off ignition and let the vehicle to roll on to a stop; listen to the noise character at various speeds during deceleration. ATTENTION. With the ignition switched off, be attentive and careful. Do not turn the key more than it is necessary, as [...]

- turn the differential side gears and differential pinions so that the last ones will roll out from the differential openings, then take them out; - remove the differential side gears with support washers. Inspection of reduction gear components Before inspection carefully wash all parts. It will help to locate wear and damages. Check for damages [...]

fails to be achieved even by increasing the washer thickness, renew the gears due to their excessive wear. Fix the gear on the differential box. Using tool A.70152 press-fit the roller bearing inner rings on the differential box. Drive gear - refitting and adjustment The correct location of the drive gear against the driven gear is provided by sele[...]

In this case fit an adjusting ring with thickness of 3.05 mm. Fit an adjusting ring of the necessary thickness on the driving gear and press fit using tool A.70152 (fig. 3-74) the rear bearing inner ring which was taken from tool A.70184. Fit the distance sleeve. ATTENTION. When repairing the rear axle reduction gear, install a new distance sleeve,[...]

Differential housing bearings preload and adjustment of the side gap in final drive gears mesh These operations are carried out simultaneously using tool A.95688/R and key A.55085. Fix the tool on the reduction gear casing (see fig. 3-77) with screws 1 and 6, having screwed them in the bolt apertures for the adjusting nut lock plate. Move bracket 7[...]

After moving the driven gear, check the side gap by indicator 2 (see fig. 3-78). Repeat the adjustment if the clearance does not correspond to the rated value. Remove tool A.95688/R, fit the adjusting nut lock plates and fix them by bolts with spring washers. In spare parts the lock plates are delivered of two types: with one or two tabs depending [...]

driven gear teeth the contact pattern is located in regular intervals closer to the narrow end of the tooth, occupying two thirds of length and without covering the top and the base of the tooth, as shown on fig. 3-80, e. The examples of wrong location of contact pattern on the tooth working surface are shown on fig. 3-80 (a, b, c, d). The unit wil[...]

Front axle The design of the front axle is shown on fig. 3-81. A number "13" is painted on the reduction gear casing for distinction. Fault diagnosis Diagnosis Remedy Constant excessive noise at front axle operation 1. Worn or badly adjusted differ- ential bearings 2. Wrong adjustment, damage or wear of gears or bearings of reduction gear[...]

ing the guidelines given in subsection "Rear axle", distance "D" (see fig. 3-79) should increase by 0.08 - 0.11 mm. For adjustment use bracket 67.8701.9508 with a measuring end piece and key 67.7812.9520. Place cover 12 with sealing 8 on the inner joint bearing cas- ing 9 (see fig. 3-81), then press fit bearing 7. Refit spring w[...]

state this ring should pass free through the spline opening in race 11, what allows to connect and to separate the joint and shaft 4. The joint is protected by boot 6 from dirt and moisture, which in its turn is protected from mechanical damages by shroud 5. On the shaft 4 and on the joint case the shroud is fixed by clamps 9. The use of straight g[...]

- using a knock-out and a hammer, beat the inner joint race from shaft 4; - after removing the thrust ring, move the shroud from the shaft; - wash the inner cavities of the joint housings and other com- ponents. The most difficult and crucial are the operations on disman- tling and reassembling the outer joint, the components of which are shown on [...]

Chapter 4 Wheel suspensions Fault diagnosis Noise and knock in suspension at vehicle movement 1. Faulty shock-absorbers 2. Loose anti-roll bar fastening bolts 3. Worn arm silent blocks 4. Loose shock-absorber fastening or worn shock absorber eye rubber bushes 5. Worn arm balljoints 6. Excessive gap in wheel hub bearings 7. Wheels significantly out [...]

Un-even tyre tread wear 1. Excessive speed at cornering 2. Excessive wear of suspension joints and bushes 3. Wheels out of balance (stains in regular intervals on tread outer path and on central path when driving with a disbalanced wheel for a long time) 4. Uneven wheel braking 5. Shock-absorbers do not work 6. Wheel camber misalignment (wear of tr[...]

Excessive wear of tyre tread 1. High driving speed 2. Heavy vehicle acceleration 3. Often braking 4. Wrong wheel alignment angles 5. Excessive clearance in front wheel hub bearings 6. Vehicle overload 7. Recommended rearrangement of wheels was not carried out Tyres squeal at cornering 1. Abnormal tyre pressure 2. Wrong wheel alignment angle 3. Defo[...]

Front wheel alignment angle - checking and adjustment The check and adjustment of the front wheel alignment angle is carried out on special test-benches according to the instruc- tions. ATTENTION. It is necessary to check the wheel align- ment angle after replacement or repair of suspension com- ponents, that could have caused the misalignment of w[...]

104 Before adjusting the wheel alignment angles check the fol- lowing: - pressure in tyres; - axial gap in front wheel hub bearings; - serviceability of shock-absorbers (absence of rod jamming); - radial and axial runout of tyres; - gap in suspension balljoints; - free play of steering wheel. Rectify any detected malfunctions and make necessary adj[...]

105 After adjustment, refit the fastening clamps with the slot fac- ing back with allowable deviation downward by 60° to the hori- zontal plane of the vehicle. With the nuts tightened the clamp slot edges should not contact. After toe-in adjustment, ensure that wheels and steering mechanism components do not hit the adjacent components of the susp[...]

