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Lada Niva 2121 Service Manual

1. Fig 2 60 Engine cooling system 21 20 19 1 radiator return hose 2 thermostat 3 thermostat hose 4 return hose to pump 5 return pipe heater radiator 6 delivery pipe heater radiator 7 return hose from intake manifold preheater to part throttle channel heater 8 part throttle channel heater 9 expansion tank 10 coolant temperature sensor 11 hose between radiator and expansion tank 12 radiator feed hose 13 left hand fluid cooler 14 radiator cap 15 radiator matrix 16 fan ring 17 radiator drain tap 18 radia tor mounting rubber 19 right hand fluid cooler 20 water pump 21 feed hose to pump 35 Fig 2 63 Removing the impeller Fig 2 61 Checking the water pump belt tension 1 puller 2 impeller 6 7 8 55 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 i a i la 11 e 12 10 blower fan 11 cover plate 12 fan hub 36 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
2. Fig 4 11 Press fitting the upper control arm balljoint 1 control arm shaft 2 tool 67 7853 9519 3 fixture A 74177 1 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 deformations and ensure that the ends lie in one plane if deformation is insignificant the bar can be straightened at significant deformations renew the bar Carefully inspect and ensure that the suspension arms crossmember and steering knuckles are not deformed and have no cracks Renew the specified components in case of cracks and deformations Suspension crossmember Use tool 67 8732 9501 to check the geometrical parameters of the crossmember At significant deformations of the crossmember when it is impossible to adjust the front wheel alignment angle with washers and at satisfactory condition of all other elements renew the crossmember Silent blocks The criteria for renewal are described in chap ter Front suspension inspection Replacement of silent blocks The upper arm Between the eyes of the arm establish tool 67 7823 9527 on the shaft and place the arm on tool A 47045 fig 4 10 Press the arm shaft 1 with the punch to press o
3. 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 the primary and secondary venturi Throttle valves 8 and 10 are connected so that the secondary barrel starts opening when the primary one is 2 3 open Idling system runs on fuel from the emulsion well behind fuel jet 7 Fig 2 83 Fuel is fed to fuel jet 2 which is fitted with fuel cut off solenoid 1 At the jet outlet the fuel is mixed with the air coming from the port and from a flared part of the venturi to ensure the carburettor smooth operation at idling Emulsion goes under the throttle plate through the correcting orifice adjusted by idle mixture adjustment screw 9 Air correction systems Following the throttle opening but prior to activation of the main metering system the air fuel mix ture enters the primary barrel through idling fuel jet 2 and air correction system passage 8 located at the level of the closed throttle plate edge the secondary barrel through outlet orifice 6 being slightly over the edge of the closed throttle plate Fuel flows from jet 4 through the tube to be further mixed with air from air jet 5 flowing through the idling air passage Part throttle enr
4. 390 el IM SSS ata L DE 22 Fig 8 4 Anchorages of vehicle units and assemblies ai CUPIN EIAS 0 datum lines 1 centre of steering mechanism 2 brake and clutch pedal axis 3 steering wheel shaft axis 4 attachment of rear suspension shock absorbers 5 rear wheel axis 6 attachment of front pipe main silencer 7 rear attachment of main silencer 8 bottom radiator attachment 9 top radiator attachment 10 front sus pension cross member attachment 11 differential centre 12 wheel centre 13 front anti roll bar attachment 14 rear power unit mounting attachment 15 transfer case attachment 16 attachment of handbrake lever bracket 17 front attachment of rear suspension trailing arms 18 rear attachment of rear suspension trailing arms 19 rear suspension shock absorber attachment 20 attachment of rear suspension trailing arms 21 front attachment of main silencer 22 attachment of exhaust pipe 171 Fig 8 5 Weld contours front wing and roof panel Dots designate seams of resistance welding Arrowed are places tacked by gas welding 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
5. disconnected loose or broken wiring to solenoid or solenoid control unit faulty solenoid control unit defective fuel cutoff solenoid 4 Carburettor choke not opening at first flashes in cylinders 1 Carry out the following operations blow fuel pipes clean fuel tank renew fuel filter Clean filters check pump operation and renew any damaged components 2 Refer to section Ignition system 3 Carry out the following check wiring and connections renew damaged wires renew control unit replace solenoid with a new one 4 Eliminate any leakage of choke pull down unit Engine idles erratically or stalls 1 Incorrectly adjusted idle speed 2 Defective carburettor solenoid control system 3 Faulty carburettor blocked carburettor jets or internal passages water in carburettor broken choke control diaphragm 4 Ignition system fault 5 Vacuum leak through damaged hose between intake pipe and brake servo unit 6 Air leak through gaskets at connections between intake pipe and car burettor cylinder head 7 Leaking distributor vacuum pipe 1 Adjust idle speed 2 Refer to Engine fails to start 3 Carry out the following blow carburettor jets and internal passages remove water from carburettor drain sludge from fuel tank fit new diagram 4 Refer to section Ignition system 5 Replace damaged hose 6 Tighten retaining nuts or renew gaskets eliminate carbur
6. 19 e 16 16 20 e 1 i v9 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 and CHECK ENGINE light 11 main fusebox 12 LED antitheft system 13 control module antitheft system 14 to door courtesy light switch 15 to interior light switch 16 diagnostic plug 17 electric fuel pump and fuel level sender 18 fuel pump relay 19 speed sender 20 main relay 21 crankshaft position sender 22 knock sensor 23 oxygen sensor 24 fan relay 25 electric fans 26 injection system fusebox A to power supply 197 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 using specialized tools and diag nostic charts refer to PEUGEOT Repair Manual for Diesel Engine The diesel engine operation depends much on the sound fuel injection system this is why this section focuses on the fuel sup ply units and components In t
7. 92 Q Z Ew ASS ee BSS ADN 2 Fig 3 72 Making the measurements to define the thickness of the drive gear shim 1 tool A 70184 2 fixture A 95690 with indicator a4 and a distance from tool end face to differential bearing journal make a few turns clockwise with handle 4 During rotation of the driving gear the movable indicator 1 should not pass indicator 2 and should show no less than 157 Necm 16 kgf cm If the moment of resistance to rotation is less than 157 N cm 16 kgf cm and for bearings after 30 km 39 2 Necm 4 kgf cm tighten the driving gear flange nut but do not exceed the rated tightening torque and check again the driving gear moment of resistance to rotation If the moment of resistance to rotation has appeared to be more than 196 N cm 20 kgfecm and for run in bearings 58 8 Necm 6 kgfecm this will indicate excessive bearing preload Renew the deformed distance sleeve After replacing the dis tance sleeve re assemble the unit with the appropriate adjust ments and checks Refitting the differential housing Fit in the casing previously assembled differential housing together with the outer bearing rings Place two adjusting nuts 4 fig 3 77 so that they adjoin the bearing rings Fit the bearing covers and tighten the fastening bolts with a torque wrench Fig 3 73 Final drive gears 1 driven gear 2 serial number 3 allowance in hundredth
8. The crankshaft endfloat is restricted by two thrust washers The thrust washers are fitted on both sides of the rear main bear ing a sintered one yellow at the rear end and a steel aluminium one at the front end The thrust washers are of two sizes stan dard and 0 127 mm thicker Crankshaft bearing shells are thin walled aluminium with steel backing The upper bearing shells of No 1 2 4 n 5 bearings have inner oil grooves whilst the lower bearing shells are plain shells The upper and lower bearing shells of the centre bearing No 3 are plain without an oil groove The big end bearing shells both upper and lower ones are also plain The oversize bearing shells are thicker for the crankshaft journals reduced by 0 25 mm 0 5 mm 0 75 mm and 1 mm Flywheel is cast iron with the pressed in steel starter ring The flywheel centering is ensured by a front input shaft bearing which is pressed into the crankshaft A taper recess on the rear face of the flywheel near the ring gear is provided as a positioning mark Adjust it against cylinder No 4 crankpin Inspection and overhaul Crankshaft Inspect the crankshaft Make sure there are no cracks Examine the faces which mate the oil seal working edges for evident cracking scoring or scuffing Mount the crankshaft on two V blocks as shown in Fig 2 37 and check the run out with a dial gauge e main bearing journals maximum 0 03 mm mounting surfaces for the input shaft s
9. 1 spark gap 2 ignition coil 3 control module 4 0 01 Ohm resistor 1 at least 20 W A to square wave generator B to oscilloscope Fig 7 26 Displaying pulse waveform at the oscilloscope control module pulses II alternator pulses A dwell current saturation time B maximum current T pulse period Tu pulse width 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 generator pulses while the 2nd channel for the control module pulses Square wave pulses simulating those of the distributor sen sor are supplied to the module terminals 3 and 6 The pulse fre quency should be within 3 33 233 Hz while the duty cycle peri od to pulse length ratio T Tu should be set to 3 The maximum voltage Umax is 10 volts the minimum voltage Umin should not exceed 0 4 volts Fig 7 26 Il A sound control module should generate the pulses as shown in oscillogram I For 3620 3734 and 76 3734 modules at the supply voltage 13 5 0 5 volts the current flow B should be from 7 5 to 8 5 amps There is no standard dwell current saturation A For RT1903 module at the supply voltage of 13 5 0 2
10. 119 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 freely without jamming there should be no signs of wear or damages on the surface of the rings and balls Check the axial clearance between the head of the adjusting screw 8 see fig 5 5 and the groove in the pitman arm shaft 7 The gap should not exceed 0 05 mm If more replace the adjust ing plate 9 with a plate of greater thickness Note In the spare parts the adjusting plates are supplied of eleven sizes with thickness from 1 95 mm up to 2 20 mm the increase in each size makes 0 025 mm Inspect locking plates 5 see fig 5 3 Renew if they are deformed Steering shaft dismantle and reassembly Dismantle Undo the U joint fork fastening bolt and separate the intermediate and upper shafts of the steering mechanism If the upper shaft or its bearings are damaged flare the places of the bracket pipe punching and take out the pipe from the shaft 15 see fig 5 1 in assembly with bearings 11 If the shaft rotates in the bearings without jamming and there is no radial free play in the bearings the resilient radial move ments of the steering shaft are allowed it is not
11. disconnect the lower balljoint 18 from the suspension arm disconnect the shock absorber 14 from the lower arm 4 and steering drive side tie rod from the steering knuckle shaft 29 move the front wheel drive shaft fully forward to the front axle by turning the steering knuckle 29 relatively the upper balljoint 41 remove the knuckle from the joint casing tail 23 using tool 67 7853 9535 with washer 67 7853 9540 press out from the cavity of the steering knuckle the inner rings of bear ings 27 with dismantling rings and seals 25 The bearing outer rings are pressed off using washer 67 7853 9534 and press fit ted with tool 67 7853 9536 Mark the bearing rings so that to put them on former place when reassembling 105 eo Fig 4 6 Front suspension on the vehicle rear view 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 JIWTOJT 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 the bearing inner rings the oil seal bush and press fit the sealings fit the steering knuckle on the joint case tail and connect the balljoint to the lower arm fix the shock absorber and attach the side tie rod of the steering mechanism to the steering knuckle arm fit the hub in assembly with
12. inspection Carefully inspect the beam especially on a vehicle after col lision A damaged beam can become the reason of noise in the rear axle and quick wear of tyres The deformation of the axle beam is checked both horizon tally and vertically Attach flange A 70172 to each end of the beam place the beam with the flanges on identical V blocks located on a surface plate with length no less than 1600 mm so that the abutment sur face between the casing and the beam will be vertical Fig 3 54 Rear axle 1 wheel cap 2 brake drum to wheel securing bolt 3 oil deflector 4 brake drum 5 brake drum iron ring 6 wheel cylinder 7 bleeder 8 axle shaft bearing 9 bearing locking ring 10 rear axle beam flange 11 oil seal 12 suspensi shaft guide 16 differential bearing adjusting nut 17 nut locking plate 18 di 23 axle shaft 24 differential side gear 25 rear axle reduction gear casing 26 shim 27 bearing spacer sleeve 28 final drive bearing 29 grease seal 30 splash guard 31 flange 32 oil screen 33 final drive gear 34 pinion shaft 35 axi shaft bearing mounting plate 39 plate fastening bolt holder 40 rear brake backplate 41 rear brake shoe 42 shoe pad Can EN Q 7 ASN Md a E ES OR JS gra P ND hj INN Pag ALRI Ga ee CES OGRE i FREI L4 NN N STAR 36 4521 ay SRN T m D SRG 34 ASA 31 on spring cup 13 rear axle beam 14 rear suspension bar
13. upper arm shaft 50 shims 51 upper arm shaft securing bolts 52 suspension spring mounting upper 53 suspension spring seat upper 54 spring sealing gasket 55 crossmem ber to tie rod securing bracket 56 thrust washer 57 balljoint rubber bush 58 balljoint sleeve outer 59 balljoint sleeve inner 60 balljoint thrust washer Front wheel alignment angle Table 4 1 eheexing and adjustment Front wheel alignment angle parameters The check and adjustment of the front wheel alignment angle Front wheels for vehicle with vehicle kurb weight is carried out on special test benches according to the instruc alignment angle load 3140 N 320 kgf tions Camber 0 30 20 0 30 lt o 0 20 20 0 20 s 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 wheel Caster 3 30 30 3 30 0 1 30 30 1 30 9 angle The check and adjustment of wheel angles is carried out on a vehicle under static load of 3140 N 320 kgf four men and 40 Toe in 2 4 mm 1 7 mm 4 5 6 5 mm 3 5 9 5 mm kg in boot Follow the parameters specified in tab 4 1 to check and permissible front wheel alignment angle for the elastic elements stabilization time before adjust the wheel alignment angles the first maintenance 2000 3000 km 103 Before adjusting the whe
14. 2 relief valve 3 relief valve spring 4 shell 5 rubber insert 6 exhaust manifold 7 main valve spring 8 main valve seat 9 main valve 10 retainer 11 adjuster nut 12 piston 13 sleeve D coolant inflow from engine P coolant inflow from radiator H coolant outflow to pump Gradually heat the water from the starting 73 75 C in incre ments of approximately 1 C 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 mostat face side and is 80 2 C or 83 2 C The thermostat is subject to renewal when its main valve opening temperature dif fers from the value stated on the thermostat face or when the main valve stroke is below 6 0 mm The easiest way to check the thermostat is serviceable is to touch it directly in the vehicle The thermostat is good when after the engine cold start the lower radiator pipe gets warmer as soon as the coolant temperature reaches 80 85 C the coolant tem perature gauge needle is 3 4 mm from the red area of the scale Radiator Removal Withdraw the radiator from the vehicle in the fol lowing order remove the spare wheel and its supporting tube drain the fluid from the radiator and cylinder block through the respective caps in the left hand fluid cooler
15. 2 Adjust wheel alignment angles 3 Replace deformed parts rectify body front elements breaks and one sided buckling of rubber undercutting and wear of rubber on the end faces of joints if the outer bush radial displacement A relative to the inner bush exceeds 2 5 mm if size B is not within the limits of 3 7 5 mm If size B exceeds the specified limits check the press fitting of the silent block in the arm socket The gap in the upper balljoints is checked in the following order place the vehicle on an even horizontal platform with hard surface lift the right left front part of the vehicle and take off the wheel put a 230 mm wooden pad under the lower arm which is closer to the ball pin and lower the vehicle on it ensure that resin does not come out from the runner chan nel of the upper ballpin housing if necessary smooth with a file to avoid errors when measuring fix tool indicator bracket 4 fig 4 3 on the top of stub axle place the indicator 2 in centre of the pin balljoint housing 3 sphere with small preliminary preload and then align the zero division of the scale with the arrow fix a fork lever 5 with length of 0 7 m on the front suspension upper arm using dynamometer 6 create load of 196 N m 20 kgf m on the fork lever end 294 N in vertical direction first to press in and then to pull out the ball pin from the joint housing record the maximum deviations of the i
16. 2 Excessively tough spring of oil pressure relief valve 10 1 Renew valve 2 Renew spring 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 1 Tighten fittings or replace gaskets and oil seals 2 Wash components of crankcase ventilation system 3 Rebore and renew pistons and rings 4 Renew rings 5 Clean windows and slots of carbon change motor oil as recommended in Attachment 4 6 Renew oil caps 7 Renew valves repair cylinder head Excessive fuel consumption 1 Choke not fully opened 2 Excessive resistance to vehicle motion 3 Incorrect ignition timing 4 Defective distributor vacuum unit 5 High fuel level in carburettor leaking needle valve or its gasket seizure or excessive friction hindering normal float operation 6 Choked carburettor air jets 7 Leaking part throttle enrichment diaphragm 8 Carburettor solenoid failed to shut off fuel at overrun no earthing of idle switch sliding contact broken wire between control module and carburettor idle switch faulty control module 1 Adjust choke linkage 2 Check and adjust pressures in tyres braking system wheel alignment 3 Adjust ignition timing 4 Renew vacuum unit
17. 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 retainer securing bolt 17 seat back reclining mechanism handle retainer 18 trim seat back reclining mechanism 19 seat sliding mechanism grab handle 20 front seat cushion frame 21 front seat cushion Fig 8 31 Front seat rails Fig 8 32 Front seat back reclining and tipping mechanisms 1 slide 2 seat sliding mechanism handle 3 bottom seat back rake adjuster 1 hook 2 spring 3 bottom seat back rake adjuster lever 4 top seat back lever 4 seat sliding spring 5 locking catch 6 shaft 7 stop 8 catch 9 rake adjuster 5 control cable seat back tipping 6 outer cables 7 seat back roller 10 tracks tipping handle 8 bracket 9 synchronizer 182 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 Move the seat fully rearward undo the front bolts securing the rails and withd
18. 7 Fig 3 86 Removing the race from the cage Take the race out from the cage to do that place one of the race ledges in the elongated opening of the cage see fig 3 86 and then roll out the race in the direction of the straight edge of the aperture Wash all components and blow with compressed air The reassembly of the outer joint is carried out in reverse sequence paying attention to the following grease all components with LUPYC 4 before reassembly when refitting the cage race assembly in the joint casing ensure the matching of labels made before dismantle the race should be fitted with the ring groove for the thrust ring facing the shaft when refitting the balls in the cage incline the race approx imately by an angle twice bigger than the cage fill the joint with 60 cm of LLIPYC 4 before striking the shaft 4 see fig 3 82 to connect it with the inner race 11 it is necessary to fit a new circlip 12 strictly in the centre and then sharply strike downward on the shaft end the circlip will compress and slip through the race spline opening Use tool 67 7853 9533 to press fit the sealing ring in the joint housing After reassembly the race might be blocking at shaft rolling when the ball does not rotate This does not indicate a poor qual ity assembly as such blocking will not appear at the joint rotation during operation Using the above mentioned procedure dismantle com
19. Renew retainer 3 Adjust door position by key or locking knob Bend lever top end away of handle shoulder to have 0 5 2 0 mm clearance Failure to unlock door with exterior handle Excessive clearance between exterior handle shoulder and top end of lock exterior linkage Bend lever top end to handle shoulder to have 0 5 2 0 mm clearance Failure to lock door 1 Broken or weak spring of lock central shaft or external control lever 2 Loose riveting of external operating lever shaft On closing the lever lug fails to engage ratchet due to lever misalignment 3 Seized exterior control lever due to dust or grease coking 1 Renew lock 2 Remove lock and ensure reliable riveting 3 Remove lock wash and lubricate friction parts with grease Litol 24 Failure to unlock door with interior handle Insufficient travel of inner control lever due to insufficient operating link travel Adjust lock inner control lever Failure to unlock bonnet from passenger compartment 1 Lock operating link broken 2 Excessive operating link length 1 Renew operating link 2 Adjust operating link length through loop on lock hook 167 Cause Remedy Failure to 1 Lock spring broken or loose 2 Shorter lock operating link 3 Incorrect position of lock lock bonnet 1 Renew spring 2 Adjust operating link length through loop on lock hook 3 Adjust lock position Failure to secure sliding glass in position Spring brake o
20. 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 on the location of the nut slot Adjustment and repair of reduction gear components is car ried out on a bench on which it is possible also to test the reduc tion gear for noise and to check the arrangement and the form of the pattern on teeth working surfaces as set forth below Final drive gear teeth mesh pattern check To finally check the quality of final drive gear mesh on the test bench after adjustment place the reduction gear on the bench and grease the working surfaces of the driven gear teeth with a thin layer of lead oxide start the bench and decelerate the rotation of the axle shafts so that under load on the driven gear teeth surfaces there were visible traces of contact with the driving gear teeth change the rotation direction and while decelerating ensure forming the contact patterns on the other side of the driven gear teeth what will simulate the reverse movement of the vehicle The gear mesh is considered to be OK if on both sides of the Fig 3 78 Checking the side gap in final drive gear mesh using tool A 95688 R 1 bracket securing screw 2 indicator for checking the gear mesh side gap 3 indicator rod securing sc
21. To alternator terminal B To rear foglight switch To heated rear window switch To ignition switch terminal 15 To fuel level sensor terminal T To coolant temperature sender 13 To coolant temperature sender Oo co 41 DO A CO no c c Y O Coolant temperature gauge checking The coolant tem perature gauge is associated with the relevant sender in the cylinder head At the sensor resistance of 640 1320 Ohm the needle should be at the low end of scale at 77 89 Ohm it should rest at the front of the red area at resistance of 40 50 Ohm the needle should go to the end of the red area Fuel level gauge checking The fuel gauge is associated with the relevant sensor in the petrol tank The same sensor operates the fuel reserve warning light when 4 to 6 litres are left in the petrol tank At the sensor resistance of 200 238 Ohm the needle should at the low end of scale at 59 71 Ohm at the mid dle scale while at 17 23 Ohm the needle should go to the high end of scale mark 1 208 Speedometer checking Check the speedometer turning its drive shaft at various speeds The data required for checking is shown in Fig 9 4 Table 9 4 Speedometer specification Speedometer Drive shaft readings km h speed rpm 30 433 500 40 600 667 50 766 833 60 933 1000 80 1250 1333 100 1567 1667 120 1883 2000 140 2200 2333 160 2517 2667 Tachometer checking The tachometer operates on
22. Undo the pin nuts that are fastening the intermediate shaft joint to the transfer box input shaft flange and remove the intermediate shaft The refitting of propeller shafts is carried out in reverse order Before refitting the intermediate shaft in assembly with the trans fer box place the flexible coupling centering ring on the gearbox output shaft When refitting the layshaft ensure the alignment of the gearbox and the transfer box shafts see Refitting the trans fer box Before refitting the layshaft grease the inner surface of the flange centering bush with 2 3 gr of LLIPYC 4 Inspection without dismantle After cleaning and washing the propeller shafts check the shaft U joints for smooth and easy rotation and absence of sig nificant axial and radial gaps Check the layshaft balance on a balance bench as follows It is not recommended to dismantle the propeller shafts if the yokes are turning smoothly there is no jamming the mis align ment of the drive axle shafts does not exceed 1 716 Nemm 175 grfsmm the layshaft 2 16 Nemm 200 grfsmm and there is no lubricant leak from the spider bearing seals and the layshaft pro tective shroud Dismantling Rear and front shafts Make marks with paint or punch to note mutual location of mating parts so that to refit them in the same position and avoid misalignment of shafts Place the front rear shaft in vice with aluminum jaws Remove the circlips using round nose
23. between the bulkhead and front cover plate between the rear floor rear floor extensions and rear wheel arches bodysides and rear end cross member Table 8 2 Box sections to be corrosion treated Cavity Injection location Injection direction Notes Front top cross member Headlight casings Front bottom cross member Under front wings External door sills Internal door sills Front chassis arms Front chassis arm connections Middle and rear chassis arms Middle chassis arms connections Rear floor cross member Rear end cross member Between rear wheel arches and body sides Central pillars Front pillars Door pockets Throug Front f Throug Throug Throug Throug Throug Throug h two top holes rom outside h two holes for bumper fitting h shielded opening h six side holes h hole at the back of sill end gt h holes for bumper fitting h gt oles underneath body Throug h seven holes underneath body Through holes underneath body Through holes in luggage compartment and underneath the body Through holes underneath the body Into cavity openings in luggage compartment Into hol e behind pillar Through 2 holes from interior compartment side Through openings in inner door panel Rightward and leftward Over entire surface Rightward and leftward All directions Forward and backwards Along sills Along chassis arms Rightward and
24. drive shaft bearing 37 rear axle differential gear 38 pinion 39 pinion shaft 40 pinion shaft circlip 41 spring washer 42 front axle differential gear 43 transfer box mounting shaft 44 mounting bracket rubber pad 75 q 2 MARS ou AND S o P 2 ON Z CCA WPA Me Wana A EN ee LE X 8 lock washer 9 lever shaft bush 10 lever shaft 11 differential locking lever 12 gear shift fork rod 13 gearshift lever bracket 14 gear shift lever 15 knob 16 gear shift clutch 17 gear shift clutch fork 18 distance sleeve 19 detent ball 20 detent spring bush 21 detent spring 22 differential lock warning light switch 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 Fig 3 36 Transfer box operating system 76 Fig 3 37 Transfer box mounting on vehicle 1 transfer box mounting bracket 2 filler plug 3 bracket fastening nut 4 drain orifice plug 5 shims Fig 3 38 Transfer box installation 1 layshaft and drive shaft flange fastening pin 2 transfer box 3 shims 4 transfer box to car body fastening nuts 5 nuts fastening mounting brack ets on shafts Fig 3 39 Removing the front axle case 1 front axle case 2 case cover 3 speedo
25. in the steering mechanism worm bearings Place the front wheels in position corresponding to straight movement rotate the steering wheel in both directions and check if the distance between the steering box 8 end face fig 5 2 and mark B made on the steering worm shaft will change This change will indicate a gap in worm bearings To adjust the clearance in worm bearings make 1 1 5 turns of the steering wheel to the left undo the fastening bolt from the bot tom cover 20 and drain oil from the steering box Remove the bot tom cover remove one shim or replace it with a thinner one Note Shims are delivered in spare parts with thickness of 0 10 and 0 15 mm Fix the bottom cover again check for axial shift of worm in bearings If there is no free play fill the steering box with 0 215 I of transmission oil Check the effort of turning the steering wheel having placed the front wheels on smooth metal surface It should not exceed 196 N 20 kgf 245 N 25 kgf Check and adjustment of the roller to worm mesh Having ensured there is no axial movement of the worm in the bearings use puller A 47035 to press out the balljoint pins from the apertures in the arm and disconnect the tie rods from the arm at the same time keeping the front wheels straight Move the arm by the head check for a gap in the roller to worm mesh Within the 30 turn of the steering wheel in each direction from the neutral position there should be no
26. lower 5 spring seat lower 6 compression buffer 7 upper longitudinal arm securing bolt 8 upper longitudinal arm mounting bracket 9 suspension spring 10 upper spring seat 11 spring insulating gasket upper 12 spring mounting 13 rear brake pressure regulator operating rod link 14 shock absorber eye rubber bush 15 underbody crossmember 16 additional compression buffer 17 upper longitudinal arm 18 lower longitudinal arm mounting bracket 19 transverse arm to body mounting bracket 20 pressure regulator 21 pressure regulator operating rod 22 bush clamp 23 arm bush 24 transverse arm 25 shock absorber 110 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 vehicle so that distance X mea sured from the axle beam to the body chassis arm in 100 mm from the cross bar bracket fig 4 16 will make 152 mm use a dynamometer to tighten the nuts on fastening bolts of the longi tudinal and cross bars and the shock absorbers fastening pins on the axle beam and car body Inspection Before inspection thoroughly wash all components Protect the rubber components bushes and protective cov ers from
27. rear cable guide 3 front cable return spring 4 rear cable 5 locknut 6 adjusting nut 7 spacer 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 completely ensure the serviceability of the pressure regulator If during pedal depressing the piston remains motionless this means that the piston became stuck to the housing due to corro sion and pressure regulator renewal is required After ensuring the pressure regulator serviceability and no brake liquid leaks between the piston and the pressure regulator housing apply a thin layer of 11 1 on the shaft and the acting part of the piston fill 5 6 gr of this greasing in the rubber boot and refit the cover Pressure regulator position adjustment The pressure regulator position adjustment is required if the fastening bolts became loose Raise the vehicle rear axle Disconnect arm 4 fig 6 5 from tie rod 8 and fix on its end tool 67 7820 9519 Direct the core of the tool upwards until it will get pressed against the car floor fig 6 6 This will be distance X from the arm end to the body chassis arm see fig 6 5 equal to 150 5 mm Fig 6 5 Installation of the rear brake
28. renew input shaft or clutch disc 6 Renew clutch cover pressure plate assembly 7 Bleed system 8 Tighten connections renew damaged components bleed system 9 Renew sealing rings bleed system 10 Clean opening in tank cover bleed system 11 Clean sealing ring replace in case of wear 12 Renew clutch cover pressure plate assembly Incomplete clutch engagement clutch slips 1 No gaps in clutch release drive 2 Badly worn or burnt clutch disc friction linings 3 Excessive oil on clutch disc friction linings surfaces of flywheel and pressure plate 4 Plugged compensation port in master cylinder 5 Damaged or jammed clutch release drive 1 Adjust clutch release drive 2 Renew linings or clutch disc assembly 3 Clean oily surfaces with white spirit remedy the situation 4 Wash cylinder and clean port 5 Rectify malfunctions causing jamming Clutch judder 1 Jammed clutch disc hub on primary shaft splines 2 Excessive oil on clutch disc friction linings surfaces of flywheel and pressure plate 3 Jammed clutch release drive mechanism 4 Badly worn clutch disc friction linings 5 Loose rivets on clutch disc friction linings 6 Damaged surface or buckling of pressure plate 1 Clean splines apply grease JICL 15 or Ouon 1 Ovon 2 In case of badly worn splines causing seizure renew input shaft or clutch disc 2 Clean oily surfaces with white spirit remedy the situation 3 Replace damaged parts rectify mal
29. simultaneously with activation of the windscreen wipe wash Voltage is supplied to supplementary relay 3 winding activating the relay When the terminal 30 is powered through the exterior light switch i e the headlights are on voltage is supplied through the closed relay contacts to headlamp wipers 1 and to headlamp washer motor 2 The headlamp wiper should operate at 45 60 rpm double sweeps at a load of 0 49 Nem 0 05 kgf m supply voltage of 12 volts ambient temperature of 25 10 C and maximum consump tion current of 1 5 amperes Fig 7 36 Wiring diagram for headlight wipe wash screen washer and headlight wipe wash switch 8 fusebox 9 ignition switch 1 headlight wipers 2 headlight washer motor 3 headlight wipe wash relay 4 complementary fusebox 5 headlight beam switch 6 external light switch 7 wind 161 Fig 7 37 Wiring diagram for rear window wipe wash and heating 1 fusebox 2 rear window wipe wash switch 3 rear window washer motor 4 rear window wiper motor 5 rear window heating element 6 rear window heating relay 7 warning light of heated rear window 8 rear window heating switch 9 ignition switch 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 mo
30. sion slack A in the belt Fig 2 61 at 98 N 10 kgf must be 10 15 MM while at the same pressure the deflection B must be within 12 17 mm To adjust the belt tension slacken the alternator retaining nuts move the alternator off the engine to increase tension or towards the engine to decrease tension then tighten the nuts Turn the crankshaft two revolutions clockwise and check the belt tension No excess tension of the belt is allowed to prevent hazardous loads to the alternator bearings Coolant pump Dismantling Carry out the coolant pump dismantling as detailed below disconnect pump housing 5 Fig 2 62 from cover 3 place the cover in vice using protective pads remove impeller 2 Fig 2 63 from the shaft using picker A 40026 remove hub 2 Fig 2 64 of the fan pulley from the shaft using puller A 40005 1 5 undo lock screw 8 Fig 2 62 and force out the shaft with the bearing applying force to the bearing race withdraw oil seal 7 from housing cover 3 Inspection Check the bearing axial clearance This opera tion is mandatory if the pump is noisy The clearance must not exceed 0 13 mm at load of 49 N 5 kgf Renew the bearing com plete with the shaft when the clearance is bigger Always remember to renew the pump oil seal and pump to cylinder block gasket during overhaul Check the pump housing and cover for cracks or deformation which are not permitted Reassembly The assembly is carried
31. steel tube on the axle and make arrangements to prevent liquid leaking from the brake system 12 13 14 15 16 17 18 ET ce TJ Co oO otha Oo 25 24 23 Fig 4 14 Rear suspension Disconnect the handbrake rear cable brackets from the body remove the front cable return spring and after undoing the locknut and the adjusting nut release the rear cable Disconnect from the bracket on the axle beam the tie rod 13 see fig 4 14 of the rear brake pressure regulator drive Disconnect the top ends of shock absorbers 25 Put under the rear axle beam a hydraulic jack Disconnect the longitudinal 3 and 17 and transverse 24 arms from brackets on the body lower the jack and remove the axle Start to dismantle the suspension remove the shock absorbers from the brackets on the axle beam disconnect the longitudinal and transverse arms from the brackets on the axle beam The rear suspension components are shown on fig 4 15 The rear suspension refitting is carried out in reverse sequence On the rear suspension the springs of the same class as on the front suspension should be installed In exceptional cases if the springs of A class not marked or with marks by white paint on the external side of coils are installed on the front suspension and there are no springs of the same class available t l 22 21 20 19 1 spacer sleeve 2 rubber bush 3 lower longitudinal arm 4 spring insulating gasket
32. 21214 VAZ 21214 20 vehicles meeting ASTM D 3306 86 b Engine cooling system including heating and ventilation system 11 Coolants PROCOR 3000 ACO 800 VAZ 21215 10 vehicle NAPGEL C 2400 REVCO CEL 107 Engine lubrication system including oil filter 3 75 Motor oils VAZ 21213 VAZ 21214 VAZ 21214 20 vehicles SAE 5W 40 30 to 30 C 10W 40 25 to 35 C 15W 40 20 to 45 C API SG SH CD ACEA A2 96 Engine lubrication system including oil filter 6 Motor oils VAZ 21215 10 vehicle SAE 15W 40 12 to 40 C 10W 30 20 to 30 C 5W 30 25 to 30 C 10W 40 20 to 40 C API SG CF ACEA B2 96 mini CCMC PD2 Gearbox 1 35 Transmission oils Rear axle casing 1 3 SAE 75W 90 40 to 25 C Steering box 0 18 80W 90 26 to 35 C Transfer case 0 75 85W 90 12 to 45 C Front axle casing 1 15 API GL5 Clutch hydraulic release system 0 2 Brake fluids FM VSS 571 116 DOT 4 Brake hydraulic system 0 66 SAE J 1713 Windscreen headlight washer container 5 0 Any alcohol based glass cleaners Rear door washer reservoir 2 0 Front wheel bearings Starter motor guide ring Bearings universal joints Propeller shafts spline joint Seat rails Door locks Front suspension ballpins steering joints Front wheel CV joints Transmission transfer case drive joint Battery terminals and clamps Door key holes Rear brake pressure regulator Automotive multipurpose lithium grease NLGI class 2 Automotive multip
33. 23 clutch pedal push rod 24 pin 25 push rod 26 lock shackle 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 nuts that are fixing the brackets of the servo unit and pedals to the body front and remove the bracket in assembly with the servo unit and the master cylinder and then the clutch and brake pedal bracket Refitting is carried out in reverse sequence Pay attention to correctly refit the push rod in the jack of the clutch master cylin der piston Dismantle and reassembly To dismantle remove the clutch pedal servo unit spring 14 remove return springs 8 and 17 undo nut 2 of bolt 20 take out the bolt and remove the pedals together with bushes To remove and refit the springs use tool A 70017 Reassembly of the master cylinder is carried out in reverse order When reassembling grease with JINTOJI 24 the pedal bushes spring ends connection places between the push rods and pedals and the push rod end adjoining the piston of the clutch master cylinder Fig 6 9 Master cylinder 1 plug 2 cylinder body 3 front brake drive piston 4 washer 5 rear brake front additional drive piston 6 seal
34. 3 6 8 8 4 66 6 82 3 6 8 8 4 213 Nut bolt holding recoil block bracket to cross member Nut upper control arm shaft bolt Shock absorber upper end retaining nut Shock absorber lower end retaining nut Nut front wheel hub bearing Brake caliper to steering knuckle retaining bolt Anti roll bar retaining nut Balljoint to steering knuckle retaining nut Radius rod to suspension crosspiece nut Radius rod to body retaining nut Lower arm shaft to crosspiece connecting nut Balljoint to suspension arm retaining nut Nut wheel retaining bolt Suspension upper arm shaft nut Nut swing arm retaining bolt Shock absorber retaining nut Nut Panhard rod and trailing arms retaining bolts Nut steering box retaining bolt Nut idler arm bracket retaining bolt Nut steering rod ballpin Middle shaft to upper shaft and worm shaft retaining nut Steering wheel retaining nut Steering shaft bracket and ignition switch retaining nut Drop arm nut Idler arm shaft nut M8 M12x1 25 M10x1 25 M10x1 25 M18x1 5 M10x1 25 M8 M14x1 5 M12x1 25 M16x1 5 M16x1 5 M8 M12x1 25 M14x1 5 M12x1 25 REAR SUSPENSION M12x1 25 M12x1 25 STEERING M10x1 25 M10x1 25 M14x1 5 M8 M16x1 5 M8 M20x1 5 M14x1 5 It is allowed to round tightening torques for nuts and bolts to the tenth of kgf m within the tolerance With the nut recess mismatching the cotter pin hole tighten to further torque less than 60 to ensure a reliable locking 2
35. 6 Loose fastening bolts on stee ring box or slave arm shaft brack et 7 Wrong roller to worm gap Vehicle 1 Unequal pressure in tyres 2 Wrong front wheel alignment angle 3 Different tension in front sus pension springs 4 Deformed steering knuckles or suspension arms 5 Incomplete brake release on one or several wheels 1 Check and ensure normal pres sure 2 Check and adjust wheel align ment angle 3 Adjust clearance 4 Balance wheels 5 Check and tighten nuts 6 Check and tighten bolt nuts 7 Adjust clearance wandering 1 Check and ensure normal pres sure 2 Check wheel alignment angle and adjust 3 Replace bad springs 4 nspect knuckles and arms replaces bad parts 5 Check braking system Vehicle unstable 1 Wrong front wheel alignment angle 2 Excessive clearance in front wheel bearings 3 Loose tie rod ballpin nuts 4 Excessive clearance in tie rod balljoint 5 Loose fastening bolts on steer ing box or slave arm shaft bracket 6 Excessive roller to worm gap 7 The steering knuckles or sus pension arms are deformed 1 Check wheel alignment angle and adjust 2 Adjust clearance 3 Check and tighten nuts 4 Renew tie rod balljoints 5 Check and tighten bolt nuts 6 Adjust gap 7 Inspect knuckles and arms replaces bad parts Oil leak from the steering box 1 Worn arm shaft sealing or worm 2 Loose steering box cover fas tening bolts 3 Damaged sealings 1 R
36. 9 9 from receiver unit 8 and fuel pressure regulator 5 Undo five nuts holding the receiver unit to intake pipe 1 and withdraw the receiver unit complete with gasket 7 Disconnect the wiring from the injectors withdraw fuel rail 4 with pressure regulator 5 having undone two bolts 3 holding it to the intake pipe Undo retaining nuts and bolts withdraw the brackets followed by the intake pipe with the shield Detach the ignition module and knock sensor from the left hand side of the engine Further engine dismantling is as described in chapter 2 of this Manual The engine reassembly is reverse of the dismantling pro cedure Before refitting the fuel rail lubricate the injector sealing rings with motor oil Valve mechanism design description Valves 2 Fig 9 10 are operated by the cams through rocker arms 3 One end of the lever presses down the valve while the other end rests on the spherical head of the hydraulic lifter The hydraulic lifters automatically eliminate the clearance in the valve train so during technical service you do not need to check or adjust the valve clearances Lubricating oil through pipe 3 Fig 9 11 flows to the tensioner cavity E Fig 9 12 through the bore and valve unit 2 into the working cavity B pushing down plunger 5 Tensioner hous ing 1 has a 1 mm bore to release air in the cavity E The diameter clearance between housing 1 and plunger 5 should be 0 018 0 024 mm and is mea
37. Fig 2 25 The cylinder block is of a low alloyed cast iron The cylinder bores are of five classes in steps of 0 01 mm and are designated by the letters A B C D E The cylinder class is engraved on the cylinder block bottom face Fig 2 26 The cylinders can be rebored to accommodate the oversize pistons of 0 4 mm and 0 8 mm bigger diameters The main bearing caps are machined complete with the cylin der block therefore they are not interchangeable and feature dis tinctive notches on the outside surface Fig 2 13 Inspection and repair Inspection Wash the cylinder block thoroughly and clear the oil ways Blow dry with compressed air and inspect the cylinder block visually Make sure there are no cracks in the mountings or elsewhere in the cylinder block When cooling water is suspected in the crankcase use a special test bench to examine the cylinder block for leaks To do this plug the cylinder block cooling water jacket ports force in some room temperature water at 0 3 MPa 3 kgf sq cm There should be no evidence of water leaks from the cylinder block with in 2 minutes When coolant is found contaminated with oil do not strip the engine completely rather check the cylinder block for cracks in the area of the oilways For that drain the coolant from the cool ing system remove the cylinder head refill the cylinder block water jacket with water and apply compressed air to the vertical oilway in the cylinder If th
38. LINE Clasp removal and installation of flexible coupling Gauge for selection of propeller shaft universal joint bearing circlips Cramp renewal of universal joint spider Tool for pressing in front wheel CV joint oil seal ring Installation tool front wheel CV joint rubber boot DRIVE AXLES Removal tool driving pinion rear bearing inner race Rest removal of differential box bearing inner race Spanner differential bearing nuts Tool for pressing rear bearing inner race to driving pinion Installation tool axleshaft oil seal Tool for pressing in driving pinion rear bearing outer race Pair of flanges to be fitted to rear axle beam ends during its inspection truing Tool to determine shim thickness to adjust clearance in final drive gear meshing Tool for pressing in driving pinion front bearing outer race Tool for pressing out driving pinion bearing outer race Installation tool axleshaft lockring Removal tool lockring from axleshaft Tool for checking reliable pressing of lockring onto axleshaft Tool for adjusting clearance in drive gear crown wheel meshing and differential bearing tightening Tool for selecting drive pinion shim thickness Socket dynamometer 02 7812 9501 Dynamometer for checking rotational resistance moment of drive axle pinion and steering worm shaft Spanner front axle pinion adjustment Measuring tool free axial play of axleshaft Removal tool for axleshaft rear axle Rest differential bearing removal Bracket with endpiece to
39. Liquid leak from shock absorber Wear or destruction of rod sealing Foreign particles on sealing surfaces Dent risks scuffings on rod complete wear of chrome coating Loose tank nut Tank damage in zone of sealing ring Shrinkage or damage of tank sealing ring Excessive amount of liquid in shock absorber NO of WP 1 Replace oil seal 2 Wash shock absorber components renew or filter liquid 3 Renew worn or damaged rod and oil seal 4 Tighten nut 5 Renew or repair tank 6 Renew ring 7 Ensure required amount of liquid Insufficient shock absorber resistance at recoil stroke Leaking recoil valve or bypass valve Piston ring broken or stuck in flute Insufficient amount of liquid due to leak Scuffings on piston or cylinder Worn guide bush opening Impurities in liquid Recoil spring set down NO cc rn 1 Renew damaged valve components or repair 2 Renew ring or rectify sticking 3 Renew damaged components and top up liquid 4 Renew damaged components and liquid 5 Replace guide bush 6 Wash all parts renew liquid 7 Replace spring Insufficient shock absorber resistance at compression stroke Compression valve leak Insufficient amount of liquid due to leak Worn guide bush and rod Impurities in liquid Worn or damaged compression valve discs oar won 1 Renew damaged components or repair 2 Renew damaged components and top up liquid 3 Renew worn par
40. M8 15 9 25 7 1 62 2 62 CLUTCH Clutch securing bolt M8 19 1 30 9 1 95 3 15 Nut clutch brake pedals bolt M12x1 25 12 7 20 6 1 3 2 1 Retaining nut clutch brake master cylinders and pedal bracket M8 9 8 15 7 1 0 1 6 Nut clutch hydraulic drive connection pipes M12 24 5 31 4 2 5 3 2 Nut brake hydraulic drive connection pipes M10 14 7 18 6 1 5 1 9 212 TRANSMISSION Reversing light switch M14x1 5 Clutch housing to engine bolts M12x1 25 Clutch housing to transmission retaining nut M10x1 25 Clutch housing to transmission retaining nut M8 Shift rod detent cover bolt M8 End cover retaining nut M8 Output shaft rear end nut M20x1 0 Intermediate shaft bearing clamping washer bolt M12x1 25 Fork to shift rod retaining bolt M6 TRANSFER BOX Mounting bracket to rubber shaft retaining nut M10x1 25 Mounting bracket to body retaining nut M8 Nut holding covers of transfer box casing front axle drive casing speedometer drive unit housing control lever bracket M8 Differential lockup switch M16x1 5 Fork to selector rod retaining bolt M6 Fork to differential lockup rod retaining bolt M12x1 25 Driven gear retaining bolt M10x1 25 Retaining bolt driving shaft rear bearing and intermediate shaft rear bearing M18x1 5 Nut holding propeller shaft flange to driving shaft and to front rear axle driveshafts M16x1 5 DRIVE LINE Nut bolts holding flexible coupling to gearbox and transfer box flanges M12x1 25 Nut bolt holding propeller shaft flange
41. N N N N N Amrit T E AAAA N 3 SS 497 L N SSSSSSSSSS L A A 2 2 2 2 2 g 4 lke ses A A 5 A A 5 A 3 A 4 Wr COLL E 7 e u g 2 2 7 EN A dA Fig 3 50 Dismantling the U joint 1 rest 2 bush 3 joint fork 4 spider 82 iw Z L Fig 3 51 Installing the bush for dismantling the U joint 1 bush iif ANT SAL Fig 3 52 U joint reassembling 1 circlip 2 feeler gauge H gap A B C D E F G feeler gauge blades with thickness in mm 1 45 1 48 1 52 1 56 1 60 1 64 1 67 Fig 3 53 Balancing the propeller shafts 1 washers for balancing A B E F out of balance check points C D shaft rest points on the balancing fixture 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 1 67 mm If the blade of the smallest thickness 1 45 mm does not fit into gap H replace circlip 1 with the one having thickness of 1 4 mm and repeat the procedure If the blade of the greatest thickness 1 67 m
42. 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 mechanism and power unit mounting The differences include the sequential ignition system used instead of the carbu rettor the hydraulic valve lifters and hydraulic chain tensioner in the valve timing gear All this results in different engine disman tling and reassembly with respect to removal and refitting of air supply units fuel metering system and lubrication system Power unit removal and refitting Before removing the power unit depressurize the fuel supply system For that disconnect the fuel pump wiring plug from the injection wiring harness operate the engine let it run until it stops then operate the starter for three seconds to equalize pressure in the fuel lines Disconnect the battery negative lead Fig 9 7 Removing the accelerator linkage 1 bracket 2 return spring 3 support bracket 4 throttle cable 5 sector with throttle lever 6 cable retaining bracket 7 throttle pedal 8 pedal pad Fig 9 6 Fuel tank and fuel pipes 1 return pipe 2 cap 3 electric fuel pump 4 petrol tank 5 fuel filter strap 6 fuel filter 7 fuel return hose 8 fuel delivery hose 9 fuel delivery pipe 10 fuel
43. The mating valve pump cover surfaces should show no dents or flash to prevent a drop of oil pressure in the lubrication system Check the relief valve spring tension against the values as given in Fig 2 72 Fig 2 69 Dismantling the oil pump 1 relief valve 2 valve spring 3 cover 4 housing 5 shaft Fig 2 70 Checking the oil pump radial play 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 certain the oil port in the front bush is aligned against the oilway in the cylinder block bush turn ing The inner surface must be smooth and without scuffs Measure the diameter of the shaft and bushes to determine the clearances between the bushes and shaft bearing surfaces When the clearance is over 0 15 mm limit wear value or in case of damaged or loose bushes renew the bushes For removal and refitting use tool A 60333 1 2 Fig 2 73 observing the following the bushes must be pressed in place with the oil port in the front bush aligned against the oilway in the cylinder block after pressing in the bushes are machined to the final inner diameter Refer to Fig 2 68 for the sizes For optimum concentri
44. bolts of the plate and oil screen 6 see fig 3 62 and fix them in place by bending back the bolt retainers On vehicle measurement of the axle shaft axial play Slacken the rear wheels fastening nuts Put blocks under front wheels and raise the rear axle Release the handbrake and place the gear shift lever in neutral Remove wheels and brake drums Attach tool 02 7834 9504 fig 3 64 to the axle shaft pass through one of the axle shaft openings the indicator 1 leg extension until it will rest against the braking plate or the oil screen and fix the indicator Make the measurement with the indicator applying to the axle shaft flange force of approx 49 N 5 kgf in both directions along the rear axle shaft The free play should not exceed 0 7 mm Reduction gear The rear axle reduction gear assembly is shown on fig 3 65 It is unified with the reduction gear of VAZ 2106 and has a label on the housing as figure 6 Fault diagnosis by noise Fault diagnosis is carried out in the following sequence Test 1 In order to clearly determine the character of noise drive the vehicle on a highway with speed approximately 20 km h Then gradually increase speed up to 90 km h listen care fully to various noises and note speed at which they occur and disappear Release the throttle pedal and without applying the brake pedal shift to lower gear During deceleration listen how noises change and note the moment when noise increases Usua
45. brake disc on the joint case tail and establish the taper bush 21 turn the new adjusting nut and adjust the gaps in wheel hub bearings using tool 67 7853 9528 fit the wheel hub cap replace the brake caliper and the wheel Note In all cases when the nut is unscrewed from the tail of the outer joint case renew the nut or use one from another vehicle Balancing the wheels The wheels are balanced on special benches according to the instructions attached to the test bench The wheel out of bal ance is eliminated by balance weights which are fastened on the rim with special springs 106 1 lower control arm 2 crossmember 3 tie rod fastening bracket 4 anti roll bar to body securing bracket 5 tie rod 6 anti roll bar Front suspension removal and refitting Place the vehicle on the lift or over an inspection pit set the parking brake open the hood and take out the spare wheel Place supports under rear wheels and take off front wheels Using remover 67 7824 9516 see fig 5 10 press out pins from the steering knuckle arms and draw aside the steering tie rods Disconnect the anti roll bar 6 fig 4 6 from the suspension lower arms Disconnect the tie rods 5 from body brackets and the cross member Disconnect the shock absorbers from the suspension lower arms Remove the engine crankcase protective plate and the splash guard Remove from each side the front brake caliper without dis