- remove old greasing and wash with kerosine the inner cav- ity of the steering knuckle, the outer and inner cavities of the hub, the CV-join case tail and bearings; - fill 40 gr of fresh ãàíé ã-24 in bearing cages, spread even- ly in the cavity of the steering knuckle between the bearings, grease the splines of the joint casing tail; - fit th[...]

Note. When removing the upper arm shaft, note the amount and arrangement of washers between the upper arm shaft and the crossmember, and also the number of shims between the crossmember and car body chassis arm, so that at refitting all washers and shims will be properly replaced. Disconnect the engine mounting rubber pads from the cross- member br[...]

- remove the front wheel hub in assembly with the brake disc, using pusher 67.7823.9516; - remove the front brake splash guard; - remove the front suspension shock-absorber; - lower the suspension lower arm on a support and compress the suspension spring to fully unload the lower arm; - disconnect the balljoint housing from the suspension lower and[...]

the front suspension, it is permissible to install the A class springs on the front suspension. But you can not install the B class springs on the front suspension, if the A class springs are installed on the rear suspension. Inspect the gaskets and renew, if they have damages. Anti-roll bar, suspension arms, steering knuckle. Check the bar for def[...]

The lower arm. The pressing-out and press-fitting of the joint can be carried out on a press, using tool 67.7823.9526, and also with tool 67.7823.9517 (fig. 4-12), which is installed on the arm so that the head of the tool screw was directed inside. Tighten the tool screw to press out the joint. For press fitting, insert the joint into the arm beze[...]

for the rear suspension, it is permissible to install the B class springs (with black marking). If on the front suspension the springs of B class are installed, the rear suspension should be fit- ted with B class springs only. To avoid damage and excessive tightening of control arm rubber bushes and shock-absorbers: - load the rear part of the vehi[...]

112 Fig. 4-18. Front and rear suspension shock absorbers: 1 - lower eye; 2 - compression valve body; 3 - compression valve discs; 4 - compression valve throttling disc; 5 - compression valve spring; 6 - compression valve holder; 7 - compression valve cap; 8 - recoil valve nut; 9 - recoil valve spring; 10 - shock absorber piston; 11 - recoil valve c[...]

speed of 60 min -1 , rod stroke length of 80 mm for the front shock- absorber, and 100 mm - for the rear one. The curve of the diagram (fig. 4-19) should be smooth, and in points of transition (from the recoil stroke to the compression stroke) - without areas parallel to zero line. Evaluation of diagram results. The resistance of recoil and compres[...]

Chapter 5. Steering The steering mechanism design is shown on fig. 5-1, 5-2. Since November, 1998, vehicles are fitted with a telescopic intermediate shaft instead of a cylindrical intermediate shaft 17 (see fig. 5-1) and the steering wheel 19 is fastened by a self-lock- ing nut. There are two variants of fitting the steering pitman arm roller: on [...]

115 Fig. 5-2. Steering mechanism, sectional view: 1 - adjuster screw plate; 2 - adjuster screw; 3 - cap; 4 - screw nut; 5 - oil filler plug; 6 - cover; 7 - worm; 8 - housing; 9 - drop arm; 10 - securing nut; 11 - spring washer; 12 - oil seal; 13 - bronze bush; 14 - drop arm shaft; 15 - drop arm shaft roller; 16 - worm shaft; 17 - upper ball bearing[...]

Steering - inspection, check and adjustment General inspection The steering system should be examined at any signs of mal- function (rattle, excessive free play of the steering wheel or, on the contrary, its hard rotation, and so on). The inspection is car- ried out on the trestles or an inspection pit in the following order. Clean the components o[...]

Inspect the tie-rod balljoint protective caps. If the protective caps are in good condition and provide inside cleanness, their service life is practically unlimited. Moisture, dust and other foreign particles inside the joint will result in premature wear of components. The cap should be replaced in case of cracks, breaks and in case greasing is s[...]

tening nut and fix it in three points. Move the combination switch case fully towards the steering wheel, and tighten the switch fas- tening clip. Reconnect the wires of the ignition switch and fix the switch on the steering column bracket with screws. Reconnect the combination switch plugs to the vehicle har- ness plugs. Refit both halves of the s[...]

6). Undo the fastening bolt, take off cover 12 (see fig. 5-5) of the steering box together with cap, adjusting screw 8, adjusting plate 9, lock washer 10 and jam nut. Take out from the steering box 1 the pitman arm shaft 7 in assembly with the roller. Undo the fastening bolt, remove cover 3 from the worm shaft thrust bearings together with shims 4.[...]

After press-fitting in the steering box, finally process the bushes with a reamer A.90336 up to the size of 28.698-28.720 mm. The mounting gap between the pitman arm shaft and the bushes should be within 0.008-0.051 mm. Check for easy rotation of the pitman arm roller on the ball bearing. The ball bearings on the worm and the roller should rotate f[...]

Chapter 6 Braking system The design of the braking system is shown on fig. 6-1. Fault diagnosis Diagnosis Remedy Insufficient efficiency of braking 1. Leak of brake liquid from wheel cylinders of front or rear brakes 2. Air in brake system 3. Damaged rubber sealings in master brake cylinder 4. Damaged hydraulic system rub- ber hoses Spontaneous bra[...]

122 Fig. 6-1. Braking system: 1 - rear brake wheel cylinder; 2 - parking brake rear cable; 3 - rear brake guide; 4 - parking brake front cable; 5 - parking brake lever; 6 - brake pedal; 7 - servo unit; 8 - second circuit pipeline; 9 - primary circuit pipeline; 10 - master cylinder; 11 - wheel cylinder block, front brakes; 12 - master cylinder tank;[...]