46. burning of central con tact point on distributor rotor arm 5 Cracks fouling or burnings of rotor arm or distributor cap 6 Control module faulty wrong waveform of ignition coil primary winding impulses 1 Examine leads and connections Renew damaged leads 2 Examine plugs regap spark plugs renew damaged spark plugs 3 Renew carbon brush 4 Clean central contact 5 Inspect renew rotor or cap 6 Check spark control module with oscilloscope renew faulty control module Engine lacking power or sluggish 1 Incorrect ignition timing 2 Jammed distributor weights weak weight springs in ignition dis tributor 3 Spark control module faulty wrong waveform of ignition coil pri mary winding pulses 1 Check and adjust ignition timing 2 Examine and renew damaged parts 3 Check spark control module with oscilloscope renew faulty control module WARNING The vehicle is fitted with high energy transis torized ignition system with extended application of elec tronic components Caution should be exercised to avoid personal injury or damage to electronics Always observe the following rules Do not touch any ignition system parts spark control module coil or HT leads when the engine is running Do not start the engine through a spark plug gap and do not check the ignition system through sparking between the ends of the spark plug leads and earth lead Do not route LT and HT ignition leads toget
47. can be damaged by considerable current flow Check the alter nator operation using an ammeter or a voltmeter Never check the alternator diodes by applying voltage over 12 volts or using a megohmmeter as its voltage is very high and can damage the diodes by short circuit Never check the vehicle wiring by a megohmmeter or a lamp powered in excess of 12 volts If the check is really necessary disconnect the leads from the alternator first Always use the test bench and disconnect the winding from the diodes when performing the high voltage check of alternator stator winding insulation resistance When welding the body units or components remember to disconnect first the leads from all battery and alternator connectors Alternator testing Using tester A tester helps determine whether the alternator is faulty or meets the specification The carbon brushes of the unit tested should slide smoothly on the slip rings which should always be clean 141 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 below 55 amperes When the measured amperage is much lower this is an indi cation of some fault in the stator or rotor windings or
48. clean Components inspection Armature Using a megohmmeter or a 220 v test lamp check the armature for the earthed winding The voltage through the test lamp is supplied to the commutator segments and armature core An illuminated lamp is an indication of a commutator being short ed to earth When using the megohmmeter the reading should be at least 10 kOhms Renew the earthed armature Using a specialized device check for internal faults in the armature winding and commutator segments check for loose connections where the winding wires are soldered to the com mutator Inspect the commutator When dirty or burnt sand it with fine emery paper Check the runout between the core and shaft jour nal Renew the armature when the runout is over 0 08 mm Check the surfaces of splines and armature shaft journals There should be no scuffs scores or wear In the event the shaft surface has yellow marks because of the pinion bush remove the marks with the help of fine emery paper since this can pos sibly cause a pinion jam in the shaft Actuator unit The starter motor actuator unit should operate over the armature shaft smoothly without jams The pinion should turn on the armature shaft in the direction of the armature rotation at a maximum torque of 0 27 Hem 2 8 kgf cm The pinion is not supposed to turn in the reverse direction If the teeth are scored regrind them with a small diameter fine abrasive disc When the drive ass
49. clutch disc 12 spring Fig 3 9 Slave cylinder components 1 body 2 bleeder 3 cap 4 pushrod 5 sealing ring 6 piston 7 sealing ring 8 sleeve 9 spring 10 disc 11 lock ring 62 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 of the piston should have no damages or marks The inner diameter of the cylinder should be within the limits of 19 035 19 075 mm Inspect the piston return spring and replace if it has become weak Renew sealing rings Inspect the protective cap on the rear end of the cylinder and renew in case of damage Before reas sembly accurately clean and wash all parts in brake liquid Do not let mineral oil petrol kerosine or diesel fuel to get in contact with the parts as this may cause swelling of the rubber sealings After inspection reassemble all parts of the master cylinder in reverse order grease all components with brake liquid or preservation liquid HI 213 Slave cylinder Turn out plug take off protective rubber cap 3 fig 3 9 together with pushrod 4 take out piston and disman tle it previously having removed lock ring 11 After dismantle ac
50. counterweight fully to the left Repeat both operations and determine the chain difference on the length L Fig 2 59 between the axis of the wheels Using vernier calipers measure the distance between the wheels then add the diameter d value to get the distance L between the wheels axes For a new chain the distance L between the wheels axes is 495 4 495 8 mm Renew the chain when its length is 499 5 mm Before refitting smear the chain with engine oil Cooling system Refer to the cooling system layout as shown in Fig 2 60 Checking coolant level and density Check to make certain the coolant level in the expansion tank is adequate When the engine is cold 15 20 C the coolant level within the expansion tank must be 3 4 cm above the MIN mark WARNING Always check the coolant level on the cold engine since its volume increases with rise in temperature the coolant level can be significantly higher with the hot engine When necessary use an areometer to check the coolant density to be 1 078 1 085 g cu cm for TOSOL A 40 which is used in VAZ vehicles 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 conditions change the c
51. detachable grips Weld the wing in the locations as arrowed in the figure by means of COe arc welding Soldering is allowed too Use solder ing bars of J162 J163 type 2 3 mm in diameter Refit the bonnet and check the wing position A maximum 2 mm inward or outward misalignment of the wing against the door or bonnet is allowed the wing clearances with the bonnet or door over the outer surface should be 5 2 mm Withdraw the bonnet and door Use resistance welding with step of 40 50 mm to weld the wing to the front bodyside panel pillar splash guard and bulk head Gas welding with tin solder is possible or electric CO2 arc welding with a broken seam of 7 to 10 mm with a 50 60 mm step Use an electric semi automatic welder and 0 8 mm dia wire of cB 08 1C or cB 08 2C type Weld the wing to the front by melting the welding flange edges using a broken seam of 5 to 7 mm with a 40 70 mm step Roof removal In most cases a damaged roof requires renewal Remove the tailgate waterchannel trim windscreen headlin er and roof accessories Make a layout and cut off the roof panel over the lines as shown in Fig 8 5 172 Detach the roof panel remove the panel remainder and straighten any areas deformed Remove loose colour paint and base paint up to bare metal on the roof panel edges windscreen frame roof side panels and reinforcements Renew the gaskets on reinforcements Fit the roof panel secure it with quick detachable g
52. 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 1 Damaged sealings 2 Loose nuts and pins fixing cov ers to casing 3 Worn or damaged shaft seals 4 Worn transfer drive rod seals 1 Renew worn parts 2 Renew springs or worn parts 3 Straighten deformed parts or renew clean burrs and scores replace bad parts Oil leak 1 Renew gaskets 2 Tighten nuts and pins in places of leak 3 Renew oil seals 4 Renew sealing ring Transfer box car body floor vibration trouble shooting in the area of front seats First of all note at what speed does the transfer box vibration occur then start with the diagnosis Test 1 Place the transfer and gearbox levers in neutral posi tion and start the engine Set engine speed equal to vehicle speed at which vibration occurs If vibration still exists on a parked vehicle it is necessary to check engine mounting and supports as they are the reason of vibration Test 2 If during test 1 vibration was not diagnosed place the transfer levers in neutral position start the engine engage direct gear and set engine speed equal to vehicle speed at which vibra tion occurs If vibration is observed on a parked vehicle at this engine speed the reason should be looked for in the layshaft out of bal ance bended fastening bolts or flexible coupling flange jammed CV jo
53. diameter of the press fitted bush is 20 05 20 07 mm Insignificant surface roughness can be removed with fine sandpaper In case of serious damages and deformations renew the shaft Gears There should be no damages or excessive wear of teeth Special attention should be payed to the condition of the teeth end faces on the synchro unit crown The bearing pattern between the gear teeth should cover the complete working area which should be smooth with no signs of wear Check the gear mesh clearance the mounting gap should be 0 10 mm maximum wear gap 0 20 mm The mounting gap between the bushes and the 1st 5th gears and between the output shaft and the 2nd 3rd gears should be 0 05 0 10 mm maximum wear gap 0 15 mm If wear exceeds permissible limits renew the gears Bearings Ball and roller bearings should be in perfect con dition Their radial gap should not exceed 0 05 mm Press the inner ring to the outer one with fingers turn one of them in both directions the rolling thus should be smooth On the surface of balls and rollers and the rolling paths of the rings no damage is permissible Renew damaged bearings When replac ing the input shaft front bearing use pusher A 40006 see fig 2 11 it is possible not to remove the flywheel Rods and forks No deformation of gear shift forks is accept able The rods should freely slide in the borings without signifi cant gaps Check the condition of rod collets springs an
54. engine only Start with removing the air cleaner Next disconnect oper ating rod 15 Fig 2 87 from the throttle lever followed by oper ating rod 3 and choke outer operating rod Undo the retaining screw and remove the part throttle channel heater Disconnect the idling overrun wiring from the shutoff solenoid and idle switch Undo the carburettor retaining nuts remove the carburettor and plug the intake pipe Refitting is a reversal of the removal procedure Before refit ting examine the carburettor heat screen and intake pipe carbu rettor mating surfaces Tighten the carburettor nuts to the torques specified in Attachment 1 WARNING Never refit or tighten the retaining nuts on the hot carburettor After refitting adjust the carburettor linkage and engine idle The carburettor linkage should operate without seizures Carburettor dismantling Undo the retaining screws and remove the carburettor cover taking care not to damage the gasket float and tubes of the full throttle enrichment and secondary air correction systems Dismantle the carburettor cover Using a tool carefully push out spindle 1 Fig 2 88 of floats 3 providing you do not damage the float tabs remove the floats Remove gasket 4 needle valve 2 seat fuel supply pipe 11 and fuel filter 13 Remove the housing of the idling fuel jet with fuel cutoff sole noid 10 and remove jet 9 Fig 2 87 Carburettor linkage 1 longitudinal rod 2 rod sec
55. engine front support pads should fit into the appropriate apertures in the side brackets and perfect fit of transfer box supports to the car body bottom If necessary straighten the floor surface under the supports place the transfer box on the vehicle but do not tighten com pletely mounting bracket nuts 4 and 5 fig 3 38 by moving the transfer box in different directions find such location at which the flanges of the transfer box input shaft and the layshaft will be on one level parallel and with minimum clear ances between them the transfer box shafts should be parallel with the car bottom refit the earlier removed shims under the mounting brackets fully tighten the fastening nuts reconnect the front and rear propeller shafts to the transfer box shafts attach the speedometer cable and the wires to the differential lock warning lamp sensor When replacing the transfer box and also at engine rear mount settle down resulting in vibration of the transfer box renew and match shims 5 see fig 3 37 with those of proper thickness Matching the shim thickness ensure proper refitting of engine support pads see subsec tion Engine removal and refitting separate the flanges of the transfer box input shaft and the layshaft slacken the nuts that are fixing the transfer box supports to the car body remove the shims and and by moving the transfer box in different directions find such location a
56. flasher switch 48 ignition switch 49 instrument lighting switch 50 windscreen wiper switch 51 switch windscreen washer amp headlamp wipe wash 52 horn switch 53 direction indicator switch 54 headlight switch 55 choke warning light switch 56 choke warning light 57 door courtesy light switches 58 interior lights 59 rear window washer motor 60 instrument cluster 61 handbrake warning light switch 62 fuel level and fuel reserve gauge sender unit 63 rear lights 64 number plate light 65 rear window wiper motor 66 rear window heating element A pin assignment in steering column combination switch connector 137 60 66906909 START TIA WW v OOK Qt OOO Fig 7 2 Fuses Battery Specification Ballety x s oso ER CR 6CT 55A maintenance free Maximum voltage volt 2 0 ccc ccc A 12 Maximum capacity at 20 hour discharge rate and initial electrolyte temperature of 27 2 C ampere hour 0005 55 20 hour discharge amps rate 6 eee 2 75 Cold start amps rating with running starter motor and electrolyte temperature of 18 C 000 eee 255 Fault diagnosis Cause Remedy Battery discharge in operation 1 Alternator drivebelt slipping 1 Adjust belt tension 2 Battery surface dirty 2 Clean battery surface 3 Damaged insulation in electrical 3 Locate battery leak and remedy equipment system discharge
57. free play of pin 1 in case 3 is felt and also in case of dirt or sand penetration or corrosion on the ballpin wear of the support insert renew the joint with the tie rod end Idler arm bracket Removal and dismantle Separate the idler arm from ballpins on the middle and side tie rods remove the cotter pins having previously undone the nuts and taken out the ballpins from the arm using puller 67 7824 9516 Then undo the bolt fas tening the bracket to the body chassis arm and remove the bracket Fix the bracket in vice remove the cotter pins and undo nut 4 fig 5 12 then remove washers 3 and 6 and the idler arm 1 in assembly with shaft 9 washer 10 and self locking nut 11 remove sealings 7 and press out bushes 8 Inspection Inspect the idler arm shaft bushes in case of out of roundness or inadmissible gap between them and the shaft renew the bushes Also renew sealings 7 Check the shaft for out of roundness and damages renew if necessary Ensure the idler arm has no deformations otherwise renew Assembly and refitting Before reassembly grease the bushes of the idler arm shaft and fill the space between them with JIMTOSI 24 The reassembly order of the idler arm bracket is a reverse to dismantle If shaft 9 was replaced the bracket self locking nut 11 should be tightened with a dynamometer Washer 6 is installed with the extrusions facing upwards After tightening nut 4 the arm in horizontal position should not
58. gaskets between the oil sump cylinder block and covers tighten the securing bolts to the torque specified If oil leaks persist check the correct fitting of the gaskets and renew when applicable Since the overhauled engine is not fully bed in and frictions between the working surfaces of renewed parts show significant resistance to the rotation a certain run in period is required This especially concerns those engines where the pistons main big end bearing shells have been renewed or the crank shaft journals have been reground or the cylinders honed Therefore during run in after the engine overhaul never allow the engine to run at maximum loads When in the vehicle always run in the engine at the speeds which are recommended for the run in periods In vehicle engine inspection after overhaul Locate the engine in the vehicle thoroughly check its correct mounting Run the engine for a while then check for coolant or fuel leaks through pipe connections tighten when necessary full throttle opening and closing by the carburettor cable adjust accordingly if necessary alternator drivebelt tension adjust when applicable reliable wiring connections and operation of the warning lamps in the instrument cluster WARNING Never check the engine or vehicle on the roller stand without additional rollers for the front wheels Cylinder block General description The cylinder block basic sizes are shown in
59. gearbox input shaft splined end fig 3 4 Fig 3 4 Centering the clutch disc with tool A 70081 1 flywheel 2 clutch assembly 3 tool A 70081 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 pressure plate within 1 6 1 7 mm permitted mini mum 1 4 mm The distance from the rig base to the working surface of the thrust flange friction washer should be 40 43 mm During engine operation due to wear of the clutch disc surfaces this size increases If it will reach 48 mm or the travel of the pressure plate will be less than 1 4 mm renew the clutch cover in assembly with the pressure plate The clutch disc friction linings should be replaced at any signs of cracks reduction of distance between the rivet and the work ing surface up to 0 2 mm and also at one side scuffings To repair the clutch disc and replace the friction linings use tool 67 7822 9529 fig 3 6 Flared rivets should have no breaks The runout of the friction lining working surface should not exceed 0 5 mm If this value is exceeded straighten the disc fig 3 7 or replace with a new one Also replace the clutch disc assembly in case of cracks on th
60. grease all components with brake liquid ATTENTION To differentiate the VAZ 2121 and 21213 pressure regulators from others of similar design there is a groove on the bottom part of the piston Wash the components with isopropyl alcohol or brake liquid and inspect The components surfaces should have no marks and roughness Check the spring tension length in free condition should be 17 8 mm and under load of 76 44 64 68 N 7 8 6 6 kgf 9 mm Renew damaged components sealings and sealing rings 1 6 B 2 7 8 A 9 3 4 10 Fig 6 23 Rear brake pressure regulator non operating position A normal pressure chamber B adjustable pressure chamber P force from arm 4 1 regulator housing 2 distance sleeve 3 sealing ring 4 regulator control arm 5 gasket 6 plug 7 seal 8 spring cup 9 piston spring 10 piston 12 13 14 Fig 6 22 Pressure regulator linkage components 1 pressure regulator 2 regulator control arm shaft 3 cap 4 lock plate 5 bolt with spring washer 6 rear axle beam 7 pressure regulator control arm to rear axle bracket connecting tie rod 8 bolt washer 9 plastic bush 10 distance sleeve 11 tie rod securing bolt 12 pressure regulator control arm 13 arm thrust bush 14 bush bracket 15 washer 16 spring washer 17 nut 18 bush clamp 19 clamp to bracket fastening bolt 133 Fig 6 24 Handbrake linkage c
61. hose 3 water pump pulley 4 thermostat 5 drain pipe from throttle housing 6 coolant delivery hose to pump 7 transfer hose ther mostat 8 coolant delivery pipe for part throttle channel preheating 9 radiator delivery hose 10 radiator cap 11 hose between radiator and expansion tank 12 top fan cowl securing nut 13 radiator 14 electric fan 15 bottom fan cowl securing nut 194 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 system has necessitated its heating up by delivery of coolant via hose 8 from the cylinder head return pipe The coolant is returned through hose 5 which connects the throttle housing to the heater matrix return pipe The cooling fan motor is operated by the electronic control unit so there is no fan blower cut in sensor Fuel system The fuel system is within the Engine Management System EMS which is described in detail in a separate Repair and Service Manual for EMS Sequential Fuel Injection therefore this section describes only removal refitting and replacement of the air cleaner filter element The air filter is mounted at the front right hand side of the engine ba
62. ia b S SEI SS E ME A SI A AA Wg ON i y M ee re ge lf vob ff Le A a a A T rm ar m S Iran mamme IS ya rs 4e E s el Neri SA m S L begat nna SK NET RS Y ai Lg a Hum cc m NIS wor o a LEA n7 3 INS EIL EE SS Ten SN ES 1 ph IL IL lii A Fig 2 1 Side sectional view of the engine TA SM veri zi d ee m A OA CILTT D D PAET AE EF P air Nn nn anu m e c DEA ATR 7 a NS M p CIN e Al H TZ a Ean ad uf nm i ING ae j E esses i EN _ Rees 5 ed KJ a A prr 7917 ess hongos A 6 reel We SSS GOLOVE e Lo D NH C MN a EDS i JST ZW N x N N D Y x mum CA Mi m m e e eT a t a t A a a rm S AN a gt M ADEL ze a _ M SA ES DA P LL LL L L ee LN 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
63. its free end in a transparent vessel partially filled with liquid Sharply depress the brake pedal 3 5 times with 2 3 sec intervals undo the connector by 1 2 3 4 turn with the pedal depressed Continue to press the pedal bleed liquid with air through the hose into the vessel After the brake pedal will reach the lowest front position and the liquid drain through the hose will be finished tightly close the bleeding connector Repeat these operations until all air bubbles will be bleeded from the hose Then keeping the brake pedal in depressed position tightly close the bleeding connector and take off the hose Wipe dry the con nector and refit the protective cap All above operations should be carried out through the upper connectors first on the right rear wheel the most remote from the master cylinder then further clockwise the left rear wheel left and right front wheels Thus air from one circuit will be removed To bleed the other circuit use the lower connectors on the cylin der block of the left and right front brakes Bleeding can be start ed from the right or left wheel During bleeding maintain normal liquid level in the hydraulic system tank If there is no air in the system the brake pedal should go no more than 1 2 3 4 of full travel To exclude the influence of the servo unit and the pressure regulator on bleeding the hydraulic system it should be carried out with the engine not working and rear wheels loaded do not
64. lead to the regulator terminal B via warning light 1 Now the field winding is only battery powered Start the tester motor and increase the rotor speed up to 1500 2000 rpm Using switch 6 cut off the battery from the alter nator terminal 30 while using rheostat 4 set the output current at 10 amperes Check the voltage across the alternator terminal 30 When the diodes and stator winding are sound the output waveform is saw shaped with uniform peaks Refer to Fig 7 7 In case of a broken stator winding or shorted diodes the waveform is quite different the peaks are no longer uniform and there are very deep troughs Fig 7 7 Il n III Check to see the output waveform across the alternator ter minal 30 is normal next check voltage across the alternator ter minal 61 or at the end of the lead disconnected from the voltage regulator terminal B These points are a common connection for three supplementary diodes Fig 7 4 supplying current to the field winding during the alternator operation The output wave form must have the same even saw shaped pattern An irregular waveform is an indication of damaged supplementary diodes Rotor field winding testing The field winding can be tested with the alternator in the vehi cle It is sufficient to remove the housing and voltage regulator brush holder assembly Fig 7 7 Alternator rectified waveform sound alternator II blown diode Ill diode circuit b
65. leftward Forward and backward Rightward and leftward Rightward and leftward Rightward and leftward Over all surface Downward Downward Over all bottom inner surface Open bonnet Remove headlights Remove front bumper Remove sealing shield Remove moldings Remove front bumper Lift vehicle by hoist Lift vehicle by hoist Lift vehicle by hoist Remove trim in luggage compartment Lift vehicle by hoist Remove trim in luggage compartment Remove pillar trim Remove pillar trim Remove pillar trim 175 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 7 type sealant application front body view Fig 8 11 Locations for 51 I 7 type sealant application rear body view 1 front chassis arm connection with bottom radiator support 2 front chassis 1 rear floor to rear wheel arch joints 2 slots in angular joints of rear floor arm to bulkhead joints 3 battery tray to bulkhead connection from passen extensions with rear wheel arches bodysides and rear end cross member 3 ger compartment side 4 bulkhead to front cover abutting joints from engine bulkhead to floor sill angular joints 4 b
66. nuts When the door lock Fig 8 19 is difficult in operation adjust the lock by moving housing 4 or striker plate 5 as appropriate The gas filled struts must be renewed if they fail to hold the door open Bonnet bumpers Bonnet removal refitting and adjustment Open bonnet 3 Fig 8 20 undo the pin from pivot 1 of bon net stay 2 and detach the stay from the bonnet Holding the bonnet undo bolts 4 of upper hinge 5 links to withdraw the bonnet Refitting is a reversal of removal Align the bonnet as applic able via the slotted holes in the hinges Bonnet lock adjustment Adjust the lock position when locking is not reliable or when unlocking requires excessive efforts Fig 8 21 Open the bonnet mark the contour of lock housing 1 slack en the retaining nuts and move the lock housing as appropriate within the slotted hole Tighten the nuts and check the lock for satisfactory operation Puc 8 19 Tailgate lock door 1 lock operating handle 2 handle escutcheon 3 operating link 4 lock housing 5 door striker 6 rotor 7 lever 8 return lever Fig 8 20 Removing the bonnet 1 pivot 2 stay 3 bonnet 4 bonnet securing bolt 5 hinge Fig 8 21 Bonnet lock 1 lock body 2 spring 3 ejector 4 hook 5 release cable 6 handle Fig 8 22 Front bumper 1 bumper 2 securing bolt 3 connecting piece 4 rubber seal 5 tow eye 6 plastic side
67. of mm to nominal 4 drive gear Fig 3 74 Fitting the rear bearing inner ring on the drive gear 1 roller bearing ring 2 tool A 70152 3 shim 4 drive gear Fig 3 76 Checking the drive gear bearing preload Fig 3 75 Dynamometer 022 7812 9501 1 movable indicator 2 torque limit indicator 3 body 4 handle 5 rod with sleeve adapter 1 dynamometer 02 7812 9501 2 casing 3 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 along the tool guide rail until arm 5 will touch the outer side surface of the cover and tighten screw 8 Loosen screws 1 and 3 fig 3 78 and place bracket 4 so that the leg of indicator 2 will be based on the side surface of the dri ving gear tooth near the tooth edge then tighten screws 1 and 3 Turn the adjusting nuts and make the preliminary adjustment of the side gap between the teeth of the driving and driven gears within the limits of 0 08 0 13 mm The gap is check by indicator 2 while rocking gear 6 Bearings should have no preload The adjusting nuts should be only in contact with bearings otherwise the accuracy of prelo
68. operation ensured by a relay of PC 514 model A thermal bimetal fuse is provided to protect against the motor overheating in the event of the blades binding to the glass or resistance to sweep The washer pump is combined with the motor and is fitted to the washer fluid container in the engine compartment The pump motor is operated by pulling up the right hand lever of the steer ing column combination switch Fault diagnosis Cause Remedy Inoperative wiper motor and bimetal fuse non blown fuse 2 in fuse and relay box 1 Motor supply wires damaged ends of wires in connectors cor roded 2 Wiper switch faulty 3 Motor brushes sticking foul or burnt commutator 4 Broken wires between motor brushes and connector 5 Bimetal thermal fuse damaged 6 Motor armature winding lead broken 1 Inspect and renew leads when found damaged Clean wire ends 2 Renew 3 stalk switch 3 Inspect eliminate wiper blades sticking or renew damaged compo nents clean commutator 4 Check and when necessary sol der wires 5 Clean thermo bimetal fuse con tacts or renew it 6 Renew armature or motor Wiper motor inoperative bimetal thermal fuse operative or fuse 2 in fuse box blown 1 Wiper arms bent or conflict with bodywork 2 Wiper blades stuck because of ice or snow 3 Foreign object in wiper mecha nism 4 Short circuit in motor armature winding 1 Examine straighten wiper arms or renew
69. or ignition distributor 5 Carry out the following check for any foreign matter entrapped between needle and valve seat renew valve or gasket as applicable check and when necessary replace floats 6 Clean jets 7 Replace diaphragm 8 Following to be done clean solenoid contact surfaces check wiring and connections renew damaged wire renew control unit Engine overheating Coolant temperature gauge needle is in the red sector Start tracing the failure with checking coolant temperature gauge and its sender Refer to section Instrumentation 1 Slackened pump and alternator drive belt 2 Insufficient coolant in system 3 Incorrect ignition timing 4 Dirty radiator outside 5 Defective thermostat 6 Faulty radiator cap inlet valve opening pressure is below 0 07 MPa 0 7 kgf cm 7 Defective coolant pump 1 Adjust drive belt tension 2 Top up coolant to cooling system 3 Adjust ignition timing 4 Clean radiator outside with water jet 5 Renew thermostat 6 Renew cap 7 Check pump operation renew or repair pump Sudden coolant drop in expansion tank Damaged radiator Damaged cooling hoses or pipe gaskets loose clips Leaking heater tap or heater matrix Leaking water pump seal Damaged radiator cap or cap seal Defective cylinder head gasket Leaks from fissures in cylinder block or cylinder head No onf c rno 8 Leaks from fissures in water pump housing water
70. out as follows using the appropriate tool fit the oil seal to the housing cover look out not to skew press in the bearing and shaft applying the force to the bearing race so that the holes for the locking screw are matched tighten the bearing lock screw and punch the seat over the contour to prevent its self loosening using tool A 60430 Fig 2 65 press the pulley hub onto the shaft maintaining a size of 84 4 0 3 mm When the hub is of sintered quality press in the new hub only using tool A60430 press the impeller onto the shaft main taining a size of 48 0 2 mm as shown in Fig 2 62 This ensures the required clearance between the impeller blades and pump housing Fig 2 64 Removing the pulley hub 1 pump housing cover 2 pulley hub 3 tool A 40005 1 5 Fig 2 65 Fitting the impeller to the pump shaft using tool A 60430 1 base 2 pump shaft 3 pump housing cover 4 shell 5 set screw reassemble the pump housing with the cover having placed the gasket in between Thermostat To test whether the unit is serviceable check the temperature of the main valve opening and valve travel Using the test bench BC 106 000 suspend the thermostat with a piece of string in a container of water or coolant Position the bracket arm of the gauge against main valve 9 Fig 2 66 37 1110 9 8 13 12 Fig 2 66 Thermostat 1 intake manifold engine side
71. pro 1 Rectify under press or renew peller shaft 2 Propeller shafts out of balance 2 Check and balance shafts see Shaft balancing 3 Worn or damaged centering 3 Renew coupling flange bush bush on layshaft flexible coupling flange 4 Worn U joint 4 Repair joints and renew worn parts 5 Loose grease seal retainer on 5 Tighten grease seal and com spline joint of front or rear pro press retainer renew oil seal in peller shaft case of oil leak 6 Insufficient greasing of spline 6 Grease spline joints with Ovon 1 joints or Mvon 2Y using oil cups Lubrication leak 1 Loose grease seal retainer on 1 Tighten grease seal and com spline joint of front or rear pro press retainer renew oil seal peller shaft 2 Damaged layshaft CV joint boot 2 Dismantle joint renew greasing and boot In case of damage renew joint assembly Removal and refitting Place the vehicle on a lift or over an inspection pit provide free rotation of front and rear wheels from one or both sides of the vehicle Reliably anchor the vehicle release handbrake and place the gearshift lever in neutral Remove the front and rear propeller shafts Place fixture A 70025 on the layshaft flexible coupling 3 see fig 3 14 and while turning the shaft undo the bolt nuts that are fastening the flexible coupling to the gearbox output shaft flange Remove the transfer box see subsection Transfer box in assembly with the intermediate shaft
72. rail 190 Fig 9 8 Removing the components and units of air intake system 1 part throttle channel heater hose 2 throttle body 3 return hose from throttle body 4 air intake 5 air intake end piece 6 intake manifold hose 7 MAF sensor 8 air cleaner cover 9 filtering element 10 air filter housing 11 filter mounting 12 receiver unit 13 gasket 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 clips and remove hose 6 of the intake manifold Cut off three rubber mountings 11 holding the air clean er to the body and one mounting that retains the cold air intake end to the radiator remove the air cleaner complete with mass air flow meter 7 From the receiver unit disconnect the vacuum hose to the fuel pressure regulator and to the brake servo unit Disconnect the canister purge hose from the throttle housing when the vehicle is fitted with the evaporative emission control System Disconnect the wiring from the throttle manifold ignition mod ule injector wiring harness all relevant sensors on the power unit and from reversing light switch on the transmission Next proceed with the usual
73. raise the rear part of the vehicle If the brake liquid was completely drained from the system do the following before bleeding air undo the bleeding connector by 1 5 2 turnei on all wheel cylinders sharply depress the brake pedal and smoothly release it close the connector when liquid will be drained Then bleed the hydraulic system as described above If despite continuos bleeding the air bubbles still come out from the hose into the vessel it means air penetrates into the sys tem through damaged pipelines because of insufficient tightness of connections or due to malfunction of the master or wheel cylin ders When bleeding the vehicle the braking system of which has worked for a long time renew the brake liquid If the brake liquid is suitable for further use carefully filter the liquid and then desilt in a tightly closed vessel 4m nn A Fig 6 7 Bleeding the brake hydro system 125 p e 19 3i 23 19 22 o DS Fig 6 8 Clutch brake pedal bracket exploded view 1 bracket 2 nut 3 spring washer 4 brake pedal inner bush 5 brake pedal outer bush 6 brake pedal 7 distance sleeve 8 brake pedal return spring 9 clutch pedal outer bush 10 hook 11 cap 12 clutch pedal limit screw 13 nut 14 servo spring 15 clutch pedal inner bush 16 plate 17 clutch pedal return spring 18 washer 19 pad 20 bolt 21 clutch pedal 22 cotter pin
74. rate the situation exceeds 11 mA with loads discon nected 4 Too many accessories fitted by 4 Disconnect new electrical con vehicle owner sumers 5 Check alternator 6 Charge battery drain electrolyte flush fill with new electrolyte and recharge battery 7 Short circuits between plates 7 Renew battery 8 Electrolyte level below top plate 8 Restore electrolyte level edge 5 Alternator faulty 6 Electrolyte contaminated Electrolyte on battery cover 1 Too high electrolyte level caus 1 Replenish electrolyte as required ing spillage 2 Electrolyte leaks through frac 2 Replace battery tures in battery case 3 Electrolyte boiling due to 5 Replace alternator excessive alternator voltage 4 Electrolyte boiling through plate 4 Replace battery sulfation 138 Dry storage battery putting into operation The vehicles are factory fitted with ready to use batteries i e batteries filled with electrolyte and fully charged Replacement batteries can be supplied dry without elec trolyte In order to operate such battery first remove any provi sional plugs or masking tape Then using a funnel made of glass or acid resistant plastic slowly fill the battery with electrolyte at 25 C of 1 28 g cm for normal climates or 1 23 g cm for tropics All procedures required to activate the battery should be per formed at the ambient temperature of 25 10 C Allow 20 minutes for the internal plate
75. recommended to dismantle the upper steering shaft Renew the shaft and the bearing in case of wear or damage The reassembly is carried out in reverse order paying atten tion that the U joint lock bolt passes through the ring groove on the upper shaft Then punch the bracket pipe in two points from both sides to fix the shaft bearings Tie rods and balljoints Removal and refitting Remove the cotter pins and undo the nuts with which the side tie rod ballpins are fastened to the arms on the steering knuckles Using puller 67 7824 9516 fig 5 10 take out the ballpins from the cone apertures on the arms Remove the cotter pins and undo the nuts fastening the ballpins of the middle and side tie rods to the pitman arm and to the idler arm Using puller 67 7824 9516 take out the pins from the corresponding jacks on the arms and remove the tie rods The tie rods are refitted in reverse order All ballpin nuts are tightened with a dynamometer with subsequent splinting If the nut cut does not match the opening for the pin the nut should be 120 screwed in to an angle smaller than 60 to provide for subse quent splinting After refitting adjust the front wheel toe in Check and repair Inspect the protective caps 3 fig 5 11 as described above see Inspection check and adjustment of steering mechanism Renew damaged protective caps Inspect the condition of the tie rod balljoints by their radial and axial clearance If the
76. relay winding and headlight wiper motors at all wiper positions except initial Heated tailgate relay winding Tailgate wipe wash motors Windscreen washer motor 2 8 A Windscreen wiper relay and motor Direction indicators and indicators flasher relay turn indication mode Direction indicator warning light Tail lights reversing lamp Alternator winding at engine start up and low battery warning light Differential lockup warning light Relay and handbrake on warning light Low brake fluid warning light Oil pressure warning light Coolant temperature gauge Low fuel gauge and fuel reserve warning light Tachometer 3 8A Left hand headlight main beam Main beam warning light 4 8 A Right hand headlight main beam 5 8 A Left hand headlight dipped beam 6 8 A Right hand headlight main beam 7 8 A Left hand front lamp side marker light Right hand front lamp side marker light Number plate light Side marker warning light 8 8A Right hand rear lamp side marker light Left hand rear lamp side marker light Instrument panel illumination Heater control illumination lamp Cigarette lighter illumination Switch illumination 9 16A Direction indicators and indicators hazard relay hazard flashers mode Tailgate heating element and switch on relay contacts 10 16A Horn Inspection lamp socket Interior lamps Tail lights stop lamp bulbs 13 8A Tail lights fog lamps Headlight wiper moto
77. removal procedure as described in chapter 2 Refitting is the reverse order of removal The rubber mount ings of the air cleaner are disposal so new mountings must be fit ted when refitting the air cleaner After refitting the power unit adjust the accelerator drive At fully released accelerator pedal 7 Fig 9 7 the throttle should be fully closed The cable should be taut The cable deflection by hand force should be 10 mm as a maximum When necessary adjust the cable tension using the adjuster nuts at the cable end At fully depressed accelerator pedal the throttle should be wide open throttle sector 6 should have no further movement 191 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 the engine in the order described below Disconnect supply 1 return 3 coolant hoses Fig 9 8 and idle crankcase vent hose from throttle manifold 2 Undo the nuts hold ing the throttle housing to receiver unit 12 and withdraw the throt tle housing with gasket 13 Disconnect and remove supply 9 return 1 fuel pipes Fig 9 6 from fuel rail 10 fuel pressure regulator and from the bracket on the receiver unit Detach and remove vacuum hose 6 Fig
78. repeaters 11 battery 12 heater motor 13 heater motor complimentary resistor 14 differential lockup warning light switch 15 windscreen wiper relay 16 starter motor 17 windscreen wiper motor 18 alternator 19 windscreen washer motor 20 fuel cutoff solenoid control unit 21 spark plugs 22 ignition distributor 23 spark control module 24 ignition coil 25 temperature gauge sender unit 26 oil pressure warning light sender 27 inspection lamp socket 28 brake fluid level warning light switch 29 headlight wipe wash relay 30 rear window heating relay 31 main beam relay 32 dipped beam relay 33 ignition switch relay 34 starter motor relay 35 complimentary fuse box 36 main fuse box 37 indicators flasher relay 38 reversing light switch 39 136 i 4 H DI ws oo 2 A a RW EUR LL fee ENE ee It 3 i 340 0 X ins ee HERBES es i LE ED EF ES TT STE s lt Zx 69 x j s S2 E is En va x lt XT IBI nM iN ie n T pu ou ern j b 7 MX Br 3 P PI Coen SNES bY 4 ou K ry 3 n XK nin XJK N ia 3 ITE 4 Ugo 0 b T Male 5 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
79. replaced with the low battery warning light The instrument cluster is held to the dashboard by two nuts The connections for instrument cluster are through the printed circuit board which is fitted to the back of the housing The wiring diagram for the instrument cluster is shown in Fig 7 39 pre 1996 and Fig 7 40 1996 on The speedometer incorporates two trip recorders total mileage odometer and trip counter The trip counter can be reset Fault diagnosis Cause Remedy Temperature gauge or fuel gauge inoperative 1 Gauge faulty 2 Sender unit faulty 3 Wires damaged or wire ends corroded 1 Renew gauge or instrument clus ter 2 Renew sender unit 3 Check wiring restore connec tions Fuel gauge at zero with full tank Float stop set incorrectly beyond resistor winding Bend stop 1 2 mm down Fuel gauge needle moves erratically and frequently drops to zero 1 Poor contact between sender resistance and current collector 2 Sender resistor winding broken 1 Bend current collector 2 Renew sender Fuel reserve warning lamp stays on Sender lead earthed Warning 1 Bulb blown 2 Warning light switch faulty 3 Wires broken wire ends cor roded 4 Poor bulb holder contact with PCB Check eliminate earthing light failure 1 Renew bulb 2 Renew switch 3 Renew damaged wires clean wire ends 4 Bend bulb holder contacts or renew bulb holder Speedometer inoperativ
80. screws 1 and 7 Fig 7 31 which allow to alter vertical and horizontal settings of the reflector unit Headlight beam alignment is best carried out using optical beam setting equipment If it is not available the adjustment can be done using a screen A fully laden and equipped vehicle with a load of 735 N 75 kgf to represent a driver should be positioned on level ground facing a flat wall or screen plywood board of approx 2x1 m or similar at a distance of 5 meters with the vehicle centre line being normal to the screen Before marking off the screen make sure that the tyre pressures are correct next swing the vehicle to set tle the springs and shock absorbers Fig 7 31 Headlight alignment 1 7 headlight beam adjustment screws 2 optical unit 3 retaining screw optical unit rim 4 body front trim 5 trim retaining screw 6 optical unit rim 157 Three vertical lines should be drawn on the screen Fig 7 32 centre line O and lines A and B through the reference points E 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 2 passing through the centres of the headlight beam patterns Make sure the facia mounted switch of the headlamp aim adjustment system is in the position corresponding to the load of the driver only Switch on the
81. 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 or other cleaners Idle air control valve Replace the sealing washers with new ones The idle air control valve is of a taper shape 10 mm diam eter Always replace it with a new valve of the respective model Before fitting the idle air control valve to the throttle housing check the distance between the mounting flange and valve end Remember an excess protrusion of the valve can cause dam ages The distance should be less than 23 mm When with a new idle air control valve it is in excess of 28 mm sway the valve with your hand pushing it in To avoid damage do not hand push the valve which was in use For this purpose it is recommended to use a diagnostic tool or specialized monitor After having refitted the idle air control valve and central injec tion unit reconnect a diagnostic tool to the diagnostic plug and com mand the ECM to reset the parameters of the idle air control valve Throttle housing When reassembling the central injection unit it is a good practice to renew the sealing gasket of the fuel supply housing Scrape the gasket from the throttle housing and vacuum housing fit a new gasket Fuel supply pressure checking Carry out the following checks inspect the fuel delivery lines for leaks check the fuel pres
82. silencer 11 There is a steel heat shield over the catalytic converter Exhaust gasket 1 is fitted between the downpipe flange and exhaust manifold 1 The downpipe is connected to the catalytic converter flange through a moving joint Metal graphite ring 8 with a spherical sur face is placed between the flanges an inner spherical surface is provided in the flange of the downpipe The silencer pipes are held together by means of clasp 12 Downpipe 4 is attached by three nuts to the exhaust manifold and in addition to bracket 5 No dismantling or repair of the silencers or pipes is possible have them always replaced with new ones Electrical system Alternator The Valeo alternator is supplied together with the engine The wiring diagram for alternator is shown in Fig 9 26 When the ignition is switched on the alternator B terminal is powered through warning light 6 After the engine start current is not supplied through the warning light and it does not illumi nate The alternator W terminal is used for voltage supply to electronic tachometer 4 Starter motor The Valeo starter motor is supplied together with the engine The wiring diagram for starter motor is shown in Fig 9 27 Engine management system EMS The wiring diagram for the engine management system is shown in Fig 9 28 The system design operation and diagnostics are detailed in a separate Peugeot Manual for Diesel Engine Diagnostics Vehicle antithef
83. solvents Springs Check the tension characteristic of the spring on control points fig 4 17 previously having depressed it to bring the coils in contact Note According to length under load of 3432 N 350 kgf the springs are divided into two classes class A length more than 278 mm and class B length equal to or less than 278 mm The springs of A class can be not marked or have marks with white paint on the external side of coils and class B marked with black paint on the external side of the coils Check for spring deformation If the spring tension does not correspond to the data on fig 4 17 or the deformation can affect spring efficiency renew it Inspect the spring rubber gaskets if necessary renew Arms Check for arm deformation straighten if possible cracks on rear axle beam brackets and body overhaul the brackets in case of cracks the arm joint rubber bushes if necessary renew using a set of fixtures 67 7820 9517 Shock absorbers The design of shock absorbers of front and rear suspensions is shown on fig 4 18 Shock absorbers bench test To test the efficiency of the shock absorber make an oper ating diagram check on a dynamometer bench The working diagram is made according to the instruction attached to the test bench after no less than 5 working cycles at the shock absorber liquid temperature of 20 5 C the flywheel Fig 4 15 Rear suspension exploded view 1 l
84. special grinding pastes After regrinding and followed finishing unplug the oilways then machine the plug seats with the mill cutter A 94016 10 and spindle A 94016 Thoroughly wash the crankshaft and oilways to flush abrasive residuals and blow dry with compressed air Use tool A 86010 to press in new plugs and punch each plug in three points with a centre punch On crankshaft web No 1 mark the reduced amount under size of the main bearing journals and big end journals eg M 0 25 B 0 50 Bearing shells Remember that no adjustment on the bear ing shells is allowed Renew the shells when there are scratches scoring or flaking Fig 2 37 Permissible runouts for basic crankshaft surfaces The main and big end bearing running clearance is checked by measuring the components It is convenient to check the clearance with the help of Plastigage which consists of a fine thread of perfectly round plastic which is compressed between the bearing cap shell and the crankshaft journal under the fol lowing procedure ensure the journals and bearing shells are clean and dry cut several pieces of the appropriate size Plastigage they should be slightly shorter than the width of the bearings and place one piece on each crankshaft journal axis with the bearing shells in position in the cages fit the caps to their original locations depending on the journal checked Take care not to disturb the Plastigage Then
85. the crankshaft endfloat exceeds the specified limit of 0 35 mm Select new thrust washers of the standard size or 0 127 mm thicker to have the endfloat within 0 06 0 26 mm The crankshaft endfloat is checked with the help of a dial gauge as outlined in Section Engine reassembly Fig 2 14 The crankshaft endfloat can be also checked on the engine in the vehicle The axial shift of the crankshaft occurs at depressing and releasing the clutch pedal the endfloat value is determined by the front crankshaft end displacement Flywheel Inspect the teeth of the flywheel starter ring should they are found deteriorated renew the flywheel If there are temper colours on flywheel face 3 Fig 2 39 check the 26 starter ring interference on the flywheel The starter ring should not rotate when applying 590 Hem 60 kgfem Check to see there are no scratches or scores on flywheel face 1 mating the crankshaft flange or on surface 3 mating the Clutch disc Remove by lathing all scratches or scores on face 3 provid ed the overall thickness is reduced maximum by 1 mm Do not forget to lathe surface 2 maintaining the size 0 5 0 1 mm Ensure surfaces 2 and 3 are parallel to surface 1 The out of par allelism tolerance is 0 1 mm Mount the flywheel on the tool centralize is over the mount ing bore against surface 1 and check the run out of surfaces 2 and 3 The run out values at the outboard points must not exceed 0 1 mm Cylinder head
86. the cylin ders to the nearest oversize provide 0 03 mm honing allowance on the diameter Hone the cylinder walls so that the difference between the oversize piston diameter and cylinder bore is 0 025 0 045 mm Pistons and connecting rods General Description The basic sizes of the pistons and connecting rods are shown in Fig 2 29 Piston is an aluminium casting The piston weight is precisely maintained during the manufacturing process Consequently there is no need to select the matching piston of the same weight class during the engine assembly Fig 2 28 Measuring the cylinder bore A and B direction of measurement 1 2 3 and 4 No of lands There are five classes A B C D E of the piston according to their major diameter in steps of 0 01 mm The piston has a complex outside shape tapered in height and oval in the cross section area Therefore the piston diameter must be measured in the plane normal to the gudgeon pin at 55 mm from the piston crown There are three classes 1 2 3 of pistons as to the hole for the gudgeon pin in step of 0 004 mm The classes of piston diameters and holes for the gudgeon pin are stamped on the pis ton crown Fig 2 30 The oversize piston major diameter is 0 4 or 0 8 mm bigger The 0 4 step is marked in the form of a triangle while the 0 8 mm step is marked as a square Use the arrow on the piston crown for correct piston orienta tion and fitting within t
87. the flywheel using tool OUT0000049 loosen the crankshaft pulley retaining bolts remove the crankshaft pulley fix the flywheel with tool OUT0000015 secure the camshaft and fuel pump pulleys with retaining bolts the bolts should be hand tightened only loosen nut 2 and bolt 4 Fig 9 22 Fig 9 21 Removing and refitting the timing covers 1 securing bolts bottom cover 2 nut 3 bottom cover 4 securing bolts left hand cover 5 left hand cover 6 right hand cover 7 bolt 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 freely while plunger 1 and spring 6 are free with in the tensioner housing refit the belt providing it is taut Fig 9 22 Removing and refitting the cambelt 1 plunger 2 nut 3 tensioner roller 4 bolt 5 square type hole 6 spring 7 idler pulley refit the timing belt over the pulleys in the following order crankshaft pulley idler pulley 7 fuel pump pulley camshaft pul ley tensioner pulley water pump slacken bolt 4 to release the tensioner remove the retaining bolts and flywheel retainer tighten bolt 4 and nut 2 ro
88. the heated sections with a wooden mallet or a ham mer and facilitating the job with a flat block and anvil proceed with alternative heating and settling until you achieve the desired quality of the panel surface Panel irregularities can be rectified by means of polyester fillers thermosetting plastics cold set epoxy resins or soldering 10 169 Fig 8 2 Body components 1 front wing 2 battery tray 3 top bulkhead reinforcement 4 instrument panel crossbar 5 centre pillar 6 outer rear wheel arch 7 inner bodyside panel 8 rear floor cross member 9 roof panel 10 windscreen frame 11 bracket for wheel mudflap 12 roof reinforcements 13 rear pillar 14 rear floor panel 15 rear cross piece 16 brackets of door trim bow 17 inner arch rear wheel 18 floor to bodyside panel connection 19 floor cross member under rear seat 20 floor front panel 21 floor cross member under front seat 22 side panel front end 23 splash guard front wing 24 bulkhead 25 front chassis arm 26 front panel Fig 8 3 Main bodywork cross sections 170 Polyester fillers of Xewnponor l1 or 13 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 C The mixture of polyest
89. the opening in the front cover for oil outflow from the trans mission casing to avoid clutch disc contamination 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 together with the oil seal and spring washer see fig 3 15 Turn out the rear light switch take care not to deform the y Fig 3 14 Flexible coupling between the propeller shaft and the gearbox 1 propeller shaft flange to flexible coupling fastening nuts 2 clamp A 70025 3 flexible coupling 4 rear engine mounting crossmember Fig 3 16 Removing the circlip Fig 3 17 Removing the coupling centering ring from the propeller shaft 66 Fig 3 18 Removing the coupling flange using tool A 40005 3 9B 9C 1 flexible coupling flange 2 tool A 40005 3 3 tool A 40005 3 strap 4 tool to flange fastening bolts 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 o
90. the washers and screws then press out the bearing on a hand press Should the screw nuts fail to undo the screw ends are bent up cut off the screw ends Refit the new bearing to the alternator housing only when the bore for the bearing is not deformed and its diameter is not over 42 mm If the bore is bigger or deformed renew the housing Using a press drive in the bearing then compress the bear ing between two washers held by the screws and nuts Tighten the nuts and bend up the screw ends The slip ring rotor bearing is renewed together with the housing since when the bearing is damaged the recess in the housing is damaged too The bearing is removed from the rotor using a puller use a press tool to drive it into position Supplementary diodes renewal To replace a damaged diode unsolder its pins then careful ly take the diode out from the plastic holder taking care not to hit the diode plate Clean the holder from epoxy fit a new diode and solder it The colour coded diode terminal must be re soldered to the common output wire After soldering secure the diode to the holder with epoxy Starter motor Specification Maximum power KW 1 3 Amperage at maximum power not greater 290110 Amperage at brake on not greater s 550 Amperage at idle without solenoid not greater 60 146 General description The starter motor is of pre engaged type 35 3708 model DC with field coils i