Renew the components in the slightest doubt in serviceability. Flexible hoses, irrespective their condition, should be renewed after 100000 km or after 5 years of vehicle operation to prevent sudden breaks due to aging. After five years of operation it is recommended to renew the brake liquid. Servo unit -serviceability check Press the brake pedal [...]

Ask an assistant to press the brake pedal with effort of 686- 784 N (70-80 kgf) and simultaneously observe the outcoming part of the pressure regulator piston. If the piston moves by 0.5-0.9 mm in relation to the regulator housing, thus twisting the torsion arm, the pressure regulator is efficient. Repeat the pedal depressing 2-3 times to completel[...]

Raise the protective rubber cap 6 (see fig. 6-5) and, by turn- ing the pressure regulator on the bolts, get a slight contact between the arm and piston 2. Keep the regulator in this position, fully tighten bolts 1 and 7, then apply a thin layer of greasing Ñí -1 on shaft 5 and the work- ing part of piston 2. Fill 5-6 gr. of the same greasing in r[...]

Clutch and brake pedal bracket Removal and refitting. To remove the pedal bracket: - remove the steering shaft bracket, as mentioned in section "Steering"; - disconnect the servo unit push rod from the brake pedal, having removed lock shackle 26 (fig. 6-8) and taken out pin 24; - disconnect the wires from the stoplight switch; - undo the [...]

Check and repair. At hard pedal movement examine the working surfaces of pedals, bushes and shaft. If there will be small risks or traces of oxidation on surfaces of metal parts, grind them slightly with sandpaper; renew worn outer plastic bushes on pedals. Check the spring tension. The length of the brake pedal spring should be: under load of 12.8[...]

Inspection of components . Before reassembly, wash all components with isopropyl alcohol; dry by a jet of compressed air or wipe with a clean cloth, but do not allow their contact with min- eral oil, kerosine or diesel fuel, which can damage the sealings. Note. Time of washing the sealing rings in isopropyl alcohol is no more than 20 seconds with s[...]

Forcing a jet of compressed air through the aperture for brake liquid, push out pistons 14 from the cylinder block and take out sealing rings 4. The reassembly of the front brake is carried out in sequence reverse to dismantle. When assembling, lubricate the sealing rings, pistons and cylinder mirrors with brake liquid, and grease the protective ca[...]

assembly and take out the worn pads from the carrier grooves (fig. 6-16); - carefully depress the pistons in cylinders to a stop, paying attention not to splash the liquid from the master cylinder reser- voir, and place new brake pads in carrier grooves; - move the lower directing splay on the caliper under the lower clamping lever, press the calip[...]

The reassembly of the automatic adjuster and the wheel cylinder is carried out in reverse sequence, paying attention to the following: - piston thrust screws are tightened to torque 4-7 N•m (0.4- 0.7 kgf•m); - slot A (see fig. 6-19) on thrust rings should be directed ver- tically upward; vertical deviation should be no more than 30 ° . Such po[...]

Brake drums. Examine the brake drums. If the working sur- faces have deep risks or excessive ovality, chisel the drums. Then grind on a machine tool with abrasive fine stones. This will help to increase the lining durability, and improve the uniformity and efficiency of braking. The maximum allowable increase of drum nominal diameter (250 mm) after[...]

Remove the regulator and disconnect the arm. Plug all open- ings of the pressure regulator and pipelines. Refitting of the pressure regulator is carried out in reverse sequence. Before tightening the regulator fastening bolt place tool 67.7820.9519 (see fig. 6-6) on the end of the regulator arm. Direct the tool bar upwards to the car body. Thus, th[...]

Handbrake Removal and refitting . Place the handbrake lever in the lowest position, disconnect the cable ends from the brake shoe levers (see "Rear brake"). Slacken locknut 5 (see fig. 6-4) and adjusting nut 6, remove return spring 9 (fig. 6-24), then completely undo the locknut and nut. Take out the front end pieces of the rear cable fro[...]

135[...]

136[...]

ëhapter 7. Electrical system Wiring and fuses The electrical system is of the single-wire negative earth type. The vehicle basic wiring diagram is illustrated in Fig.7-1. Most electrical circuits are powered when the ignition is switched on. Regardless the ignition switch position, the follow- ing functions are available: horn, stoplight, cigarett[...]

136 Fig.7-1. Electrical system of VAZ-21213 vehicle: 1 - left-hand front headlamp; 2 - headlights; 3 - left-hand headlamp wiper motor; 4 - horn; 5 - fuel cutoff solenoid; 6 - idle switch; 7 - headlight washer motor; 8 - right-hand headlight wiper motor; 9 - right-hand front headlamp; 10 - side repeaters; 11 - battery; 12 - heater motor; 13 - heater[...]

137 - stop light switch; 40 - cigarette lighter; 41 - exterior light switch; 42 - heater controls illumination; 43 - rear fog light switch; 44 - rear window heating switch; 45 - heater motor switch; 46 - rear window wipe/wash switch; 47 - hazard warning flasher switch; 48 - ignition switch; 49 - instrument lighting switch; 50 - windscreen wiper swi[...]

Battery Specification Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 6ëí -55Ä, maintenance-free Maximum voltage,volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Maximum capacity (at 20-hour discharge rate and initial electrolyte temperature of (27±2)°ë, ampere-hour . . . . . . . . . . . . . . . . . . . [...]

Table 7-3 Temperature correction values to hydrometer readings for measuring electrolyte density Electrolyte temperature, °ë Correction value, g/cm 3 -40 to -26 -0.04 -25 to -11 -0.03 -10 to +4 -0.02 +5 to +19 -0.01 +20 to +30 0.00 +31 to +45 +0.01 With electrolyte temperatures over 30°ë, the correction value is added to actual hydrometer readi[...]