91. this results in rod 3 clamped by col lets 8 during engine operation plunger 6 is effected only by spring 4 The spring releases the plunger from rod 3 head so that the clearance between them is filled with oil that acts as a damper when the chain strikes Chain renewal Apply the handbrake open the bonnet remove the spare wheel with the supporting tube and withdraw the battery Remove the air cleaner and close the carburettor inlet filler with a provisional cap Disconnect the throttle and choke cables from the carburettor 46 025 Fig2 54 Basic dimensions of the camshaft and the bearing housing 32 Fig 2 55 Camshaft and ancillaries drive 1 camshaft sprocket 2 chain 3 chain damper 4 oil pump shaft sprocket 6 stoppin 7 tensioner shoe 8 chain tensioner 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 pulley marks are aligned against a long mark in the timing cover Fig 7 18 Undo the camshaft sprocket retaining bolt Slacken the chain tensioner cap nut release the tensioner rod and fix it in position using the cap nut Remove the camshaft sprocket Slacken the alternator an
92. through damp or foul distributor cap inside distributor rotor resistor blown ignition coil damaged 4 Oily spark plugs or wrong elec trode gap 5 Spark plug damaged perished insulation 6 Wrong HT leads connection to distributor cap terminals 7 Wrong ignition timing check control module with oscillo scope renew faulty control module check renew faulty contact unit of ignition switch or ignition relay 3 Carry out the following check and restore connections clean or renew leads check and when necessary renew carbon brush check clean cap from moisture and carbon deposits renew cap and rotor in case of cracks renew resistor renew ignition coil 4 Clean and regap spark plugs 5 Renew spark plugs 6 Reconnect leads as per firing order 1 3 4 2 7 Check and adjust ignition timing Engine operates erratically or stalls at idle 1 Ignition timing too advanced 2 Electrode gap excessive 1 Check adjust ignition timing 2 Check adjust electrode gap Engine running unstable or irregular at high crankshaft speeds Weak weight springs in ignition distributor Renew springs run functional bench test of centrifugal unit 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
93. to interior light C to ignition relay terminal 86 D to starter relay terminal 86 Q po 1 fo 1 Fig 9 31 Wiring diagram for direction indicators and hazard warning flashers 1 direction indicators front lights 2 side repeat indicators 3 ignition switch 4 control module theft deterrent system 5 ignition relay 6 fuse and relay box 7 direc tion indicators rear lights 8 direction indicator warning light in instrument cluster 9 indicators flasher relay 10 hazard warning flasher switch 11 direction indicator switch Fig 9 32 Wiring diagram for windscreen wipe wash 1 windscreen washer motor 2 windscreen wiper motor 3 ignition switch 4 control module anti theft system 5 ignition relay 6 fusebox 7 windscreen wipe wash switch 8 pin assignment in switch connector 9 windscreen wiper relay 10 pin assignment in windscreen wiper relay and motor connectors 206 Fig 9 33 Wiring diagram for tailgate wipe wash and heating element 1 fusebox 2 wipe wash switch 3 rear window washer motor 4 rear window wiper motor 5 rear window heating element 6 heated rear window relay 7 heated rear window warning light 8 heated rear window switch 9 ignition switch P E E P Fig 9 34 Wiring diagram for cooling fan motors 1 motor on sensor 2 fan blower motor 3 fan motor cut in relay 4 fuse 8 a
94. to the air intake wall A faulty relay is not repairable and must be always replaced with a new relay The relay should ensure the direction indicators flashing at a rate of 90 30 cycles per minutes at 92 watt ambient temperature of 20 to 50 C and supply voltage between 10 8 and 15 volts Headlamp on relay The headlights are switched by means of relay 3 and 11 Fig 7 28 model 113 3747 10 fitted below the instrument panel on the left Similar relays are used to switch the rear window heat ing headlight wipe wash The relay cut in voltage at 23 5 C must not exceed 8 volts the winding resistance should be 8558 5 Ohms Horn The vehicle is fitted with a horn of model 20 3721 The horn is located in the engine compartment behind the radiator grill The horn wiring diagram is shown in Fig 7 33 When the volume is low or the horn emits harsh sound adjust it using the adjustment screw on the horn body unit until a satis factory sound is achieved In the event of the horn failure inspect all connections and condition of the switch contacts Fig 7 33 Horn wiring diagram 1 inspection lamp socket 2 horn 3 horn switch 4 fusebox Windscreen wiper washer General description The windscreen wipe wash comprises motor linkage and blades The windscreen wipe wash wiring diagram is shown in Fig 7 34 There are two operating modes of the windscreen wiper con tinuous operation and intermittent
95. volts and frequency of 25 Hz the current flow is 7 to 8 amps while the dwell is 5 5 to 11 5 milliseconds For PZE4022 module at the supply voltage of 14 0 3 volts and frequency 25 Hz the current flow is 7 3 7 7 amps while the dwell is not specified For K563 3747 module at the supply voltage of 13 5 0 5 volts and frequency 33 3 Hz the current flow is 7 3 7 7 amps while the dwell is not specified Any distortions in the pulse waveform can result in misfires or retarded ignition The engine will tend to overheating and will not develop maximum power 154 Spark plugs If the spark plugs are foul or have deposits then prior to test ing clean them by means of a sand blasting machine and blow with compressed air When the insulator nose is covered with light tan to greyish brown deposits there is no need to clean them as it is indicative that the mixture is correct and the engine is in good condition Once the plugs have been cleaned examine them and set the correct spark gap If the insulator is chipped cracked or the side electrode weld is perished renew the spark plug Check the spark plug gap it is to be 0 7 0 8 mm with a round wire feeler blade It is not recommended to use a flat feeler blade since it is cannot account for erosion cut out on the outer electrode which appears in course of operation Bend open or close the outer side plug electrode only until the correct gap is achieved Leak test Screw the pl
96. well as for rusty surfaces Protective grease of HI M MJI type is used for inner cavities New vehicles have all inner cavities already coated with it Use a protective skin of HI 216B type on the underbody Bitumen type sound proof sealant BIM 1 offers corrosion protection and noise reduction for the underbody The thickness of the protective layer to be 1 0 1 5 mm Plastisol 4 11A helps protect the vehicle underbody against corrosion abrasive wear and contributes to better sound dead ening The layer thickness should be 1 0 1 2 mm All new vehi cles have the underbody coated with 4 11A type plastisol Plastisol 1 4A is applied on weld seams Use the wet type sealant 51 7 on body joints Both air and airless rust inhibitor spraying is recommended for hard to reach or hollow cavities For air spray method you need compressed air supplied at 0 5 0 8 MPa 5 8 kgf sq cm and a spray gun with a tank hoses and extensions for the gun The optimum coating is achieved with airless spraying at 4 12 MPa 40 120 kgf cm where high er viscosity paints can be successfully used Box sections preparations and corrosion treatment Inner cavities require specialist equipment Entrust the job to the skilled personnel in workshops Follow the procedure below when treating inner cavities against corrosion 173 Fig 8 6 Front view of the body Inner cavities of 1 top front cross member 2 headlight casings 3
97. wheel hub bearing nuts adjust the bearing clearance as specified in subsection Front suspension Dismantle and reassembly Dismantle is needed in case of damage on boot 6 and shroud 5 with the aim to check the joint components and the quality of greasing The order of dismantle is the following undo clip 9 see fig 3 82 remove it from boot 6 and move the shroud with the boot on the shaft to provide access to joint race 11 using a knock out and a hammer beat off race 11 from the shaft ATTENTION To exclude jamming circlip 12 pay atten tion not to skew the race be careful in choosing the force and direction of impact remove thrust rings 7 boot 6 and shroud 5 from shaft 4 move on the shaft the inner joint shroud and boot and after taking out lock ring 2 take out from case 1 shaft 4 in assembly with race cage and balls 1 2 3 Fig 3 83 Front wheel drive outer joint exploded view 1 joint housing 2 cage 3 race 4 ball E OARS M m Fig 3 82 Front wheel drive clip 13 outer joint casing 1 inner joint housing 2 circlip 3 boot clamp 4 wheel drive shaft 5 shroud 6 boot 7 race thrust ring 8 cage 9 clip 10 ball 11 outer joint holder 12 cir 7 8 9 10 11 12 13 98 Fig 3 84 Withdrawing the ball from the cage Fig 3 85 Withdrawing the cage race as
98. 0 Set of reamers valve guide bore machining A 90353 Reamer for bushes of oil pump drive shaft ignition distributor and fuel pump A 94003 Core drill 75 inlet valve seat machining A 94016 Core drill spindle plug machining A 94016 10 Core drill crankshaft plug socket machining A 94031 Core drill 20 exhaust valve seat machining A 94058 Core drill spindle valve seat machining A 94059 Set of guides valve seat machining A 94069 Grinding wheel spindle valve seat machining A 94078 Grinding wheel exhaust valve seat machining A 94092 Core drill exhaust valve seat machining A 94100 Grinding wheel inlet valve seat machining A 94101 Core drill 20 inlet exhaust valve seat machining A 95111 Blade for checking camshaft valve lever cam lobe clearance 02 7812 9500 Socket spanner 13 mm removal and refitting of starter motor and downpipe 02 7823 9505 Tool valve removal and installation can be used in place of A 60311 R 41 7816 4013 Socket spanner 21 mm for tightening valve lever adjuster bolt guides 41 7853 4010 Installation tool camshaft cover to engine 41 7853 4011 Installation tool oil seal retainer to crankshaft 41 7853 4016 Installation tool valve guide oil caps 67 7812 9513 Dynamometer for checking fan blower belt tension 67 7812 9514 Spark plug spanner 67 7812 9515 Spanner for checking spark plug tightening torque 67 7812 9519 Socket spark plug removal installation 67 7824 9521 Tool for checking wear extension of
99. 14 15 1 18 6 1 53 1 9 66 6 82 3 6 8 8 4 27 4 34 2 8 3 46 50 61 7 5 1 6 3 Refer to Running gear 29 1 36 2 97 3 67 15 18 6 1 53 1 9 83 3 102 9 8 5 10 5 66 6 82 3 6 8 8 4 104 9 169 5 10 7 17 3 114 7 185 2 11 7 18 9 20 6 25 75 2 1 2 63 62 4 77 1 6 37 7 87 63 7 102 9 6 5 10 5 66 6 82 3 6 8 8 4 38 2 61 7 3 9 6 3 66 6 82 3 6 8 8 4 33 3 41 2 3 4 4 2 33 3 41 2 3 4 4 2 42 1 53 4 3 5 4 22 5 27 4 2 3 2 8 31 4 51 3 2 5 2 15 18 6 1 53 1 9 199 9 247 20 4 25 2 63 7 102 9 6 5 10 5 Attachment 2 SPECIAL TOOLS FOR MAINTENANCE AND REPAIR Designation Description ENGINE A 40005 Universal pickers kit A 40026 Removal tool coolant pump impeller A 50088 Spanner intake exhaust pipe nuts A 50113 Allen key crankcase oil drain plug A 50121 Spanner crankshaft pulley bolt A 50126 Spanner for checking cylinder head bolt tightening torques with camshaft in situ A 60153 R Mandrel for pressing in out inlet exhaust valve guide A 60311 R Tool removal installation of engine valves A 60312 Removal tool oil filter A 60326 R Tool to press out ignition distributor oil pump drive gear bush from the cylinder block A 60330 R Flywheel fixing arm for fitting flywheel to crankshaft A 60333 1 2 Tool to press in out oil pump drive shaft bushes A 60334 Tool for checking cylinder head tightness A 60430 Installation tool coolant pump impeller A 86010 Tool for pressing in crankshaft plugs A 9031
100. 2 see fig 5 2 and tighten jam nut 4 After adjusting the roller to worm mesh gap use a dynamometer to check the worm friction which should be equal to 68 7 88 3 Necm 7 9 kgf cm when turning the worm shaft by 30 both to the left and to the right from the middle position and should smoothly reduce to 49 N cm 5 kgf cm when turned from the 30 position further to the stop After the reassembly check the angles of pitman rotation from the neutral position which should make 32 10 1 both to the left and to the right until the pitman arm will get pressed against the bolt head fill the steering box with 0 215 of transmission oil Check and repair Carefully examine the working surfaces of the roller and the worm for traces of wear jamming or risks Renew worn and dam aged components Check the size of the clearance between the bushes and the pitman arm shaft which should not exceed 0 10 mm If the clear ance is more than specified renew the bushes using tool A 74105 On the inner surfaces of the pitman arm bushes there are spi ral flutes which come out only from one side When press fitting the bushes should be located so that their end faces with the flutes were inside the aperture of the steering box and the outputs of the flutes were facing each other The end faces of the bushes should be deep inside the steering box aperture by 1 5 mm New bushes should be greased with transmission oil before press fitting
101. 21 rS r TA P a NG T LZ ON Fig 6 17 Rear wheel brake mechanism 1 wheel cylinder 2 upper return spring 3 friction lining 4 backplate 5 inner plate 6 rear cable sheath 7 lower return spring 8 front brake shoe 9 thrust plate 10 rivet 11 oil deflector 12 guide plates 13 handbrake rear cable 14 rear cable spring 15 rear cable end 16 rear brake shoe 17 steady post 18 shoe manual control lever 19 rubber pads 20 expander strut 21 shoe manual control lever pin 1 7 AN SIS Fig 6 18 Removing the brake drum 1 remover tool 67 7823 9519 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 Nem 0 4 0 7 kgfem Slot A see fig 6 19 on thrust rings should be directed ver tically upward vertical deviation should be no more than 30 Such position of the slot provides complete air bleeding from the brake mechanism for preliminary compression of thrust rings the pistons are press fitted in the cylinder body with a special tool having the form of a cylinder with a cone inner aperture the effort of press fitting the piston in the cylinder should be no less than 350 N 35 kgf in case effort was less than 350 N 35 kgf replace the thrust ring when press fitting the piston in the cylinder it is necessary t
102. 29 Automotive theft deterrent system 1 control module 2 LED for system state indication 3 key fob 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 relay 3 The sensor is fitted to the right hand radiator cooler The sensor contacts close at 99 3 C and open at 9443 C The relay is housed in the engine bay and is bolted to the top bulk head reinforcement The motors are maintenance free and must always be renewed in case of failure Motor specification Nominal motor shaft speed with impeller load TOM ceri pe RR Rei ede 600 2800 Current consumption at speed and load as specified ampere not greater 14 Instrument cluster The instrument cluster includes speedometer with trip counter coolant temperature gauge fuel gauge tachometer 13 warning lights Fig 9 35 The wiring dia gram for instrument cluster is shown in Fig 9 36 The instrument panel pin assignment is shown in Table 9 3 205 b A B B4 ad al u BY Fig 9 30 Wiring diagram for theft deterrent system 1 LED for system state indication 2 control module 3 ignition switch A to interior light switch B
103. 40 rpm check the fuel delivery by the pump to be at least 54 litre hour at 20 5 C while the supply pressure at zero fuel delivery must be 0 02 0 03 MPa 0 21 0 30 kg cm When found defective dismantle the fuel pump and examine all its components Dismantling cleaning and inspection To dismantle unbolt cover 5 remove the cover and fuel pump filter 2 Next undo the screws holding the housing to the lower cover separate them withdraw the diaphragm unit and spring Wash all compo nents in petrol and blow dry with compressed air Examine the state of components The pump springs must be undamaged Check the valves are not sticking The diaphragms must have no fractures cracks or hard spots 43 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 line 12 fuel line 13 hose clips 14 non return valve 15 carbu rettor 16 fuel pump 17 fine fuel filter 1 Fig 2 79 Fuel pump 1 delivery pipe 2 filter 3 housing 4 suction pipe 5 cover 6 suction valve 7 operating rod 8 hand priming lever 9 spring 10 eccentric 11 rocker 12 mechanical priming lever 13 lower cover 14 inner distanc
104. 8 kN 10000 kgf so that not to affect the housing pro file Note If the height of the rest was experimentally correctly adjusted the beam can be straightened without monitoring by a try square or an indicator Remove the beam from the press and check as mentioned above having replaced flanges A 70172 with test ones In case there is no necessary equipment available as an exception it is possible to straighten the rear axle beam first from one side then from the other but with an obligatory deformation check from both sides see Rear axle beam check Axle shafts Removal and refitting Remove the wheel and the brake drum After unscrewing the nuts fastening the brake backplate to the axle beam hold the backplate and using pusher 67 7823 9516 remove the axle shaft together with the oil screen bearing fastening plate and bearing stop ring Take out the seal from the beam flange if necessary to renew The axle shaft refitting is a reversal to removal paying atten tion not to damage the working edge of the seal Before refitting the brake drum grease the landing shoulder of the axle shaft with Fig 3 59 Checking for horizontal deformations of the rear axle beam using a try square on the outside surface of flange A 70172 Fig 3 61 Pressing out the axle shaft bearing stop ring 1 fixture 2 axle shaft graphite greasing or JICL 15 After refitting check the operation of axle shafts dur
105. 9 windscreen washer pump 10 tailgate washer pump 180 Fig 8 26 Washer pump 1 motor 2 reservoir cover 3 sleeve 4 pick up tube 5 pump housing 6 rotor shaft 7 rotor shaft support 8 rim and filter gauze 9 rotor LOS Po ees LOT LG SLEPT o2 O DOS off PO ws Fig 8 27 Windscreen and tailgate washer jets 1 jet housing 2 atomizer 3 gasket 4 pipe union Nma A 14 Fig 8 28 Instrument panel components 1 bracket 2 reinforcement 3 instrument panel 4 glovebox housing 5 lid catch 6 glovebox lid 7 spring 8 lid latch 9 shelf 10 lid hinge link 11 trinket tray 12 retaining clips 13 radio support panel 14 instrument panel surround 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 screwdriver and force the jet complete with the atomizer Detach the tube and blow atomizer 2 and housing with compressed air Refit the jet pushing its hous ing strongly into the bore in the body Adjust the fluid jet through altering the atomizer position with in the socket in the housing For that insert a needle into t
106. 9514 remove the hub cap and undo the wheel hub bearing nut 107 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 upper control arms and remove the steering knuckle smoothly unload the suspension spring and take it off using pusher 67 7823 9515 knock out the shaft and discon nect the suspension lower arm from the crossmember disconnect the upper arm shaft from the crossmember and remove the shaft in assembly with the control arm Note Before removing the upper and lower arm shafts count the amount of washers on each end of the lower arm shaft and on the fastening bolts of the upper arm shaft so that to refit them in former places remove the recoil bumper bracket and the crossmember as described above using puller 67 7824 9516 press out the balljoint pins from the steering knuckle The front suspension components are shown on fig 4 7 The reassembly of suspension units is carried out in reverse sequence When reassembling the wheel hub grease the bearing cages with JINTOJI 24 and put a thin layer in the cav ity of the steering knuckle between the bearings in the amount of 40 gr in each knuckle Whe
107. ENGINE lamp and to ignition switch termi nal 15 There are four fuses in the EMS wiring harness They are located in a separate fusebox 26 underneath the left hand end trim cover Refer to Table 9 2 for details 196 Table 9 2 Injection system fuses 2 Eleetrie fuel Electric fuel pump 3 4 ECU 5 6 Main relay contacts Oxygen sensor Vehicle speed sender Canister purge solenoid Electric fuel pump relay winding Electrical fan blower relay winding ECM MAF meter Injection wiring harness 7 8 Electric fan blower relay contacts Electric fans Besides the fuses there is a fusible link at the end of red wire which is connected to the battery terminal The fusible link represents a length of black wire of 1 mm cross section whereas the main red wire is 6 mm cross section Cooling fan motors The cooling fans are operated by two dc motors MP 8015 model on permanent magnets The motors are triggered by EMS ECU via a relay With the engine running the relay cuts in when the coolant temperature exceeds 105 C or cuts off when the coolant temperature goes below 101 C The motors are maintenance free and must be renewed in case of failure Motor specification Nominal shaft speed with impeller load rom 2000 2200 Current consumption at speeds and loads as specified amperes not greater 0 005 15 2123 1411020 10 55 37 19
108. NTION When repairing the rear axle reduction gear install a new distance sleeve if the reduction gear casing the final drive gears or the driving gear bearings were replaced If these parts were not changed the former dis tance sleeve can be used Fit the driving gear into the reduction gear casing and place on it the front bearing inner ring the oil deflector sealing the dri ving gear flange and washer Screw a nut on the gear end and having locked the driving gear flange tighten it tightening torque is specified below Adjustment of the driving gear bearings To restrict the axial shifts of the driving gear under working loads it is very important to create the bearing preload within the given limits Tension is monitored by a dynamometer 02 7812 9501 fig 3 75 which measures the driving gear moment of resistance to rotation The moment of resistance to rotation determines the tight ness of the bearing It should be 157 196 Necm 16 20 kgf cm for new bearings and 39 2 58 8 Necm 4 6 kgf cm for bear ings after mileage of 30 km and more The flange nut should be tightened to torque 118 255 Nem 12 26 kgfm periodically checking with the dynamometer the bearing s moment of resistance to the rotation of the driving gear To check the resistance torque fix the dynamometer on sleeve 3 fig 3 76 place the torque limit indicator 2 fig 3 75 on the scale division corresponding to 196 Necm 20 kgfecm and
109. Undo the lower bolts of the clutch bellhousing cover plate Disconnect the ground wires from the clutch bellhousing and the wires from the tail light switch Unhook the return spring 1 fig 3 13 from the clutch release fork 5 and take pin 4 out from pushrod 6 Disconnect the slave cylinder 8 from the clutch bellhousing Thus cylinder 8 connect ed to the master cylinder hose remains on the vehicle what excludes loosing brake liquid and necessity of the subsequent bleeding of the clutch release hydraulic drive Put clip 2 A 70025 on the flexible coupling 3 fig 3 14 and tighten This will help in subsequent removal and refitting of the flexible coupling Undo nuts 1 and by turning the layshaft remove the bolts that are fastening the flexible coupling 3 to the flange of the gearbox output shaft Disconnect the speedometer cable from the speedometer drive unit on the transfer box Disconnect the shaft flanges of the front and rear axles drive from the flanges of the transfer box shafts Lower and move aside the axle drive shafts Undo the bolts that are fastening the transfer box brackets to the car body and remove it together with the propeller shaft Using a socket spanner 02 7812 9500 undo the bolts fasten ing the starter motor to the clutch bellhousing and release it Undo the clutch bellhousing cover plate bolts Disconnect the engine rear mounting from the crossmember 4 fig 3 14 and then remove the crossmember while
110. VAZ VEHICLES VAZ 21213 VAZ 21214 VAZ 21214 20 VAZ 21215 REPAIR MANUAL Contents Section 1 General data sssesssssssees 4 Section 2 ENGNG inr Pe eite retro 7 Engine removal and refitting essssessss 12 Cylinder DlOCK citer idein enters re cci cna amr RENS 19 Inspection and repair sen 19 Pistons and connecting rods eeseeeeese 21 Selecting piston to cylinder ssessssse 23 Dismantling and reassembly sss 23 Crankshaft and flywheel sss 24 Design description eeeeeeeseeeeeeeess 24 Inspection and overhaul ssssssssssss 24 Cylinder head and valve gear 26 General JescriptiO N s siiis susretne 26 Valve clearance adjustment ssessess 27 Cylinder head removal and refitting 28 Cylinder head dismantling and reassembly 28 Camshaft and timing gear sssees 32 Cooling SYSTEM ascent rece aha ei 34 Lubrication system eese 38 aU e 42 er Tenit 46 Exhaust gas recirculation system 55 Exhaust Systeiri ener Id n reru ia 46 Chapter 3 Power train 57 d E 57 CI 1 010 ce 64 Thanster e d 73 LD som lols yet EE 80 Rear axle mE 84 FrontaXl
111. ad bolt M12x1 25 Refer to chapter Engine Cylinder head bolt M8 31 36 39 1 3 2 3 99 Nut inlet and exhaust pipe securing stud M8 20 87 25 77 2 13 2 63 Nut big end cap bolt M9x1 43 32 53 51 4 42 5 46 Flywheel securing bolt M10x1 25 60 96 87 42 6 22 8 92 Chain tensioner shoe bolt M10x1 25 41 2 5 0 4 2 5 2 Valve cover bolt M6 1 96 4 60 0 20 0 47 Camshaft bearing housing retaining nut M8 18 33 22 64 1 87 2 3 Oil pump shaft sprocket bolt M10x1 25 41 2 51 0 4 2 5 2 Camshaft sprocket bolt M10x1 25 41 2 51 0 4 2 5 2 Nut valve adjuster bolt M12x1 25 43 3 53 5 4 42 5 46 Valve adjuster bolt sleeve M18x 5 83 3 102 9 8 5 10 5 Spark plug M14x1 25 30 67 39 3 13 3 99 Coolant pump retaining bolt M8 21 66 26 75 2 21 2 73 Nut water jacket exhaust manifold M8 15 97 22 64 1 63 2 31 Crankshaft ratchet M20x1 5 101 3 125 64 10 34 12 8 Alternator bracket bolt M10x1 25 44 1 64 7 4 5 6 6 Nut alternator mounting plate M10x1 25 28 03 45 27 2 86 4 62 Nut alternator to bracket securing bolt M12x1 25 58 3 72 0 5 95 7 35 Mounting plate to alternator retaining nut M10x1 25 28 03 45 27 2 86 4 62 Retaining nut engine front mounting bracket M8 10 4 24 2 1 1 2 5 Retaining nut front mounting rubber to crosspiece bracket M10x1 25 27 4 34 0 2 8 3 46 Retaining nut rear engine mounting crosspiece M8 15 0 18 6 1 53 1 9 Retaining nut rear engine mounting transmission M8 28 3 28 8 2 38 2 94 Retaining nut rear engine mounting crosspiece
112. ad measurement is affected Evenly tighten both adjusting nuts of the bearings the differ ential bearings covers will go apart and hence distance D fig 3 79 will increase by 0 14 0 18 mm Having established the exact preload of the differential hous ing bearings finally check the side gap in the final drive gears mesh which should not change If the gears mesh gap is more than 0 08 0 13 mm move the driven gear closer to the driving gear or move it away if the gap is below this value To maintain the bearings preload move the driven gear tightening one of the bearing adjusting nuts and loosen the other one by the same angle To fulfill this procedure correctly watch the indicator 9 see fig 3 77 which shows the size of the previously set bearing pre load After tightening one of the nuts the indication will change as distance D fig 3 79 between the covers and the bearings pre load increase Therefore the other nut should be loosened until the indicator arrow will return to the initial position 93 1 3 pm oD Fig 3 77 Checking the differential housing bearing preload using fixture A 95688 R 1 fixture screw 2 key A 55085 3 driven gear 4 adjusting nut 5 inter mediate lever 6 securing screw 7 indicator bracket 8 bracket securing screw 9 indicator for checking the bearing preload After moving the driven gear check the side gap by indicator 2 see fig 3 78
113. aft balance is checked at speed of 800 min on surfaces E and F Equilibration is provided by balance washers 1 see fig 3 53 and drilling the U joint housing The out of balance condition should not exceed 1 96 Nemm 200 grf mm ATTENTION If any of the shaft components were replaced during repair it is necessary to balance the shafts After balancing lubricate the U joint bearings with grease N158 or OJT 2Y through oilers Force in the grease until it will start coming out through the sealings 83 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 1 Tighten wheel securing nuts 2 Inspect axle shaft and replace 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 Wrong adjustment damage or wear of gears or reduction gear bearings 4 Wear or wrong adjustment of differential bearings 1 Rectify beam and check dimen sions renew axle shaft bearings 2 Straighten axle shafts In case of heavy damages renew 3 Isolate problem and repair reduc tion gear 4 Dismantle reduction gear repair and adjust Noise at acceleration 1 Wrong adjustment of final drive gear mesh during reduction gear repair 2 Damaged axle shaft b
114. ainst the driven gear is provided by selecting the thickness of the adjusting ring fitted between the driving gear face and the rear bearing inner ring Select the thickness of the adjusting ring with the help of tool A 70184 and tool A 95690 with an indicator The procedure is carried out in the following sequence Fix the reduction gear casing on a bench use tool A 70185 to press fit the outer rings of the drive gear front bearing in the casing and tool A 70171 fig 3 70 for the rear bearing On tool A 70184 simulating the driving gear with the help of tool A 70152 fit the rear bearing inner ring and insert the tool into the reduction gear casing fig 3 71 Fig 3 70 Fitting the driving gear rear bearing outer ring using special tool 1 tool A 70171 Fit the front bearing inner ring the driving gear flange and while turning the tool to refit the bearing rollers correctly tighten the nut with torque to 7 85 9 8 Nem 0 8 1 kgf m Fix tool A 95690 on tool face 4 and adjust the indicator with a 0 01 mm scale to zero having established its leg on the same end face of tool A 70184 Then move indicator 1 so that its leg will be on the landing surface of the differential housing bearing Turn tool 4 with indicator left and right and find a position in which the arrow of the indicator will show the minimum reading of a fig 3 72 and record Repeat this operation on the landing surface of the second bearing and
115. an the seat cham fers from carbon using tools A 94031 and A 94092 for the exhaust valves and A 94003 and A 94101 for the inlet valves Use spindle A 94058 and centering tool A 94059 The centering tools differ in diameters use tool A 94059 1 for the inlet valve guides and A 94059 2 for the exhaust valve guides 29 32 5 32 7 Fig 2 46 Intake valve seat profile new seat Il reconditioned seat I 27 5 27 7 Fig 2 47 Exhaust valve seat profile new seat Il reconditioned seat Put spring A 94069 5 on tool A 94059 fit tapered wheel A 94078 on spindle A 94069 for the exhaust valve seats or whee A 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 dis tort the chamfer Frequent diamond dressing of the wheel is rec ommended The working chamfer width for the exhaust valve seats should be as shown in Fig 2 46 using tools A 94031 20 and A 94092 to remove the wear hardening on the minor diameter The tools should be used with spindle A 94058 and are centered with tool A 94059 The working chamfer width for the inlet valve seats should be as shown in Fig 2 47 first machine the inner chamfer with tool A 94003 Fig 2 49 to get the diameter of 33 mm then machine the 20 chamfer with tool A 94101 to achieve the working cha
116. and cylinder block open the heater drain tap and remove the radiator filler cap 38 disconnect the hoses from the radiator separate the fan cowl halves and withdraw the fan cowl undo two bolts holding the radiator to the body release the upper catch of the radiator cowling upwards move the radiator top towards the engine and withdraw the radiator from the engine compartment take out the radiator cowling Radiator leak test The radiator tightness is checked in a container full of water Plug the radiator pipes apply air at pressure of 0 2 MPa 2 kgf cm and immerse the radiator into the water for at least 30 seconds The radiator should show no air bubbles Repair or renew the radiator when it is found leaky or dam aged Radiator repair In the event the aluminium tubes are dam aged dismantle the radiator drill the defective tubes from both ends to a depth of 25 30 mm using a drill of 8 5 mm diameter Fit the undersize tubes flared at one end of 7 3 mm diame ter and 0 5 mm wall thickness into the defective tubes Then on a special stand push the tubes all the length down using a steel core of 7 5 0 05 mm On the respective bench expand each tube from both ends simultaneously Assemble the radiator and check it for tightness Lubrication system Refer to Fig 2 67 Engine oil change Change oil only when the engine is hot Allow at least 10 min utes after the drain plug is removed for all the oil
117. 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 40 components for other vehicles In the event the adjustments are lost or a component is damaged in an accident or during dismantling do not reuse the SRS 40 com ponents In case of an accident the impact sensor inside the inflator module receives an impact force pulse and at the preset pulse level activates the system releasing gas nitrogen through the holes in the housing filling the airbag that is folded inside the module During the airbag filling it breaks through the central seam on the steering wheel trim pad which halves go open up and down respectively The airbag of 40 litre capacity is deployed in front of the steering wheel The protective function of the steering wheel with the SRS 40 airbag is intended for one application only therefore after the accident renew the steering wheel complete with the inflator airbag module and other steering related parts damaged The steering fitted with an airbag features a different original steering wheel which houses the gas generator and airbag mod ule unit there is also an original bracket to secure the steering column Refer to chapter 5 for design description and repair instructions with respect to other steering associated units and components Removal and refitting WARNING 1 Always use eye protection a
118. and valve gear General description Refer to Fig 2 40 for basic sizes of the valves guides and valve seats Cylinder head is an aluminium casting with the pressed in iron valve seats and valve guides The top of the valve guides is sealed with metal rubber oil caps 3 Fig 2 41 i N N D Fig 2 40 Basic dimensions of the valves valve guides and valve seats Y IL TL Ae x Fig 2 41 Cylinder head cross sectional view showing the exhaust valve 1 oylinder head 2 valve 3 oil cap 4 lever 5 bearing housing 6 camshaft 7 adjuster bolt 8 lock nut A cam to lever clearance 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 gear Valve clearance adjustment The clearances are adjusted on the cold engine by means of the chain adequately tensioned The adjustment should result is 0 15 0 02 mm clearance for the intake valves and 0 2 0 02 mm clearance for the exhaust valves While making adjustments do not to twist the valve lever since it may result in a bigger final clearance The clearance is adjusted as follows turn the crankshaft clockwise to align the indentation i
119. antly on the warm engine When necessary use areometer to check the coolant densi ty to be 1 078 1 085 g cm for Tosol A 40 When the level in the expansion tank is below the norm while the density exceeds the value required add distilled water In case of normal density top up the coolant of the same grade as the coolant in the cooling system Coolant change Observe the following procedure when changing coolant set the heater controls in the position heating undo the caps in the bottom radiator cooler and cylinder block remove the expansion tank cap and drain coolant through two drain holes Detach the expansion tank and lift it over the radiator then remove the coolant remainder from the expansion tank to flush the cooling system fill the system with clean water start the engine and run it until the radiator bottom cooler is warm With engine idling drain water through the drain holes stop the engine and let it cool repeat flushing steps as described above after flushing refit the caps and fill the system with new coolant 25 30 mm above the MIN mark on the expansion tank Fill coolant through the filler neck of the expansion tank Refit the cap start the engine and allow it to idle for 1 5 2 minutes Stop the engine and when necessary top up coolant Cambelt removal and refitting The cam removal procedure is as follows Fig 9 21 remove covers 3 5 n 6 of valve timing mechanism fix
120. aperture Undo the retaining screws to remove the swivel glass com plete with the sliding glass weatherstrips Undo door locking knob 6 Fig 8 15 undo the screws that retain inner door handle 1 bracket 4 Undo lock securing screws 3 Fig 8 16 and remove the lock complete with the links having first detached lock release link 20 Fig 8 15 from the lock driver Undo the two securing nuts and remove the external door handle Undo the two retaining bolts and remove the check strap Reassembly is a straightforward reversal of dismantling When refitting the window lifter watch there is no overlapping of the cable on the drum Adequately adjust the tension of cable 2 Fig 8 17 and ensure smooth operation of the window lifter by means of the tension roller having slackened nut 3 Before refitting the door trim inspect the plastic clips Front door alignment Start the alignment by marking the contours of hinges on the body pillar Using impact screwdriver 2 Fig 8 12 slacken hinge retaining screws 1 Align the door with the aperture in the body to the clearances required shifting the hinges within the contour marked On com pletion tighten the screws 178 Fig 8 17 Adjusting the window lifter cable tension 1 sliding glass holder 2 cable 3 nut tensioner bolt Fig 8 18 Tailgate 1 gaskets 2 hinge 3 window seal 4 glass 5 tailgate 6 doo
121. aphragm after each dismantling Always smear the thread of the regulator cover securing screw with sealant WARNING When refitting the fuel pressure regulator check to see the diaphragm sits correctly without skewing Fuel supply housing of central injection unit During reassembly of the central injection unit always renew the gasket between the fuel supply housings and throttle plate Cut outs in the gasket should be aligned with the bores in the throttle plate Fig 9 3 Central injection unit 1 fuel pressure gauge 2 injector 3 connection for fuel delivery pipe 4 throttle position sensor 5 connection for fuel return hose to tank 6 pipe union for canister purge hose 7 pipe union for crankcase vent hose 8 pipe union for MAP sensor hose 9 idle air control valve 10 quadrant for throttle actua tion from pedal in the passenger compartment Fig 9 4 Components and assemblies of central injection unit 1 throttle stop screw preset at the factory 2 fuel pressure regulator cover 3 spring 4 diaphragm 5 air cleaner gasket 6 injector 7 holder 8 fuel delivery pipe union 9 fuel return pipe union 10 throttle position sensor 11 throttle shaft 12 grommet 13 vacuum pipes housing 14 idle air control valve Apply sealant on the thread of the housing securing screws Throitle position sensor Before fitting the TP sensor fully close the throttle then turning the
122. are tightened with torque specified in appendix 1 use tool 67 7820 9520 to reduce the transfer box shaft nuts see fig 3 46 79 Fig 3 46 Reducing the rear axle shaft flange nut 1 tool 67 7820 9520 2 flange retainer 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 quickly under the air jet to prevent damage Casing and covers There should be no cracks on the cas ings and covers no signs of wear or damage dents chipping is allowed on the surface of bearing housings Damage on surfaces between casing and covers may result in misalignment of shafts and oil leak Small damages can be repaired with a file Renew the parts with significant damage or wear Seals Carefully inspect their condition Renew in case of even insignificant damages The wear width of working edges should not exceed 1 mm Shafts On working surfaces threaded parts and on shaft splines no damages are allowed To check the runout of the input shaft and the drive shafts of the front and rear axles place them on V blocks and turn manually The runout of face ends of bear ing thrust shoulders should be no more than 0 01 mm When checki
123. ary to inspect the protective covers of suspension balljoints paying special atten tion to any possible mechanical damages It is necessary to check the suspension components for traces of hitting the road obstacles or car body for cracks on the suspension components deformations of lower arm shaft crossmember or suspension arms and elements of body front and also to check the condition of balljoints and silent blocks The deformations of lower and upper arm shafts is deter mined by visual check The deformation of the front suspension crossmember is determined by measuring the distance between the outer surface of the crossmember bracket in the zone of the upper arm shaft fastening bolt This distance should be 7361 5 mm If the crossmember is so badly deformed that it is impossible to adjust the wheel alignment angles with the help of washers but at satisfactory condition of all suspension components renew the crossmember The condition of the silent blocks is checked in the following order ensure there are no deformations of the suspension arms the lower arm shaft the suspension crossmember raise the vehicle front wheels measure the outer bush 2 radial displacement A fig 4 2 in relation to the inner bush 6 and distance B between the thrust washer 5 and the outer end face of the outer bush 2 The silent blocks of the top and lower arms are subject to replacement in case of 102 1 Ensure normal pressure
124. ashing above 80 C 2 Leaded petrol or other aggressive agents were used for dewaxing over bodywork 1 Remove minor blemishes through buffing respray body in case of major deterioration 2 Respray body Pink spots over light painted surfaces Deterioration by coolant Lighter spots over Deterioration by moisture due to prolonged vehicle storage under an air tight cover Polish affected areas dark painted surfaces Buff affected areas respray body if applicable Dull shine 1 Dry cloths were used for cleaning 2 Extended exposure to the sun 3 Aggressive cleaners were used for bodywork washing 1 Buff affected areas respray body if applicable 2 Buff affected areas respray body if applicable 3 Buff affected areas respray body if applicable Water penetration into passenger compartment 1 Excessive or irregular clearance over door aperture 2 Crumpled metal structure of door seal 3 Windscreen seal leaking 4 Heater air box drain valve is squeezed by vacuum servo unit hose 1 Centralize door and adjust door lock striker position adjust door aperture flange 2 Renew seal 3 Put 51 I 7 sealant under outer seal lug 4 Properly route servo unit hose Excessive efforts to open door 1 Door lock striker retainer pivot shaft bent 2 Striker retainer worn 3 Door position incorrect Failure to lock door Top end of lock outer control lever butts against exterior handle shoulder 1 Renew pivot 2
125. ater jacket and from coolant delivery pipe to the heater Remove the EGR valve Disconnect the starter motor shield from the exhaust mani fold downpipe and detach the bracket securing the coolant pipe heater return line Remove the valve cover complete with the gasket and fuel piping securing bracket Turn the crankshaft to align the camshaft sprocket TDC mark against the bearing housing mark Fig 2 22 Unbolt the camshaft sprocket Slacken the chain tensioner cap nut release the tensioner rod and fix it in position with the cap nut Remove the camshaft sprocket Undo the bolts securing the cylinder head to the cylinder block and remove the cylinder head complete with the gasket Refitting of the cylinder head is the reverse order of removal refer to the procedure described in section Engine reassembly Never re use the gasket between the cylinder head and cylinder block always replace it with a new one While refitting the cylinder head adjust the timing chain ten sion and valve clearances Having refitted the cylinder head adjust the carburettor linkage and ignition timing Cylinder head dismantling and reassembly Dismantling When only a single part is required to be replaced there is no need to completely dismantle the cylinder head instead remove only what is necessary Position the cylinder head on the stand disconnect the hose from the hot air intake undo the nuts and remove the carburettor complete wit
126. ating levers 20 secondary lock lever 21 lock lever spring 22 secondary throttle shaft and lever 23 primary throttle valve 24 secondary throttle valve 25 idle mixture adjustment screw cap 26 return spring secondary throttle lever 27 idle mixture adjustment screw 28 carburettor body 29 throttle stop screw CO adjustment 30 idle switch wire 31 part throttle channel heater 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 damaged components Carburettor cover Clean any dirt or oil from the cover clean all passages and holes Wash the cover in acetone or petrol blow dry with compressed air Examine the cover sealing surfaces Renew the cover in there are any damages Choke control unit Wash in petrol and blow dry all choke control associated components Inspect the parts and renew when applicable Jets and emulsion tubes Clean out the jets and emulsion pipes from dirt gummy substances wash in acetone or petrol then blow dry with compressed air Do not use any metal tool or wire for cleaning the jets never wipe the jets or other carburettor components with cotton wool cloths or rags since lint can fou
127. atio marks on the final drive and the rear axle reduction gears Reassemble and adjust the front axle reduction gear follow IW pz n EU 4 BE OPE Ui Fig 3 81 Front axle WE r AN PN NS 1 splash guard 2 reduction gear casing lower cover 3 final drive gear bearing 4 differential housing 5 drain aperture plug 6 check and filler plug 7 inner joint housing bearing 8 oil seal 9 wheel drive inner joint housing 10 spring washer 11 circlip 12 bearing cover 13 adjuster nut 14 differential housing bearing 15 bearing cover 16 cover securing bolt 17 thrust washer 18 axle shaft gear 19 pinion 20 reduction gear casing 21 breather 22 front axle mounting brack et 23 pinion shaft 24 shim 25 drive gear 26 bearing spacer 27 drive gear oil seal 28 flange 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 washer 10 and circlip11 Note The left sealing of the inner joint axle shaft for dis tinction has a mark in form of a circular groove on the body Fit the front axle mounting bracket 22 with cover on the inner joint right casing Place the inner joint a
128. ation Maximum current output at 13 volts and 5000 rpm amp 55 Adjustable voltage range voliS 4 14 140 5 Maximum rotor speed OM 6 eee eee 13 000 Engine to alternator ratio ete 1 2 04 General description The alternator of 37 3701 model is of AC three phase clock wise rotation when viewed from the drive end with integral diode plate and voltage regulator Fig 7 3 Alternator 37 3701 26 1 slip ring end housing 2 diode plate 3 diode 4 screw 5 slip ring 6 rear ballbearing 7 suppression condenser 8 rotor shaft 9 alternator termi nal 30 10 alternator terminal 61 11 voltage regulator terminal B 12 voltage regulator 13 brush 14 alternator to belt tensioner lever securing pin 15 pulley and fan 16 rotor pole end 17 spacer 18 front ballbearing 19 drive end housing 20 rotor winding 21 stator 22 stator winding 23 rotor pole end 24 buffer bush 25 bush 26 hold down bush Protective cover 4 is used for slip ring end housing Fig 7 11 The protective cover and air intake have several design alterna tives Four bolts hold together stator 21 Fig 7 3 and housings 1 and 19 Rotor shaft 8 runs in bearings 6 and 18 located in the housings The rotor winding field winding is powered through the brushes and slip rings 5 Three phase alternative current induced in the stator wind ing is conver
129. bearing housing tight ening the nuts in the sequence as shown in Fig 2 22 Refit the chain vibration damper Refit the camshaft timing chain fit the chain onto the camshaft sprocket and position the sprocket so its TDC mark is aligned with the respective mark on the bearing housing Fig 2 21 Do not tighten the sprocket bolt fully fit the sprocket to the oil pump shaft but do not tighten the retaining bolt fully fit the chain tensioner shoe and tensioner but do not tight en the cap nut so that the tensioner spring can compress the shoe screw the chain stop pin into the cylinder block turn the crankshaft two turns forward to ensure the chain tension required check the indentations in the sprockets are aligned with TDC marks in the cylinder block and bearing hous ing Fig 2 19 and Fig 2 21 when the marks are aligned hold the flywheel stationary with tool A 60330 R Fig 2 10 then tighten the sprocket securing bolts and chain tensioner cap nut to the torques specified bend the sprocket bolt lock washers should the marks are not aligned repeat the chain refitting procedure ie d m He uu i FR i Fig 2 21 Aligning the timing mark on the camshaft sprocket against bear ing housing mark 1 mark in sprocket 2 mark on bearing housing Fig 2 22 Camshaft bearing housing nuts tightening sequence Fig 2 23 Timing cover P
130. bearing securing plate 7 ring ee tt Oe SSRs 5 all laaan SASS H g Fig 3 64 Checking the axle shaft axial play with the wheel and the brake drum removed 1 indicator 2 fixture Fig 3 63 Checking the force of pressing out the axle shaft bearing stop ring 1 indicator 2 axle shaft 3 fixture 4 dynamometer 5 bearing 6 bear ing stop ring 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 specified axial load creating with a dynamometer the torque of 78 5 83 3 Nem 8 8 5 kgf m on the tool screw The screw through the ball should be pressed against the axle shaft end face There should be no even a slightest gap between the stop ring and the inner ring of the bearing After removing load and when undoing the tool screw the indicator arrow should return to zero thus proving there was no shift between the stop ring and the axle shaft If the indicator arrow does not return to zero it will mean the stop ring had shift ed and the axle shaft assembly should be renewed 88 After checking the press fitting of the stop ring replace the fastening
131. bearing shells thrust washers pistons and oil seals Always fit new crankshaft oil seals when reassembling the engine after overhaul 14 Jn ye Fig 2 10 Removing the flywheel 1 wrench 2 flywheel 3 flywheel securing bolt 4 washer 5 tool A 60330 R to lock the flywheel stationary 6 front clutch housing cover Fig 2 11 Pressing out the bearing from the crankshaft using tool A 40006 Fig 2 12 Refitting the thrust washers to the rear mounting 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 washers must be fitled so that their oil ways face away from the bearings in the block and cap anti friction coat is applied on the washer surface At the rear of the rear main bearing there fitted a sintered thrust washer yellow while at the front a steel aluminium thrust washer Locate the main bearing caps according to the marks on their outer surface Fig 2 13 Tighten the cap securing bolts Check the crankshaft endfloat To do this turn the cylinder block to have the rear side up and position the dial gauge foot against the cranks
132. bottom front cross mem ber 4 under front wing 5 outer sill 6 inner sill 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 C water Table 8 2 until the drained water is clean Do not forget to fully close the windows remove any water penetrated into the passenger or lug gage compartments blow dry with compressed air the areas where rust inhibitors are going to be applied drive the vehicle into a corrosion treatment booth and posi tion it on a lift spray the relevant rust inhibitor onto the areas shown in Fig 8 6 Fig 8 7 and Fig 8 8 lower the vehicle wipe off any dirt from the outside body surfaces with a cloth moistened in white spirit Fig 8 7 Rear view of the body Inner cavities of 1 rear chassis arms 2 between rear wheel arches and body sides 3 rear chassis arms 4 rear floor cross member 5 central pillars 6 front door pil lars 7 door pocket Restoring corrosion proof and sound proof coat ing on underbody and wheel arches When in service the vehicle underbody is deteriorated by loose gravel sand salt and water As a result undersealant and primer can be damaged and worn thus encouraging rust For the purposes of noise reduction corrosion protection and wear resistance the underbody and chassis arms a
133. brush 14 resistor 15 outside rotor contact breaker point 16 centrifugal advance unit plate 17 weight 18 screen 19 Hall sensor bearing plate 20 Hall sensor 21 ignition distributor body minal 4 to the tester plus while terminal 1 to the tester breaker terminal Set the spark gap to 7 mm Switch on the tester motor and operate the distributor shaft at 500 600 rpm On the tester graduated disc note the angle at which one of the four sparkings occurs While increasing the speed in steps of 200 300 rpm and watching the disc determine the advance angle with respect to the distributor shaft speed Compare the resulting centrifugal advance pattern to that in Fig 7 21 When the pattern differs from that shown in Fig 7 21 it can be adjusted by bending the weight spring brackets of the cen trifugal advance unit Bend the thinner spring bracket for speeds Fig 7 20 Checking the ignition distributor on the test bench 1 spark control module 2 ignition distributor A to test bench plus terminal B to test bench breaker terminal A 15 T MN L E o EH HE RER E EH 11 51 L1 HH THERE H tf B 5 Lo HEHE 8 Li n 500 1000 1500 2000 2500 3000 Fig 7 21 Centrifugal advance ignition distributor map A advance timing degrees n ign
134. c ity of the shaft bushes use the finishing reamer A 90353 for con current machining of both bushes Oil pump inner gear bush Check the bush is adequately pressed in The inner surface should be smooth with no scuffs otherwise renew the bush Use tool A 60326 R for bush pressing in or out Fig 2 74 After pressing in ream the bush to 16 016 16 037 mm Fig 2 71 Checking the oil pump endfloat 20 Fig 2 72 Basic data for checking the relief valve spring 62 5273 H 6 55 235 vec 41 5 4 y po 6 A A TILE Lh Q seme porem LLL EE ZZ w 77277777777 err WILLA o 7 Z1 ZZ DLLLS Zh 77 f E ZZ LLL ge Fig 2 73 Removal and refitting of the oil pump distributor shaft bush 1 tool A 60333 1 2 Fig 2 75 Crankcase ventilation diagram 1 filter element air cleaner 2 exhaust manifold 3 flame arrester 4 hose to draw crankcase emission on throttle body 5 discharge hose 6 oil sepa rator cover 7 oil separator 8 oil separator drain tube 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 carburet