Alternator Specification Maximum current output (at 13 volts and 5000 rpm ), amp . . 55 Adjustable voltage range , volts . . . . . . . . . . . . . . . . . . 14.1±0.5 Maximum rotor speed , rpm . . . . . . . . . . . . . . . . . . . . . . 13,000 Engine-to-alternator ratio . . . . . . . . . . . . . . . . . . . . . . . . 1:2.04 General description The [...]

Fault diagnosis Cause Remedy Warning light does not light up when ignition is switched on. Instruments inoperative 1. Blown fuse 2 in fuse box 2. Broken supply circuit in instru- ment cluster: - no voltage between terminal «Å» of main fusebox and instrument cluster; - no voltage between ignition relay and fusebox unit 3. Ignition switch or ignit[...]

Mount the alternator on the tester and connect as shown in Fig.7-5. Start the tester motor, using rheostat 4, set the alternator output voltage at 13 volts and raise the rotor speed to 5000 rpm. Run the alternator at this speed for at least 10 minutes and then measure the alternator output amperage. The reading for a sound alternator should not be [...]

When necessary, sand the slip rings with emery paper, then check the winding for continuity or earthing with an ohmmeter or a test bulb. Stator - testing The stator is tested separately after dismantling the alterna- tor and disconnecting the winding from the diodes. First test the stator winding for continuity or earthing using an ohmmeter or a te[...]

An illuminated bulb advises about short-circuit in one or more supplementary diodes. The damaged diode can be identified only after removing the diode plate and checking each diode. Discontinuity in the supplementary diodes can be detected with an oscilloscope through distortions in the voltage waveform across terminal 61 and also by low voltage (b[...]

remove housing 4. Disconnect lead 6 from alternator terminal 61 and undo contact bolt extension 5. Lock the alternator pulley with a tool from kit 67.7823.9504, undo the pulley retaining nut and press the pulley out using a puller. Remove the pulley key and taper washer. Tool kit 67.7823.9504 includes an ordinary picker and a grip. The grip consist[...]

Brush holder - renewal Always renew the complete unit if the regulator fails or brush- es are worn or protrude from the holder to less than 5 mm. In case of pre-1996 alternators, force the brush holder out of the voltage regulator housing by pressing the terminal «Ç». Avoid damaging the brushes, so remove and refit the regulator with the brush h[...]

Solenoid repetitive cutting in and out 1. Battery discharged 2. Excessive voltage drop in sole- noid power circuit caused by badly oxidized lead ends 3. Solenoid holding winding bro- ken or shorted Starter motor armature rotates, flywheel inoperative 1. Overrun clutch slipping 2. Clutch operating lever broken or pivot shaft dropped 3. One-way clutc[...]

148 Fig.7-13. Starter motor (35.3708 model): 1 - pinion; 2 - overrun clutch; 3 - guide ring; 4 - rubber plug; 5 - operating lever; 6 - drive-end housing; 7 - relay armature; 8 - relay winding; 9 - contact plate; 10 - relay cover; 11 - terminal bolts; 12 - commutator; 13 - brush; 14 - armature shaft bush; 15 - commutator-end housing; 16 - end cover;[...]

To withdraw the actuator unit from the armature, retrieve the circlip from under stop collar 16. Dismantle the actuator unit after removing the lockwasher from the clutch hub. To dismantle the solenoid, undo the clamp bolt nuts and unsolder the winding leads from terminal 50 and from the end which is secured at the bottom solenoid terminal bolt. On[...]

Ignition distributor is of 3810.3706 model, four-event sparking rate, non-shielded, with vacuum and centrifugal advance units, with built-in Hall sender. Spark control module is of 3620.373 model, or 76.3734, or RT1903, or PZE4022, or ä563.3747 model. The module process- es the control output pulses from the Hall sender into current pulses for the[...]

Engine gasps at all speeds 1. Ignition wires damaged, con- nections loose or lead ends oxi- dized 2. Electrodes worn or oily spark plugs, strong fouling; cracks in plug insulation 3. Carbon brush in ignition distrib- utor worn or damaged 4. Strong burning of central con- tact point on distributor rotor arm 5. Cracks, fouling or burnings of rotor ar[...]

- start the engine and point the flashing timing light at the tim- ing mark on the pulley; when the ignition is correct, then at idling speed the TDC mark on the flywheel should be as outlined in Attachment 3. To adjust the ignition timing, switch off the engine, slacken the nuts securing the ignition distributor and turn the latter to the angle de[...]

up to 1500 rpm or the thicker spring bracket for speeds over 1500 rpm. Increase the spring tension for a smaller angle (retard) or decrease the spring tension for a bigger angle (advance). To obtain the vacuum advance pattern, connect the vacuum advance unit to the vacuum pump of the tester. Operate the tester motor and run the distributor drivesha[...]

Resistance of the insulation to earth should be at least 50 MOhm. Spark control module The spark control module can be tested using an oscilloscope and square wave pulse generator connected as shown in Fig.7- 25. The pulse generator resistance should be 100-500 Ohm. It is preferable to use a double-channel oscilloscope - the 1st channel is for the [...]

When sparking occurs at the pressure below 0.3 åPa (3 kgf/Òm 2 ), the spark plug is defective. Only a few sparks are allowed in the spark gap; when no sparking is observed either on the spark plug or in the spark gap, it is likely that the insulation is cracked and the central electrode arcs internally to earth. Always discard such spark plugs. I[...]

156 Fig.7-29. Wiring diagram for exterior lighting: 1 - sidelights in headlights; 2 - fusebox; 3 - exterior light switch; 4 - instrument illumination switch; 5 - exterior light warning lamp in instrument cluster; 6 - number plate lamp; 7 - sidelights in rear light units; Ä - to illumination lamps for instruments, switches and heater controls Fig.7[...]

General description The headlight wiring diagram is shown in Fig.7-28. High and low beam is operated through supplementary relays 3 and 11. The control voltage to the relay winding is supplied from headlight combination switch 10 when external light push switch 5 is fully depressed. Regardless the position of push switch 5, the high beam can be bri[...]

Three vertical lines should be drawn on the screen (Fig.7-32): centre line O and lines A and B through the reference points Ö cor- responding to each headlamp center. These lines should run sym- metrical to the centre line of the car. Draw line 1 at the height of 600 mm which is the distance to the centres from the ground and 75 mm below draw line[...]

Indicators flasher relay Relay 8 (Fig.7-30) (231.3747 model) is intended for intermit- tent light signals both for direction indication and hazard flashing. It also allows to identify a failed bulb in the direction indicator. With good bulbs in the direction indication mode, the relay ensures flashing warning light 7. With a failed bulb in the dire[...]

Continuous operation of wiper blades in intermittent mode 1. Wiper relay breaker winding blown 2. Motor gear cam does not oper- ate limit switch spring plate 3. Foul motor limit switch contacts 4. Foul wiper relay breaker con- tacts Wiper stops in intermittent mode. Blades do not stop at park position Motor limit switch contacts cor- roded or close[...]

Wiper motor - dismantling, reassembly and inspection Commence to dismantle the motor by undoing cover 1 (Fig.7- 35) retaining screws. Remove the cover complete with plate 2. Next unscrew cover 16 from motor housing 7 and separate them. Extract arma- ture 8 from the motor housing. To remove motor gear 3, undo crank 9 retaining nut, retrieve the circ[...]

Rear window wipe/wash and heating, cigarette lighter The rear window wiper includes a motor of 471.3730 model, arm and blade. The wiper arm and blade have a right-hand park position as viewed with the vehicle in forward motion. The motor has a thermal bimetal fuse for overload protection. The washer motor integral with the pump is secured on the br[...]

Blower motor specification Shaft speed (with fan impeller load) at 12 v and (25±10)°ë, rpm . . . . . . . . . . . . . . . . . . . . . . . .3000±150 Consumption current at the load and rpm as above, ampere, not greater . . . . . . . . . . . . . . . . . . . . . . . . 4.5 Fault diagnosis Cause Remedy Motor does not operate 1. Wires damaged or wire [...]

Instrument cluster - removal and refitting The instrument cluster is removed as follows: - disconnect the battery negative lead; - undo the screws holding the facia, pull the bottom edge of the facia and release the top catches; - undo the two securing nuts and withdraw the instrument cluster from the facia; - disconnect the wiring and speedometer [...]

Instrument cluster - dismantling and reassembly Undo the trip counter knob by pulling it outward, then remove the surround and glass, having first released its bottom edge from the retaining spring wire. Undo the nuts holding the instru- ments to the PCB and withdraw the instruments. Reassembly is the reverse of the dismantling procedure. Instrumen[...]

Table 7-7 Coolant temperature sender specification Temperature, Supply voltage, Resistance, °ë volts Ohm 30 8 1350-1880 50 7.6 585-820 70 6.85 280-390 90 5.8 155-196 110 4.7 87-109 Low oil pressure warning light switch. The switch is fitted to the cylinder head. The switch contacts should close and open at 20-60 kPa (0.2-0.6 kgf/cm 2 ). Fuel gaug[...]

Chapter 8. Bodywork Fault diagnosis Cause Remedy Dark spots over bodywork 1. Hot water was used for washing (above 80°ë) 2. Leaded petrol or other aggressive agents were used for dewaxing Pink spots over light painted surfaces Deterioration by coolant Lighter spots over dark painted surfaces Deterioration by moisture due to prolonged vehicle stor[...]

Cause Remedy Failure to lock bonnet 1. Lock spring broken or loose 2. Shorter lock operating link 3. Incorrect position of lock Failure to secure sliding glass in position Spring brake of window lifter broken Excessive efforts or failure to recline front seat back forward or rearward 1. Excessive friction in seat reclining mechanism 2. Worn compone[...]

Bodywork - repair Refer to Fig.8-1, Fig.8-2 and Fig.8-3 for body frame design and relevant cross-sections. 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 si[...]

170 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 - re[...]

171 Polyester fillers of «ïÂÏÔÓÔÓÎ-è» or èù-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 ° ë. The mixture of polyester fi[...]

172 Chip off the wing with a sharp thin chisel or cut with a grind- ing tool over the lines as shown in Fig.8-5. Detach the wing, remove the remainders of the wing, straight- en the deformed edges and smooth them with an electric or pneumatic grinding tool. Refit the front door and new wing, secure the wing using quick detachable grips. Weld the wi[...]

over the weld seams and on the joints of the replaced parts. Remove the stopper surplus with a cleaning cloth moistened in white spirit. Ensure the surrounding area is protected against overspray (use genuine masking tape or several thickness of newspaper). With the aid of a spray gun, apply primer like É î-073 or Çã- 023 over the areas rubbed [...]

- position the vehicle on a lift, dismantle all relevant compo- nents and trims which may obstruct access to box sections; - through provisional or drain holes flush inner cavities and the underbody with warm (40-50 ° ë) water (Table 8-2) until the drained water is clean. Do not forget to fully close the windows; - remove any water penetrated int[...]