135. c 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 residues After that paint the beam to protect from corrosion Straightening the rear axle beam Attach to each end of the beam flanges A 70172 the set used for straightening and not for checking the beams and place it on supports of a hydraulic press so that the ends of the clamp ing crossrail 2 fig 3 60 were in the zone of deformation The most probable location of the zone is in 200 300 mm from the end faces of the beam flange Establish rack 7 with the indicator so that the leg of the indi cator will rest against the top part of the flange side surface and Cy Bur oa Fig 3 57 Checking for twisting of the rear axle beam using a try square on the side surface of flange A 70172 86 the arrow of the indicator will point to the division equal to the size of beam deformation measured by a feeler gauge when checking the beam On the other end of the beam place either a rack with an indicator or a try square 4 Place rests 6 under the beam in the zone of deformation straighten the beam on a hydraulic press first horizontally and then vertically monitoring the results by an indicator or a feeler gauge with a try square 4 The maximum pressing force during straightening should not exceed 9
136. camshaft drive chain 67 7834 9506 Tool for checking fuel pump pushrod protrusion 67 7854 9519 Adjuster bush for fitting normal and oversize pistons of 82 mm dia 67 8125 9502 Ring gauge 82 mm dia for setting inside gauge to zero 67 8151 9505 Gauge for checking fuel level in carburettor TCO 3 379 Crosspiece engine removal and installation BC 106 Thermostat inspection rig 215 A 70017 A 70081 67 7813 9503 67 7822 9517 67 7851 9500 A 40006 A 55035 41 7816 4068 41 7816 4069 41 7853 4028 41 7853 4032 41 7853 4039 67 7853 9558 A 70025 41 8734 4092 67 7823 9522 67 7853 9533 67 7853 9537 A 45008 A 45028 A 55085 A 70152 A 70157 A 70171 A 70172 A 70184 A 70185 A 70198 67 7823 9530 67 7823 9529 A 95601 R A 95688 R A 95690 A 95697 5 02 7812 9501 67 7812 9520 02 7834 9504 67 7823 9516 67 7853 9559 67 8701 9508 A 47045 A 57034 R 216 CLUTCH Tool clutch pedal spring removal and installation Mandrel clutch disc centering Tooling clutch disc repair Jig clutch disc lining renewal Mandrel clutch disc lining rivetting TRANSMISSION Puller front input shaft bearing Jointed box spanner gearbox removal and installation Input shaft fixing arm Tool for fitting removing circlip to from output shaft Mandrel for fitting output shaft bearing Mandrel installation of intermediate shaft bearing Mandrel installation of output shaft oil seal Mandrel for driving on transfer case differential bearing DRIVE
137. ch belong to the same class of cylinders The max imum permissible gap for worn parts is 0 15 mm When the engine in the course of operation shows a clear ance of over 0 15 mm reselect the pistons to the cylinders to have the clearance as close to the design value as possible The pistons of classes A C E are intended for replacement These classes can be selected to closely match any cylinder in the event of the engine overhaul since the pistons and cylinders are classified with small overlapping in the sizes It means the piston of class C can match the cylinders of class B and D Dismantling and reassembly Dismantling Prise out the gudgeon pin circlips from the pis ton press out the gudgeon pin and detach the connecting rod from the piston Remove the piston rings The bolts are pressed into the connecting rod and must never be pressed out from the connecting rods during the engine or pis ton connecting rod dismantling When some components of the piston or connecting rod are not damaged or show little wear they can be re used Identify them accordingly during dismantling to facilitate further reassem bly with the respective components and to the original cylinder Reassembly Before reassembly select the gudgeon pin to match the piston and connecting rod For new components the class of the holes for the gudgeon pin in the connecting rod and pistons must be identical to the class of the gudgeon pin In case of used
138. changeable as a complete unit with the brush holder Some vehicles can be fitted with alternators made in Slovenia Bulgaria or Germany These alternators are inter changeable with the alternator of 37 3701 model as to specifica tion and mounting sizes though are slightly different in design This chapter describes the alternator of 37 3701 model prefer ably used in VAZ 21213 vehicles Fig 7 4 Alternator wiring diagram 1 battery 2 alternator 3 instrument cluster 4 resistor 51 Ohm 5 W 5 diode 6 low battery charge warning light 7 fuse box 8 ignition relay 9 ignition switch 140 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 b of main fusebox and instrument cluster no voltage between ignition relay and fusebox unit 3 Ignition switch or ignition relay faulty faulty contact part or ignition relay no voltage between ignition switch and ignition relay break or no contact in the igni tion relay earth wire 1 Renew fuse 2 Carry out the following check wire O and its connec tions between fuse boxes and instrument cluster check wire TH and its connec tions between ignition relay and fusebox 3 Carry out t
139. choke must be completely closed by spring 7 If not remedy the situation With the choke fully closed press choke control rod 3 to its stop This results in choke 5 opening to 3 0 mm starting clear ance B Adjust the clearance using screw 2 Primary throttle 12 with the choke fully closed should be open to 1 1 mm starting clearance C Using screw 10 adjust the clearance as necessary Carburettor linkage adjustment With fully depressed throt tle pedal 7 Fig 2 87 the primary throttle must be wide open and rod 15 must have no further travel With pedal 7 released the 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 throttle stop screw 1 Cap 4 is provided for adjustment screw 2 Remove the cap to access the screw Idle adjustment is done on the warm engine coolant to be at 85 90 C after the valve gaps and ignition timing are correctly adjusted the choke should be wide open Using throttle stop screw 1 set the crankshaft speed within 750 800 rpm Using idle mixture adjustment screw 2 set the content of car bon monoxide CO in exhaust emissions at maximum 1 5 with throttle stop screw 1 at the preset position as above CO
140. clearance that is no evident free play of the arm If the free play of the arm can be felt remove cap 3 see fig 5 2 slacken nut 4 on the adjusting screw and having raised the washer tighten the adjusting screw 2 to take up the backlash Do not tighten the adjusting screw too much Then hold the adjust ing screw with a screwdriver and tighten nut 4 Ensure that the arm does not move connect the balljoint pins Check the effort of turning the steering wheel If it exceeds 196 N 20 kgf slacken adjusting screw 2 and refit cap 3 Steering mechanism Removal and refitting Removal Disconnect the wires from the battery and take off the horn push pad trim Undo the steering wheel fastening nut remove the steering wheel and both halves of the steering col umn shroud Note If it is necessary to remove only the steering box undo the bolt that is fastening the intermediate shaft lower U joint fork on the worm shaft and the bolts fastening the steering box to the body chassis arm Remove the instrument cluster and disconnect the connector plugs of the three lever switch from the harness connectors Disconnect the wires from the ignition switch terminals undo the fastening screws push down the switch lock and remove the ignition switch Loosen the fastening clip of the switch housing incorporating the turn lights headlights and wipers and remove Undo the bolt that is fastening the intermediate shaft lower U joint fork t
141. components for perfect mating the gudgeon pin when oiled should fit the relevant piston hole by force of the hand thumb Fig 2 32 it should not drop out while held as shown in Fig 2 33 If the gudgeon pin drops replace it with a new one of the next class When the piston is fitted with the gudgeon pin of the third class renew the piston gudgeon pin and connecting rod The reassembly of the piston and connecting rod is a rever sal of dismantling After reassembly oil the gudgeon pin through the holes in the piston bosses Refit the piston rings in the order as detailed below Oil the piston rings and grooves in the piston Arrange the pis ton rings so that the gap of the first compression ring is at a 45 interval to the gudgeon pin space the gap of the second com pression ring at about 180 interval to the first compression gap afterwards align the gap of the oil ring at about 90 interval to the first compression ring gap Fig 2 32 Fitting the gudgeon pin using the thumb pressure Fig 2 33 Checking the gudgeon pin fitting 23 Fig 2 34 Checking the piston ring to groove gap Fig 2 35 Checking the piston ring gap Make certain the second compression ring is positioned with the recess facing down Fig 2 30 while the TOP or BEPX mark should face up the piston crown Before refitting the oil ring check to see the joint of the coil expander spreade
142. connect its wiring remove four spring holders and fan blower cowl 18 com plete with the blower Fig 8 33 Heater unit 1 air distribution cover 2 lever 3 windscreen demister airduct flap 4 windscreen heating flap control knob 5 air intake cover control knob 6 tap control knob 7 control levers bracket 8 control cable 9 interior ventilation airduct 10 side demister airduct 11 windscreen demister airduct 12 air intake cover 13 air intake grommet 14 air intake 15 heater matrix 16 delivery and return pipes 17 tap 18 fan cowl 19 spring clip 20 fan motor 183 Fig 8 34 Heater components pad 1 air distribution cover 2 fan shroud 3 resistor 4 guide cowl 5 heater matrix housing 6 air intake cover gasket 7 air intake cover 8 spring clips delivery and return pipes 9 spring clip 10 gasket 11 heater matrix 12 delivery and return pipes 13 heater tap 14 fan impeller 15 fan motor 16 spring clip 17 mounting 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 remove the housing and air intake unit Refitting of the heater is a reve
143. connecting the brake hoses and suspend it so that the caliper will not hang on hoses Compress the suspension spring to completely unload the lower arm Disconnect from the lower arm the balljoint and take off the spring having smoothly unloaded it repeat the procedure for the other unit of the suspension Disconnect the upper arm shaft 49 see fig 4 1 from sus pension crossmember bracket 7 and remove the upper arm 46 in assembly with the steering knuckle wheel hub front brake and the outer joint case Fig 4 7 Front suspension exploded view 1 coil spring lower seat 2 lower control arm 3 lower arm shaft 4 lower control arm silent block 5 coil spring 6 upper seat 7 spring insulator gasket 8 com pression buffer 9 compression restrictor 10 suspension crossmember 11 lower control arm shaft bush 12 crossmember bracket 13 engine mounting bracket 14 spring upper mounting 15 shim 16 upper control arm shaft 17 upper control arm 18 recoil buffer bracket 19 recoil buffer 20 upper control arm silent block 21 balljoint 22 boot 23 body to tie rod mounting bracket 24 tie rod 25 shock absorber 26 securing clamp 27 rubber pad 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 a
144. cover 7 cover retainer 8 front cover 179 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 and windscreen washers Windscreen renewal To replace a damaged windscreen remove the windscreen wiper arms and moulding Then applying pressure to the top windscreen corners force the windscreen out Ask your assistant to support the windscreen from the outside Fig 8 23 Remove the windscreen seal Refitting is carried out in the following sequence rinse seal 9 grooves Fig 8 9 with water then blow dry with compressed air Fig 8 23 Removing the windscreen ws S W N E Uus Ww D A Fig 8 24 Fitting the windscreen 1 cord for windscreen fitting 2 seal refit the seal to the windscreen using glycerine or soapy water wet seal 2 groove Fig 8 24 which is used for attaching it to the body flange using a screwdriver place cord 1 into the groove refit the windscreen to the aperture then tighten cord 1 ends inside the body to have the glass with seal 2 fitted snugly to place Ask your assistant to stand outside and slightly press the wind screen
145. curately wash and check all parts as it is specified for the master cylinder Do not refit a damaged pushrod After inspection begin to reassemble in reverse order grease all parts with brake liquid Fig 3 10 Checking the leak proofness of the rear sealing ring 1 master cylinder 2 reservoir 3 adapter with sealing 4 manometer 5 T connector 6 adjusting screw A air from compressor B air outcome Clutch master cylinder bench check Checking the leak proofness of the rear sealing ring Place the master cylinder on the test bench see fig 3 10 and ensure good sealing between the cylinder flange and the surface of the test bench Connect reservoir 2 with hydraulic liquid to the cylinder Open the compressed air vent with the adjusting screw 6 being open and then slowly close the adjusting screw until all air will be expelled from reservoir 2 Control air pressure by the pressure gauge it should be with in 0 05 0 08 MPA 0 5 0 8 kgf cm If pressure is less replace the rear sealing ring Checking the leak proofness of the front sealing ring Place the master cylinder on the test bench and connect it to the reservoir with hydro drive liquid and with manometers fig 3 11 Close manometer vent 3 and by moving the master cylinder pushrod provide constant pressure of 0 2 MPA 2 kgf cm With a fixed pushrod and no liquid leaks pressure should remain constant during 2 minutes Close pressure ga
146. d 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 K563 3747 model The module process es the control output pulses from the Hall sender into current pulses for the ignition coil primary winding Ignition coil is of 8352 12 or 27 3705 or 027 3705 or 27 3705 01 model oil filled sealed open loop magnetic circuit Spark plugs are of A17QBPM model or A17HBPM1 model with suppressant chokes Ignition switch is of 2101 3704000 11 model theft deterrent Fault diagnosis Cause Remedy Engine will not start 1 Hall sender pulses fail to reach control module broken circuit between sender and control module Hall sensor faulty 2 No pulses to primary winding broken circuit between control module and solenoid or control module and ignition coil 150 1 Carry out the following check wiring and connections renew damaged wires check Hall sensor using adapter and voltmeter renew failed sensor 2 Carry out the following check wires and connections renew damaged wires control module faulty ignition switch or ignition relay failed 3 No HT to spark plugs HT lead ends loose broken off or oxidized leads dirty or insulation damaged carbon brush worn or damaged or has no contact with rotor arm tracking through cracks or burns in distributor cap or rotor
147. d 0 7 mm Suspension springs Carefully examine the springs If any deformations affecting the spring efficiency will be found renew the springs To check the spring set down fully compress it three times The spring compression is made along the spring axis the bear ing surfaces should meet the vehicle suspension spring seats Then apply load of 6 276 N 640 kgf According to the spring length see fig 4 9 under the specified load the springs are divided into two classes class A length more than 192 mm and class B length is equal to or less than 192 mm The springs of A class can be not marked or have marks with white paint on the external side of coils spring of B class are marked with black paint On the front suspension the springs of the same class as those on the rear suspension should be installed As an excep tion when on the rear suspension the springs of B class are installed and there are no springs of the same class available for Fig 4 8 Inspecting the balljoint on fixture 02 8701 9502 1 balljoint 2 indicator 3 dynamometer 4 fixture 02 8701 9502 A method of checking the radial clearance B method of checking the axial clearance 6276H 640krc Fig 4 9 Main parameters for checking the front suspension coil spring 108 Fig 4 10 Pressing out the upper control arm balljoint 1 control arm shaft 2 tool 67 7823 9527 3 balljoint 4 tool A 47045
148. d detent balls Parts having any traces of jamming or wear should be renewed Hubs sleeves and baulk rings Ensure the hubs have no damage in particular on the sleeve sliding surface Draw special attention to the condition of the sleeve spline face The synchro rings should show no sign of excessive wear They should be renewed in case the end face is resting on the synchro unit sleeve Roughness interfering free sliding should be removed with a fine cut file Badly worn parts should be renewed Transfer box Fault diagnosis Diagnosis Remedy Vibration of the transfer box and body floor in the area of front seats when starting and accelerating to 80 km h 1 Transfer box not centralised against power unit 2 Loose or damaged transfer box mountings and power unit rear mount 3 Hard turning or jamming of front or rear propeller shaft joints 4 Incomplete handbrake release 5 Hard turning of layshaft CV joint 1 Centralise transfer box 2 Tighten securing nuts and bolts renew if necessary 3 Repair U joints or renew shafts 4 Adjust handbrake 5 Inspect boot and joint Renew joint in case of damage Vibration of the transfer box and body floor in the area of front seats at a steady state movement most typical at speed of 80 90 km h 1 Propeller shafts out of balance 2 Interaxial differential out of balance 3 Jammed propeller shaft U joints 4 Jammed layshaft CV joint 5 Loose engine mounti
149. d remove the alternator drivebelt Apply the 4th gear of the gearbox undo the nut and withdraw the alternator drivebelt pulley from the crankshaft Remove the timing cover complete with the gasket Undo the nuts holding the cover to the cylinder block then undo the bolts retaining the oil sump to the cover Undo stop pin 6 Fig 2 55 and withdraw the camshaft timing chain The refitting procedure is a reversal of removal observing the recommendations outlined in section Engine assembly Lif kes AWASA 1 220 AA fa f FATA F4 TES N SSSSNNNN 2 T D IEP CEL D oL sS SSS pA 2227 P ZLILA y 02 05 Fig 2 56 Sectional view of the chain tensioner 1 cap nut 2 tensioner housing 3 core 4 spring 5 washer 6 plunger 7 spring 8 collet 9 spring ring A plunger surface B centre punch points on housing face Before refitting smear the chain with engine oil Always use new gaskets for the timing cover and valve cover The chain refitted adjust the chain tension and alternator dri vebelt tension adjust the carburettor linkage and ignition timing Inspection Camshaft The camshaft journals must have no scores scuffs scratches or aluminium galling from the bearing housing The maximum wear of the cam lobe surfaces is 0 5 mm there should be no evident scoring or cut type wear of the cams Mount the crankshaft on two V blocks located on the test plate an
150. d using a dial gauge check the centre camshaft journal endfloat to be 0 04 mm maximum If the endfloat exceeds the value specified straighten the camshaft on the straightening press 123 5 8 8 H 12 640 9 Kec 181 3 13 7 H 18 5 1 4 Kac Fig 2 57 Basic data for checking the tensioner spring 33 mio et 4 WS T i i e RT NDS F 7 Fig 2 58 Tool 67 7824 9521 for checking the chain wear extension 1 roller 2 adjuster nut 3 counterweight Fig 2 59 Checking the chain wear extension 1 pulleys 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 in case of damages Check the hous ing for cracks if this is the case renew the bearing housing Chain tensioner When the tensioner plunger is seized in the housing dismantle the chain tensioner For that undo cap nut 1 Fig 2 56 push plunger 6 full way then tighten the cap nut File the housing edges at the points B of centre punching withdraw plunger 6 with spring 4 Undo the cap nut and withdraw rod 3 complete with spring 7 and washer 5 Prise free spring ring 9 and take out clamp
151. dal 1 master cylinder 2 servo unit 3 bracket 4 sealant cup 5 clutch brake pedal mounting bracket 6 brake pedal return spring 7 stop light switch 8 9 nuts 10 stoplight buffer 11 brake pedal 12 push rod 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 5 6 times with the engine not working to create in cavities A and B fig 6 2 identical pressure close to atmospheric Simultaneously by effort applied to the pedal define whether the valve housing 21 is jammed Stop the brake pedal in the middle of its travel and start the engine If the servo unit is OK the brake pedal after engine start should go forward If the pedal does not go forward check the fastening of the hose end piece condition and fastening of the end piece flange in the booster hose to end piece fastening and connection to the engine inlet pipe because loose fastening or damage will signifi cantly reduce the underpressure in cavity A and performance effi ciency of the unit In case of vehicle spontaneous braking check the servo unit for leak proofness with the engine running first with a released and then depressed m
152. damaged diodes If this is the case very thorough diagnostics will have to be carried out in order to locate the fault The output voltage should be measured at rotor speed of 5000 rpm Set rheostat 4 to test amperage of 15 amps and take the reading of the alternator output voltage to be within 14 1 0 5 volts at the ambient alternator temperature of 25 10 C If the voltage reading falls outside the range specified replace the complete voltage regulator with a new unit which is proved good Then repeat the test procedure Normal voltage indicates that the old regulator is faulty and must be renewed If the fault per sists check the alternator windings and diodes Alternator oscilloscope test The oscilloscope offers an accurate and quick way to check the alternator and identify the fault through the output waveform To perform the check make the connections as shown in Fig 7 6 Disconnect the output lead common for three supple Fig 7 5 Wiring connections for diode plate test 1 warning light 12 v 3 W 2 alternator 3 voltmeter 4 rheostat 5 amperemeter 6 switch 7 battery Fig 7 6 Alternator wiring connections for oscilloscope test 1 warning light 12 v 3 W 2 alternator 3 voltmeter 4 rheostat 5 amperemeter 6 switch 7 battery mentary diodes from the voltage regulator terminal B and make sure the lead end does not touch the alternator housing Connect the battery
153. damaged sealing rings of the master or slave cylinders During bleeding the liquid level in the reservoir should be higher than the opening of the tube connecting the reservoir with the master cylinder the end of the bleeding hose should be always dipped in liquid after bleeding top up liquid in the reservoir to the lower edge of the filler neck 59 E Eia wi 72 18 17 7 6 Fig 3 3 Slave cylinder and clutch release fork 1 release bearing 2 ball pivot 3 clutch release fork 4 pushrod 5 adjusting bolt 6 locknut 7 return spring 8 plug 9 bleeder 10 cylinder body 11 sealing ring 12 protective cap 13 piston 14 sealing 15 sleeve 16 spring 17 spring disc 18 lock ring 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 end face if necessary replace the bearing 60 inspect the splines on the clutch disc hub and the gearbox input shaft clean the splines and grease with a thin layer of greasing JICU 15 or MOJT 1 OUON 2 refit the clutch disc with the hub protruding part facing the gear box and centralise the plate against the bearing using tool A 70081 simulating the
154. drive spindle at least Nem kgfm oo ee eee eee 12 1 2 At 14 volts and ambient temperature of 25410 C on a cold engine Windscreen wiper relay The relay of PC 514 model is used for intermittent operation of the windscreen wiper The relay is located beneath the instru ment panel on the left hand side and is attached to the body by means of two screws The relay must ensure 9 to 17 wiper cycles per minute at sup ply voltage of 10 volts and ambient temperatures of 20 to 50 C The resistance of the electromagnet winding is 66 2 Ohm while the breaker winding resistance is 23 1 Ohm When the wiper is activated for an intermittent operation while the breaker bimetal plate is not warm enough the wiper blades can make up to 4 continuous double sweeps Headlight wipe wash The headlight wipe wash includes two right hand and left hand motors arms and blades The wiper arms and blades park at the bottom position The motor unit is fitted with a thermal bimetal fuse for overload protection or 8 amps fuse in the motor yellow black wire The headlight wipe motor unit is built as a complete unit therefore it is not serviceable and is subject to renewal in case of failure The headlight washer pump motor is the same as that for the windscreen washer The wiring diagram for wipe wash operation is shown in Fig 7 36 The headlight wipe wash system is operated only with the headlights on by steering column lever 7 i e
155. e WARNING To avoid damage to the instrument cluster glass never use solvents for its cleaning Fault diagnosis Cause Remedy Motor does not operate 1 Wires damaged or wire con nections corroded 2 Blown fuse 1 in fuse and relay box unit 3 Heater switch damaged no voltage across switch terminals 4 Motor brushes stuck or worn armature winding broken or com mutator foul 5 Armature winding shorted to earth fuse blows at motor cut in 1 Check and restore connections Renew damaged wiring 2 Renew blown fuse 3 Check switch renew when applicable 4 Check motor overhaul or renew as applicable 5 Renew motor Motor is restricted to one speed 1 Wires damaged or wire con nections corroded 2 Heater switch damaged 3 Supplemental resistor blown Slower motor 1 Dirty or corroded commutator brushes worn 2 Internal earthing in armature winding 3 Armature shaft seized in bear ings 1 Renew damaged wires clean wire ends 2 Renew switch 3 Renew resistor armature rotation 1 Clean commutator renew brush es 2 Renew motor 3 Dismantle motor clean shaft journals Instruments General description All gauges and warning lights are grouped within the instru ment cluster The instrument cluster includes a speedometer with trip counter coolant temperature gauge fuel gauge tachometer voltmeter with LED and 12 warning lights In 1996 the voltmeter was
156. e 1 Loose speedometer cable ends retaining nuts 2 Cable broken 3 Speedometer mechanism dam aged 1 Check tighten nuts 2 Renew cable 3 Renew speedometer Noise from speedometer cable 1 Outer cable broken dents twists etc 2 Cable routed with bending radius less than 100 mm 1 Renew cable 2 Route cable correctly 163 i2 8 4 5 Y 16 14 13 12 11 10 t gt XX so Of m sm Fig 7 39 Wiring diagram for pre 1996 instrument cluster rear view 1 wiring connector and pin assignment 2 tachometer 3 voltage stabilizer 4 instrument illumination lamp 5 coolant temperature gauge 6 fuel gauge 7 resistor 470 Ohm 0 25 W 8 resistor 36 Ohm 5 W 9 warning light exhaust emission system 10 heated rear window warning light 11 foglamp warning light 12 high beam warning light 13 external light warning lamp 14 direction indicator warning light 15 voltmeter 16 low brake fluid warning light 17 diode IN4002 18 oil pressure warning light 19 differential lockup warning light 20 fuel reserve warning light 21 seat belt reminder 22 handbrake on warning light Instrument cluster removal and refitting disconnect the wiring and speedometer drive cable disconnect the battery negative lead Take precautions not to loop or twist the cable which can undo the screws holding the facia pull the bottom edge of PSUIDI NE g ler cable parmana
157. e 23 flange 24 bellows 25 spring 26 gear shift lever 27 lever rod 28 damper rubber pad 29 grommet 30 distance washer 31 retaining sleeve 32 collar 33 cap washer 34 ball socket 35 gearshift lever housing 36 guide plate 37 driveline coupling flange 38 nut 39 centering ring oil seal 40 centering ring 41 circlip 42 output shaft rear bearing oil seal 43 output shaft rear bear ing 44 distance washer 45 oil deflector washer 46 5th reverse gear unit 47 5th synchro unit hub 48 reverse idler gear 49 intermediate shaft rear bearing 50 intermediate shaft 1st speed gear 51 1st 2nd synchro sleeve 52 intermediate shaft 2nd speed gear 53 intermediate shaft 3rd speed gear 54 filler and check orifice plug 55 intermediate shaft 56 intermediate shaft constant mesh gear 57 intermediate shaft front bearing 58 intermediate shaft bearing clamping washer 59 clamping washer bolt 60 input shaft constant mesh gear 61 input shaft rear bearing 62 circlip 65 7 NN OS LCS EE Fig 3 13 Clutch release drive 1 fork return spring 2 locknut 3 adjusting nut 4 cotter pin 5 clutch release fork 6 pushrod 7 slave cylinder fastening bolt 8 slave cylinder Fig 3 15 Clutch bellhousing view from inside The black arrows point to the gearbox to clutch bellhousing fastening nuts the white arrow points to