When only the Ñ-11Ä plastisol coating is affected, while the primer is intact, scour any dirt from the relevant areas, then on a dry surface apply Åèå-1-type plastisol by means of a brush or airless spray (1.5 mm thick). Allow to dry at ambient temperature within a day or at 90 ° ë within 30 minutes. In the event of major damages of protecti[...]

176 Fig.8-9. Rubber seals: 1 - of swivel glass; 2 - front door seal frame; 3 - seal molding; 4 - front door seal; 5 - of sliding glass; 6 - of tailgate aperture; 7 - of side window; 8 - lower seal of sliding win- dow; 9 - of windscreen; 10 - drain pipe; 11 - bonnet seal; 12 - of air intake; 13 - of front bumper connection Fig.8-10. Locations for 51[...]

Door Front door - removal and refitting Fully open the door, push out the finger holding the check strap to the front pillar and disconnect the check strap. Hold the door open and using impact screwdriver 2 (Fig.8- 12), undo screws 1 securing the door hinges to the pillar. Withdraw the door. Refitting is the reversal of removal. Prior to finally ti[...]

With the sliding glass fully up, undo the retaining screws and remove the front and rear glass guide channel. Slide the window down and slacken the window lifter tension roller. Detach the cable from the sliding glass holder and remove it from the rollers. Holding the cable taut, undo the retaining nuts and withdraw the window regulator. Clamp the [...]

It is a good practice to mark the door striker contour on the body pillar before making any alignments. If the door fits too tight, slacken the door striker securing screws, move the striker outward and tighten the screws. If the door fails to close firmly, move the striker inward. Check to see the door is not seized and lines up within the body ap[...]

Bumpers - removal and refitting The bumpers (Fig.8-22) are made from aluminium profile, with the face lined lengthwise with black rubber strip 8. The bumper ends are fitted with plastic black cover plates 6. Both bumpers are secured to the body with two bolts to be undone when removing the bumpers. Refitting is reversal to removal. Bodywork glazing[...]

together with the filter gauze. Extract sleeve 3, then carefully tap- ping rotor 9 shaft 6, push support 7 out and withdraw the shaft and rotor. Reassembly is a reversal of dismantling. Removal and refitting of washer jets. Working from the engine bay, slightly squeeze the holders of plastic housing 1 (Fig.8-27), next pick its top with a screwdrive[...]

182 8Fig.8-30. Seats: 1 - seat back; 2 - headrest; 3 - headrest frame; 4 - headrest guide; 5 - cotter pin; 6 - front seat back frame; 7 - rear seat back trim; 8 - trim backing; 9 - seat back catch; 10 - seat back clamp; 11 - seat back base; 12 - cushion base; 13 - carpet; 14 - rear seat cushion padding; 15 - seat back rake adjuster knob; 16 - retai[...]

When necessary, remove the centre facia and side facia vent nozzles together with the associated air ducts. Refitting is a reversal of removal. Seats - removal and refitting The front seats design is shown in Fig.8-30, Fig.8-31 and Fig.8-32. Front seats. To remove the seat, move it fully forward, undo the rear bolts securing the rails to the floor.[...]

- remove the instrument panel surround, through this aper- ture, working on bracket 7, loosen the screws of air intake cover 12 cable clips and windscreen heating duct shutter 3. Remove the rods from the control levers; - undo the nuts holding heater matrix 15 housing to air intake 14, disconnect the negative lead secured under one of the nuts, rem[...]

Chapter 9. VAZ-21213 vehicle modifications, alternative and additional equipment VAZ-21214 vehicle The VAZ-21214 vehicle is fitted with 1.7-L engine, Central Fuel Injection (CFI). Instead of the carburettor, a single injector is used for injecting fuel into the central injection unit. Here fuel is mixed with air, the resulting combustion mixture is[...]

Central Injection Unit Removal and refitting Select the neutral position of the gearchange lever and apply the handbrake. Since, after the engine is stalled, fuel remains under pres- sure, always depressurize the fuel system. To do this, disconnect the fuel pump wiring plug from the injection wiring harness. Start the engine and run it until it cut[...]

Apply sealant on the thread of the housing securing screws. Throttle position sensor. Before fitting the TP sensor, fully close the throttle, then turning the sensor anticlockwise, align the flats of the shaft with the sensor pickup lever. Tighten the securing screws. WARNING. Never clean or wash the TP sensor or idle air control valve with petrol [...]

crankshaft position pulses are fed to the ECU when the engine is not running. To re-activate the fuel pump, switch off the ignition for ten seconds, then switch it on again. After the fuel pump is shut off, the fuel pressure can slightly go down and then stabilizes; or it can go up, if the engine is warm. When the fuel pressure fails to stabilize a[...]

189 Fig.9-5. Wiring diagram for VAZ-21214 vehicle, CFI: 1 - electric fuel pump and fuel level sender; 2 - injector; 3 - oxygen sensor; 4 - octane potentiometer; 5 - air temperature sensor; 6 - MAP sensor; 7 - throttle position sen- sor; 8 - coolant temperature sensor; 9 - idle air control valve; 10 - diagnostic plug; 11- speed sender; 12 - canister[...]

VAZ-21214-20 vehicle The VAZ-21214-20 vehicle is fitted with a 1.7-L engine, Sequential Fuel Injection. Engine 21214-10 The engine 21214-10 is four-stroke, four-cylinder, in-line, SOHC, with Sequential Fuel Injection System. The 21214-10 engine is based on the 21213 engine. Both engines have similar housing components, piston / connection rod mecha[...]

Disconnect hoses 7 and 8 (supply and return) (Fig.9-6) from pipes 1 and 9. Plug the hose / pipe ends to prevent dirt ingress. Disconnect accelerator cable 4 (Fig.9-7) from sector 6 on the throttle hosing, bracket 5 on the receiver unit and from bracket 3 on valve cover. Disconnect the crankcase evap hose from hose 6 (Fig.9-8) connection, loosen two[...]

192 Check the injection system for satisfactory operation, as out- lined in Repair Manual for Fuel Sequential Injection System. Engine - dismantling and reassembly The main differences on dismantling and reassembly are related to alternative design of the air supply system. Mount the engine on the test bench, drain oil from the oil pan, dismantle t[...]

193 Fig.9-10. Valve actuation: 1 - cylinder head; 2 - valve; 3 - valve lever; 4 - rail, hydraulic valve lifter; 5 - camshaft; 6 - hydraulic valve lifter; 7 - nut Fig.9-11. Exploded view of chain tensioner: 1 - chain; 2 - tensioner shoe; 3 - oil delivery pipe to tensioner; 4 - chain tensioner; 5 - camshaft sprocket; 6 - chain damper; 7 - oil pump sh[...]

194 Fig.9-12. Hydraulic chain tensioner: 1 - tensioner housing; 2 - valve unit; 3 - ball, non-return valve; 4 - stop pin; 5 - plunger; 6 - volume restrictor; 7 - spring; Ç - working cavity; ë - locating slot; Ñ - hole; Ö - reserve cavity Fig.9-13. Cooling system: 1 - radiator pad; 2 - radiator return hose; 3 - water pump pulley; 4 - thermostat;[...]

When refitting to the engine, the tensioner should be free from oil, dowel 4 should not protrude from the housing. Cooling system The cooling system features two electric fans 14 (Fig.9-13). The fan cowl is mounted in front of the radiator and is held by two top 12 and two bottom 15 nuts. The introduction of the throttle housing in the cooling syst[...]

Exhaust emission system Exhaust gases are drawn from the engine through the exhaust manifold, front exhaust pipe 2 (Fig.9-15), catalytic con- verter 11, front silencer 15 and main silencer 13. The downpipe is connected to the catalytic converter flange by means of a movable joint. Between the flanges there is a met- allographite ring with a spheric[...]

197 Fig.9-16. EMS wiring diagram (Sequential Fuel Injection), VAZ-21214-20 vehicle: 1 - coolant temperature sensor; 2 - throttle position sensor; 3 - mass airflow meter; 4 - canister purge solenoid; 5 - injectors; 6 - spark plugs; 7 - ignition module; 8 - elec- tronic control unit; 9 - idle air control valve; 10 - instrument cluster with tachometer[...]

VAZ-21215-10 vehicle The VAZ-21215-10 vehicle is fitted with the diesel engine DHW (XUD-9SD). The section gives a brief description of diagnostic procedures for fuel and electrical systems, engine removal and refitting, repair procedures for engine systems. For detailed design, repair and diagnostic procedures with respect to all engine systems usi[...]

From the engine (Fig.9-17) disconnect the coolant supply and return hoses, remove the radiator complete with the grille and fan cowl. Disconnect the cooling hoses from the thermostat. Disconnect the hoses between the engine and heater. From the air cleaner (Fig.9-18) disconnect the crankcase vent hose, undo three securing nuts, remove the air clean[...]

Cooling system Design description The cooling system is of closed-, pressurized type, with expansion tank (Fig.9-20). The coolant pump is of centrifugal type, driven by a V-belt from the crankshaft pulley. The cooling system includes radiator 7 with expansion tank 5, thermostat 13, coolant temperature gauge, water jacket and con- necting hoses. Dur[...]

- use special wrench (of 10 mm square size) for 5 mm square hole and turn the bracket clockwise to remove spring 6; - tighten bolt 4; - remove the cambelt. Refitting is the reversal of the removal procedure: - make sure the camshaft and fuel pump pulleys are in the position required and secured, idler pulley 7 (Fig.9-22) and ten- sioner 3 rotate fr[...]

Refitting. Refit the belt over the pulleys and ensure the belt is located properly within the groove of each pulley. Belt tensioning is carried out in the following sequence: - tighten the belt through loosening bolt 8; - locate tool OUT0000016; - use bolt 8 to tighten the belt until the tool reads 115±10 SEEM; - remove the tool, tighten the tensi[...]

Adjust idle with the help of screw 1. The idle speed should be 800-850 rpm. Engine rundown - checking. Using load lever 4 set the engine speed at 3000 rpm. Release the load lever, the engine rundown should be 2.5 - 3.5 seconds. After returning to idle, the speed difference should not exceed 50 rpm. WARNING. The adjustment screws for maximum fuel fe[...]

204 Fig.9-26. Wiring diagram for alternator: 1 - battery; 2 - alternator; 3 - instrument cluster; 4 - digital tachometer; 5 - resistor 50 éhm, 5 W; 6 - low battery warning light; 7 - fusebox; 8 - ignition relay; 9 - control mod - ule, theft-deterrent system; 10 - ignition switch Fig.9-27. Wiring diagram for starter motor: 1 - starter motor; 2 - ba[...]

Headlight wipe/wash. The vehicle VAZ-21215-10 is not fit- ted with the headlight wipe/wash. Cooling fan motor. Two dc motors powered from constant magnets of MP 8019/37 type are provided to operate the engine cooling fan blower. The wiring diagram for cooling fan motor is shown in Fig.9-34. The motors are triggered by sensor 1 through complementary[...]

206 Fig.9-30. Wiring diagram for theft-deterrent system: 1 - LED for system state indication; 2 - control module; 3 - ignition switch; Ä - to interior light switch; Ç - to interior light; ë - to ignition relay terminal 86; D - to starter relay terminal 86 Fig.9-31. Wiring diagram for direction indicators and hazard warning flashers: 1 - directio[...]

Table 9-3. Instrument cluster pin assignment Pin No Pin assignment Connector ï1 (red or amber) 1 - 2 To ignition switch terminal «15» 3 Spare 4 To instrument cluster lighting switch 5 To alternator terminal «W» 6 To housing 7 To ignition switch terminal «50» 8 To handbrake warning light switch 9 To seat belt relay 10 To fuel gauge terminal ?[...]

Connector ï2 (any colour, except red and amber) 1 - 2 To high beam relay 3 To exterior lighting switch 4 - 5 To indicators flasher relay 6 To alternator terminal «Ç» 7 - 8 To rear foglight switch 9 To heated rear window switch 10 To ignition switch terminal «15» 11 To fuel level sensor terminal «T» 12 To coolant temperature sender 13 To coo[...]

209 Steering with BREED «SRS-40» driver’ s airbag in the steering wheel Design description The SRS-40 system is housed in the steering wheel, being an additional protection to the seat belt, the system is intended to prevent serious chest and head injuries to the driver. The system is activated at the frontal impact and at 30 ° impact leftward[...]

WARNING. Never fit the steering wheel SRS-40 to other vehicle models, since the impact sensor in the gas genera- tor is tailored to parameters and characteristics of VAZ- 21213 vehicle and its versions. Due to variations in parameters and characteristics among vehicle models and within similar models of different production years, NEVER use the SRS[...]

211 6. Always check the steering wheel is reliably secured before fitting the gas generator, never pierce or rotate the ignitor unit through the D-shaped hole in the housing. 7. Store the gas generator in a box, while the airbag mod- ule in a plastic bag. Do not dismantle; protect the gas gen- erator from damages, since inside its sealed housing th[...]

ATTACHMENTS Attachment 1 TORQUE WRENCH SETTINGS * Part Thread Tightening torque, N•m (kgf•m) ENGINE Main bearing cap bolt å10ı1.25 68.31-84.38 (6.97-8.61) Oil pump bolt å6 5.10-8.20 (0.52-0.85) Breather cover retaining stud å8 12.7-20.6 (1.3-2.1) Breather cover nut å8 12.7-20.6 (1.3-2.1) Cylinder head bolt å12ı1.25 Refer to chapter «Eng[...]

213 TRANSMISSION Reversing light switch å14ı1.5 28.4-45.1 (2.9-4.6) Clutch housing-to-engine bolts å12ı1.25 53.9-87.2 (5.5-8.9) Clutch housing-to-transmission retaining nut å10ı1.25 31.8-51.4 (3.25-5.25) Clutch housing-to-transmission retaining nut å8 15.7-25.5 (1.6-2.6) Shift rod detent cover bolt å8 15.7-25.5 (1.6-2.6) End cover retaining[...]

214 Nut, bolt holding recoil block bracket to cross-member å8 15.1-18.6 (1.53-1.9) Nut, upper control arm shaft bolt å12ı1.25 66.6-82.3 (6.8-8.4) Shock-absorber upper end retaining nut å10ı1.25 27.4-34 (2.8-3.46) Shock-absorber lower end retaining nut å10ı1.25 50-61.7 (5.1-6.3) Nut, front wheel hub bearing å18ı1.5 Refer to «Running gear»[...]

215 Attachment 2 SPECIAL TOOLS FOR MAINTENANCE AND REPAIR * Designation Description ENGINE Ä.40005 Universal pickers kit Ä.40026 Removal tool, coolant pump impeller Ä.50088 Spanner, intake / exhaust pipe nuts Ä.50113 Allen key, crankcase oil drain plug Ä.50121 Spanner, crankshaft pulley bolt Ä.50126 Spanner for checking cylinder head bolt tig[...]

216 CLUTCH Ä.70017 Tool, clutch pedal spring removal and installation Ä.70081 Mandrel, clutch disc centering 67.7813.9503 Tooling, clutch disc repair 67.7822.9517 Jig, clutch disc lining renewal 67.7851.9500 Mandrel, clutch disc lining rivetting TRANSMISSION Ä.40006 Puller, front input shaft bearing Ä.55035 Jointed box spanner, gearbox removal [...]

217 Ä.57070 Spanner, front shock-absorber removal and installation Ä.74177/1 Tool for fitting silent blocks to front suspension upper control arm (to be used with tool 67.7853.9519) 02.8701.9502 Tool for checking front suspension balljoints 67.7820.9514 Cross-member for engine lifting 67.7820.9520 Mandrel, nut reduction 67.7820.9521 Lever for mov[...]

218 Attachment 3 Adjustment and checking DATA Valve clearances, cold engine (18-20°ë), mm: inlet valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Attachment 4 Fuel, lubricants and fluids Location Capacity, Description litres Fuel tank, VAZ-21213, VAZ-21214, VAZ-21214-20 vehicles 42 Automotive petrol, at least 95 RON as per EN 228 Fuel tank, VAZ-21215-10 vehicle 45 Diesel fuel as per EN 590 Engine cooling system, including heating and ventilation system, 10.7 Ethylene glycol-based coolant VAZ[...]

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