158. e clutch disc or the damper springs ie E _ a TA S777 weer 4 VAY Fig 3 5 Clutch check 1 pressure plate thrust flange 2 central diaphragm spring 3 clutch disc 4 ring Master and slave cylinders removal and refitting First drain working liquid To do this attach one end of the hose to bleeder 9 see fig 3 3 on the slave cylinder and the other end place in a clean reservoir unscrew bleeder 9 by 1 2 3 4 turn and depress the pedal several times until all liquid will be removed from the hydrosystem then disconnect the tubes between the master and the slave cylinders disconnect the return spring 7 remove the pin from the pushrod end and the slave cylinder having prior undone two fastening bolts To remove the master cylinder undo two nuts with which it is pinned to the pedal bracket and disconnect the flexible hose from the reservoir To refit the master and slave cylinders the above described operations are executed in reverse order After filling with working liquid bleed the system Fig 3 6 Replacing the clutch disc friction linings 1 tool 67 7851 9500 2 clutch disc 3 fixture 67 7822 9517 61 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 Fig 3 7 Straightening the
159. e damaged parts Ensure that the oil drain aperture is not fouled shown by an arrow on fig 3 15 Clean the oil drain plug Seals Inspect the oil seals and ensure there is no damage severe wear or roughness on the working edges The permissi ble amount of wear of seal working edges is no more than 1 mm In case of any insignificant defect renew the seals Shafts On the working surfaces and on the splines of the output shaft no damages or excessive wear is allowed There Fig 3 34 Gear change mechanism 1 guide plate washer 2 guide plate 3 gear change lever housing 4 ball Socket 5 cap 6 spring 7 8 circlips 9 gear change lever 10 bellows 11 flange 12 reverse locking plate 13 spring 14 guide bar 15 sealing ring A mark 72 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 mounting gap between the shaft and the bush of the reverse idler gear should be 0 056 0 09 mm the maximum permissible size is 0 15 mm The clear ance is checked by measuring the shaft diameter and the open ing of the gear bush On new parts the shaft diameter is equal to 19 079 19 094 mm and the inner
160. e damaged buffers 12 Rear suspension stiffness due to rear axle overload 12 Unload vehicle rear part Wheel alignment angles can not be adjusted 1 Deformed lower arm shaft or suspension arms 1 Replace shaft or arm Vehicle wandering 1 Different pressure in tyres 1 Adjust pressure in tyres 2 Misalignment of front wheels 2 Align wheels 3 Wrong gap in front wheel bearings 3 Adjust bearing clearance 4 Deformed suspension arms 4 Replace deformed arms 5 Unequal tension of suspension springs 5 Renew weak spring 6 Incomplete release of wheel brake mechanism 6 Rectify fault 7 Significant difference in tyres wear 7 Replace worn tyres 8 Front wheels significantly out of balance 8 Balance wheels 9 Displacement of rear axle due to deformation of rear suspension bar 9 Straighten or replace suspension arms Shimmy 1 Insufficient tyres pressure 1 Adjust pressure in tyres 2 Excessive gap in front wheel hub bearings 2 Adjust clearance 3 Shock absorbers do not work 3 Renew shock absorbers or repair 4 Loose fastening nuts on balljoint pins 4 Tighten nuts 5 Misalignment of front wheels 5 Align wheels 6 Worn arm shaft silent blocks 6 Renew silent blocks 7 Wheels are significantly out of balance 7 Check and balance wheels 8 Worn arm balljoints 8 Replace joints Often stiffness in suspension 1 Suspension springs set down 1 Renew springs 2 Shock absorbers do not work 2 Renew shock absorbers or repair 3 Deformed fro
161. e gasket 15 outer distance gasket 16 delivery valve 44 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 A gasket of 0 27 0 33 mm B gasket of 0 70 0 80 mm C gasket of 1 10 1 30 mm Refit as shown in Fig 2 80 in the following sequence Locate the gasket A then heat screen to the cylinder block next place the gasket B on the face mating the pump Using tool 67 7834 9506 measure the distance d minimum rod protru sion to be set through slow crankshaft rotation When the size d is within 0 8 1 3 mm secure the fuel pump to the engine When the size d is below 0 8 mm replace the gasket B with the gasket A When the size d is over 1 3 mm replace the gas ket B with the gasket C Recheck the size d and secure the pump to the engine Make sure the gasket A is always fitted between the cylinder block and heat screen Fig 2 80 Checking and adjusting the fuel pump pushrod projection A gasket of 0 27 0 33 mm B gasket of 0 70 0 80 mm d pushrod projection 45 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 syst
162. e gear 13 pinion shaft 14 pinion shaft spring washer 15 washer 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 vise and use a universal remover tool to remove the thrust ring and rear bearing 11 fig 3 41 Remove low gear 9 together with bush 10 gear engagement clutch 8 clutch hub 7 and top gear 6 from the input shaft Dismantle the differential remove circlip 1 fig 3 42 and spring washer 2 from the front bearing remove the rear and front bearings from the differential cas ing fig 3 43 using a universal puller and a rest block 67 7853 9559 undo the differential driven gear fastening bolts make risks on the differential casings to mark their location against to each other and dismantle the casing remove the differential driven gear a SO C5 13 12 11 78 r1 TERM e Fig 3 43 Pressing off the bearing from the differential housing 1 puller A 40005 1 6 2 rest 67 7853 9559 3 bearing Fig 3 44 Refitting the drive and layshafts into the housing 1 layshaft 2 drive shaft f PLEA Weil un Fig 3 45 Press fitting
163. e is carried out in sequence reverse to removal After refitting fill the brake liquid in the reservoir and bleed the system to expel air from the hydraulic drive Dismantle and reassembly Take out pins then shafts 5 see fig 6 12 hold the clamping levers 3 so that not to loose the springs Remove the clamping levers and their springs and then caliper 7 in assembly with block 1 Remove brake pads 2 Take out cylinder block 1 from the caliper grooves by moving apart the caliper grooves up to 118 5 mm and pressing on lock 12 Remove the dust caps 3 fig 6 14 from cylinders Fig 6 13 Removing the front brake Arrows are pointing to the bolts that should be undone to remove the front brake 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 caps with 1T 1 Components inspection Carefully examine all components having previously washed them in warm water with washing liquid and dried by a jet of com pressed air If on pistons and on cylinder mirrors any traces of wear or jamming are found renew the cylinder block complete with pis tons Note In all cases when the piston is taken out from the cylin der it is r
164. e on Remedy Fuses blown Bulb filament blown 3 Switch or relay pins corroded 4 Damaged leads corroded ends of leads loose lead connections Brake light inoperative Brake light switch inoperative Failure to switch between low and high beam 1 Corroded pins of combination switch 2 High beam or low beam relay faulty Steering column levers are inoperative 1 Lever catch ball dropped 2 Lever catch recesses damaged 1 Renew fuses 2 Renew bulbs 3 Clean contacts 4 Check renew damaged leads clean wire ends Check with a test lamp renew faulty switch 1 Renew 3 stalk switch 2 Check and renew relay 1 Renew 3 stalk switch 2 Detto shoulders worn or broken Steering column levers fail to switch between the positions 1 Renew 3 stalk switch 2 Detto 1 Lever catch balls jammed 2 Self cancelling device seized Turn signal warning light inoperative 1 Renew bulb 2 Renew relay 1 Bulb filament blown 2 Indicators flasher relay faulty Direction indicator warning light flashes at higher rate 1 Direction indicator bulb blown 1 Renew bulb front or rear 2 Indicators flasher relay faulty 2 Renew indicators flasher relay Headlight adjustment The headlight beams should be adjusted so that the area in front of the vehicle is properly illuminated and the drivers of the oncoming traffic are not dazzled with the dipped beam The headlights are adjusted by means of
165. e 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 and a knock out tool take out the front and rear bearings of the inter mediate shaft from the transmission casing Make marks on the inner rings of the double row bearing for further refitting in the bearing outer ring Take the intermediate shaft out from the transmission casing inclining it as shown on fig 3 25 Take out from the transmission casing the 1st 2nd 3rd and 4th selector rods one by one previously having undone the securing bolts Taking out the rods simultaneously remove three detents 6 fig 3 26 Remove the output shaft idler bearing lock plate fig 3 27 Undo the fastening nut of the reverse idler gear shaft and remove it Fig 3 25 Withdrawing the intermediate shaft from transmission casing 22 21 20 19 18 17 VN l 2 Ke PS 16 YR L 15 Ar M A m Spa wT 7 NT ADS T Ax Bel fa e N e co Fig 3 26 Gear shift mechanism 1 3rd 4th selector fork 2 1st 2nd selector rod 3 3rd 4th selector rod 4 1st 2nd selector fork 5 5th reverse selector rod 6 detents 7 detent cover 8 det
166. e the 49 227777222277272 A 777 Fig 2 85 Accelerator pump 1 atomizer 2 fuel delivery ball valve 3 diaphragm 4 pushrod 5 operat ing lever 6 cam 7 primary throttle valve 8 non return ball valve 9 sec ondary throttle valve 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 opened by means of lever 4 edge 4 3 Choke 5 shaft is not centralized therefore after the engine is started the choke is opened by force of air flow extending spring 7 to result in a leaner air fuel mixture Vacuum from the throttle body operates diaphragm 1 and opens the choke by means of rod 3 Adjuster screw 2 makes pos sible to control the degree of the choke opening The maximum choke opening rate at the engine start up and warm up depends on choke lever 4 positions or choke lever slot width Idling overrun control unit disables the idling system on the overrun during engine deceleration downhill movement or gear shifting thus improving fuel economy and reducing CO emission to atmosphere On the overrun at over 2100 rpm and carburettor idle switch 7 shorted to ground Fig 7 40 throttle pedal released fuel cu
167. e vehicle is carried out in a reverse sequence When refitting the axle the fastening nuts and bolts should be tightened with torque specified in the appendix Fill the front axle casing with transmission oil through the filler neck the oil level should reach the lower edge of the opening Dismantle Place and fix the front axle on a bench for repair Turn out plug 5 and drain oil from the casing then do the following from both ends of the front axle undo the inner joint casing bearing 7 cover 12 fastening nuts and take out the joint paying attention not to damage the sealing after removing circlip 11 and spring washer 10 press off bearing 7 from the inner joint casing 9 and remove oil seal 8 Remove the axle casing stamped cover and sealing It is not recommended to remove bottom cover 2 Dismantle the front axle reduction gear using the procedure described in subsection Rear axle Inspection Parts are inspected according to the procedure given in sub section Rear axle and besides ensure that the ball bearing of the inner joint casing is not worn or dam aged renew the bearing if the radial gap exceeds 0 05 mm the inner joint casing is not deformed and the landing places are not damaged there are no scuffings and dents in the grooves of the inner joint casing there is no wear and cracks on the casing landing places Renew worn and damaged parts Reassembly Before reassembly match the r
168. eaks between the fuel tank and central injection unit check the gauze filter for tightness then re check pressure in the fuel delivery sys tem A lower pressure below 190 kPa can be caused by a faulty fuel pressure regulator or by a restricted flow in the fuel delivery system The fuel delivery system capacity can be checked by return flow When necessary renew the gauze filter The fuel pressure regulator can be checked by a pressure gauge for that disconnect the return hose and immerse it into a container Operate the electric fuel pump pinch the return hose and check the pump pressure by the pressure gauge Release the hose The pressure gauge reading is the pressure of the fuel pres sure regulator valve actuation Renew the fuel pressure regulator when applicable A higher pressure in the fuel supply system in excess of 210 kPa can be caused by a faulty fuel pressure regulator or a high er resistance to fuel return to the fuel tank To check this connect a pressure gauge to the system then working in the engine bay disconnect the return hose and immerse it to the container Switch off the electric fuel pump and read the pressure gauge to check the pressure Should the pressure exceeds the normal value renew the fuel pressure regulator otherwise identify and eliminate the cause of higher resistance to fuel return Electric fuel pump Removal and refitting Disconnect the wiring and depres surize the fuel delivery
169. eal 3 intermediate shaft 4 upper shaft 5 locking plate bracket front end 6 bracket 7 upper shroud 8 bearing bush 9 needle bear ing 10 steering wheel 11 lower shroud 12 steering system mounting bracket components 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 of the steering mechanism and the steering box Place the wheels in position corresponding to straight movement Fig 5 4 Steering mechanism installation on vehicle 1 steering box securing bolts 2 pinch bolt intermediate shaft lower end 3 bracket securing bolts 4 steering shaft bracket 33 1 mm distance from the pitman aperture to the steering box thrust surface at middle position of the pitman 116 Turn the steering wheel in both directions and ensure the steering wheel free play does not exceed 5 when mea sured on the wheel rim no more than 18 20 mm To perform this operation use tool 67 8720 9501 there is no rattle in joints connections and steering mecha nism reliable fastening of the steering box and the slave arm bracket tighten the threaded connections if necessary there is no fr
170. earing 3 Insufficient amount of oil 4 Worn gap in final drive gear mesh during reduction gear 5 Excessive gap in driving gear bearing due to loose flange fas tening nut or worn bearing Noise a and engine deceleration 1 Adjust gear mesh 2 Renew bearings 3 Top up oil and check for leaks from seals and rear axle beam 4 Adjust clearance 5 Check moment of resistance to rotation tighten nut or renew dam aged parts t cornering 1 Damaged axle shaft bearings 1 Renew bearings Knock at the beginning of movement 1 Worn opening in differential 1 Replace differential box box for differential pinion shaft 2 Loose rear suspension arm 2 Tighten bolts fastening bolt Oil leak 1 Worn or damaged driving gear seal 2 Worn axle shaft seal deter mined by excessive oil on braking plates drums and pads 3 Loose fastening bolts on rear axle reduction gear casing dam aged sealings 84 1 Renew oil seal 2 Check axle shaft runout beam sag Straighten or replace damaged parts 3 Tighten bolts replace gaskets Rear axle removal and refitting The removal and refitting of the rear axle beam is described in subsection Rear suspension To remove the rear axle it is enough to disconnect the suspension arm and the shock absorbers only from the rear axle beam When refitting the rear axle the bar fastening bolts should be tightened according to the regulations in subsection Rear suspensi
171. ecommended to renew the dust cap and the sealing rings in the cylinder block flutes to ensure satisfactory operation of the system Brake disc runout check Check the axial runout of the brake disc without removing it from the vehicle fig 6 15 The maximum allowable runout by the indicator is 0 15 mm if the runout is greater it is necessary to grind the disc but the final thickness of the disc after grinding should be no less than 9 5 mm In case of damage or very deep risks and also if wear exceeds 1 mm on each side renew the disc Replacement of brake pads Renew the pads if the friction lining thickness has decreased to 1 5 mm To replace the pads do the following remove the pins from the shaft of the upper clamping lever take out the shaft and remove the lever remove the caliper Fig 6 14 Front brake components 17 18 1 carrier 2 caliper 3 piston cap 4 sealing ring 5 cylinder block 6 brake pads 7 brake disc 8 caliper dust cover 9 brake splash guard 10 bleeder 11 brake hoses 12 cylinder block detent 13 detent spring 14 piston 15 clamping lever spring 16 clamping lever 17 pin 18 clamping lever shaft 129 Fig 6 15 Checking the brake disc runout 1 magnetic block 2 indicator 3 brake disc Fig 6 16 Replacing the brake pads 1 brake pads 2 carrier 3 brake disc 4 brake hoses 5 cylinder block complete with calip
172. edial actions remove and test pump using specialized equipment 198 3 Engine does not start emitting white smoke cold engine Check the following items glow plugs secondary warming up system cylinder head gasket injection timing If smoke persists after repair work remove pump for inspection 4 Difficult cold engine start with black smoke Check the following items glow plugs fast idle thermostat injection timing injectors hydraulic lifters and valve clearances compression Should smoke persists after repair remove and test pump using spe cialist equipment 5 Engine starts and stalls Check the following items idle adjustment oil grade and oil level ventilation system fuel feed system solenoid secondary warming up system air cleaner non return valve on LUCAS pump Should engine stalls despite repair performed remove fuel pump 6 Unstable idle Check the following items settings of engine stop prevention system and idle for LUCAS settings for idle and fuel remainder return for BOSCH accelerator lever spring fuel feed system injectors valve clearances cam belt tension In case of failure to adjust idle speed remove and examine pump on a specialist test bench Engine removal and refitting Place the vehicle on the lift or over an inspection pit chock the front wheels and raise the rear axle from one or both sides Wi
173. ee diodes marked red make positive rectified voltage These diodes are plus and are pressed within one diode plate connected to the alternator termi nal 30 Three other diodes minus marked black have neg ative rectified voltage to the housing They are press fitted to the other diode plate connected to earth First make sure both positive and negative diodes are not shorted internally For this connect the battery positive terminal through a test bulb to the alternator terminal 30 whilst the nega tive terminal to the alternator housing Fig 7 8 I The illuminat ed bulb indicates shorted positive and negative diodes Short circuit in the negative diodes can be detected by con necting the battery plus terminal through a test bulb to one of the diode plate securing bolts while the minus to the alterna tor housing Fig 7 8 II The illuminated bulb is an indication of a short circuit fault in one or more negative diodes Note that in the latter case the bulb may come on as a result of stator winding being earthed to the alternator housing However this fault is much less frequent than short circuits in the diodes Fig 7 8 Diode check 1 battery 2 warning light 3 alternator concurrent check of positive and negative diodes Il check of negative diodes III check of positive diodes Short circuit in the positive diodes can be detected by con necting the battery plus te
174. ee fig 3 12 and distance sleeve 44 loosen the cover fastening bolts 5 fig 3 20 and undo bolts 2 and 4 that are securing the fifth speed reverse gear unit Remove the oil deflector washer 45 see fig 3 12 then bush 1 fig 3 21 from the fifth speed gear and take out rod 1 fig 3 22 from fork 2 Thus distance bush 3 is removed from the rod Then remove the gear unit 4 from the inter mediate shaft splines Fig 3 20 Undoing the fastening bolts of the gear unit and the 5th reverse fork 1 reverse idler gear 2 gear unit fastening bolt 3 fork rod 4 fork fastening bolt 5 detent cover 67 Fig 3 21 Removing the 5th gear bush 1 bush E 2 CV m Le gt gt uni e Fig 3 23 Removing the reverse idler gear 5th gear synchro unit and fork assembly 1 reverse idler gear 2 5th speed coupling 3 5th speed reverse gear GSD ili Ru Sp ina SERE ngs AS A H ECCE NUUS Sen 450 ES iid 9 Fig 3 22 Removing the 5th speed reverse selector rod 1 5th reverse selector rod 2 5th reverse fork 3 distance sleeve 4 gear unit 1 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 68 Simultaneously remove th
175. ee play in the tie rod balljoint and in the slave arm bracket and there is no axial displacement of the worm shaft the steering wheel turns with the effort with the front wheels standing on smooth surface not exceeding 196 N 20 kgf 245 N 25 kgf Check the tie rod adjuster pins ensure reliable tightening of the clamps Inspect the balljoint and protective caps as set forth below Inspection of the tie rod balljoint First check the movement of the tie rod ends along the pins For this purpose move the end parallel to the pin using a lever and a support The axial movement of the end in relation to the pin should be 1 1 5 mm This will prove that the pin insert is not jammed in the tie rod end and it moves together with the pin depressing the spring Replace the joint with a jammed insert Rotate the steering wheel in both directions by touch ensure there is no free play in the tie rod joints If the free play in the ball is detected replace the tie rod ends or tie rod assembly 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 squeezing out when the joint is pressed with fin gers Checking and adjusting the clearance
176. eedle valve 7 float 8 secondary throttle valve 9 main fuel jets 10 primary throttle valve a WN NAN V Eod P d d d dii S XN P 4 d d NER Gl quae i 7772 e dL d dis S ahhh At he ee we Py ae LIII I E d d d d d Fig 2 83 Idling and air correction systems 1 fuel cut off solenoid 2 idling fuel jet 3 idling air jet 4 fuel jet and tube secondary air correction system 5 air jet secondary air correction system 6 outlet ori fice secondary air correction system 7 main fuel jets 8 primary air correction passage 9 idle mixture adjustment screw 48 11 10 77 eo TN Das T QAANAANNAD 7 d 7 e grh a 7 L Fig 2 84 Part throttle and full throttle enrichment systems enrichment A Z 13 V4 NZ k D ON ADi A 4 a MET 77 Z PSY N REA ITNT VAN ALAS NA 4g 32 Oy HB n ZZ Gi Z 77 3 H e AV Aaa Nie A PRPA K WAY QUA Y 1 eae WY Y a 2777 1 secondary throttle valve 2 main fuel jet secondary barrel 3 fuel jet and tube full throttle enrichment 4 main fuel jet primary barrel 5 primary throttle valve 6 vacuum port 7 part throttle diaphragm 8 ball valve 9 fuel jet part throttle enrichment 10 fuel passage 11 choke 12 main air jets 13 injection tube full throttle r NN NN E N NN AE 2 1
177. eels in the straight ahead position so that steering wheel 5 top elements Fig 9 37 are horizontal Next carry out the following remove two caps 9 Fig 9 38 from the steering wheel side trim working from the side of the steering wheel unscrew four bolts securing airbag module 13 carefully withdraw the airbag module from the steering wheel using a screwdriver retract spring type locking tab 4 Fig 9 39 then turn inflator unit 12 Fig 9 38 anticlockwise to align its base with recesses in steering wheel adapter 1 Fig 9 39 WARNING Never apply excessive force to the inflator unit when dismantling If the inflator unit doesn t turn make certain the locking tab is fully retracted exercise care and withdraw the gas generator from the Steering wheel adapter undo nut 11 Fig 9 38 and remove the steering wheel Refer to chapter 5 of Repair Manual for further dismantling of steering associated parts and units Refitting of the steering is a reversal of the removal proce dure observing the following before refitting the steering wheel make sure the unit A Fig 9 39 for putting the system in the ready to work position D shaped projection in the centre of the steering wheel adapter is not bent or broken otherwise renew the steering wheel refit the steering wheel to the steering shaft so that the top elements of the steering wheel are horizontal Torque the steer ing wheel nut to 31 4 51 Nem 3 2 5 2
178. el 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 adjustments After placing the vehicle on a test bench immediately prior to inspection apply 2 or 3 times a downward force of 392 490 N 40 50 kgf first on the rear bumper and then on the front one The wheel alignment angle should be checked and adjusted in the following sequence 1 Caster angle 2 Camber angle 3 Toe in Caster angle If the check will show that the angle size does not correspond to the above data it is necessary to change the quantity of adjusting washers 50 see fig 4 1 between the upper arm shaft and the crossmember arm see tab 4 2 Table 4 2 Camber and caster angle vs number of washers in a set Number of washers added to the set or withdrawn camber caster front bolt rear bolt 1 1 8 42 0 1 1 8 42 0 1 0 7 30 20 24 1 0 7 30 20 24 0 1 15 18 25 18 0 1 15 18 25 18 1 1 27 30 43 18 1 1 21 36 40 Note Data are given for washers with thickness of 0 75 mm Plus adding a washer minus removing a washer To adjust the caster angle undo the fastening nuts of
179. em of drawing crankcase emission on the throttle body a part throttle channel heater and secondary barrel locking The carburettor has two main fuel jet systems for the primary and secondary barrels a primary barrel idling system with air cor rection a secondary barrel air correction system part throttle enrichment economizer full throttle enrichment econostat diaphragm type accelerator pump semi automatic choke control unit On the overrun an idling overrun control unit is actuated Refer to Table 2 2 for carburettor data Fig 2 81 Carburettor 21073 1107010 1 throttle valve lever 2 secondary barrel lock lever pin 3 primary throttle valve opening adjustment screw 4 screw for choke valve cable end fitting 5 choke valve control lever 6 choke valve lever 7 choke valve return spring 8 diaphragm rod pull down unit 9 fuel shutoff solenoid 10 fuel supply manifold 11 bracket for choke outer cable end fitting 12 secondary barrel adjuster screw 13 secondary throttle valve lever 14 secondary throttle lever 15 primary throttle return spring 46 21073 1107010 CARBURETTOR Table 2 2 Parameters Primary barrel Secondary barrel Barrel diameter mm Venturi diameter mm Main jet system fuel jet marking air jet marking Emulsion tube type Idling and air correction systems primary barrel fuel jet marking conventional flow air jet Air correcti
180. en removing atomizer 10 Undo the nut of the primary throttle spindle remove cam plate 4 of the accelerator pump linkage then the washer Undo the retaining screw remove wire 30 from throttle stop 52 screw CO adjustment screw 29 and when applicable remove Screw 29 Remove plastic plug 25 and undo idle mixture adjusting Screw 27 Lift out part throttle enrichment cover 5 diaphragm 6 and spring Unscrew fuel jet 7 of the part throttle enrichment unit Undo main air jets 12 with the emulsion tubes and main fuel jets 13 Carburettor components cleaning and inspection Fuel filler Wash the filter and blow dry with compressed air Examine the filter When the filter or the fuel supply manifold are damaged renew them 31 30 2 Fig 2 89 Carburettor housing components 1 accelerator pump diaphragm 2 operating lever accelerator pump 3 cover 4 cam accelerator pump linkage 5 cover part throttle enrichment 6 diaphragm part throttle enrichment 7 fuel jet part throttle enrichment 8 valve part throttle enrichment 9 return valve accelerator pump 10 atomizer and fuel feed valve accel erator pump 11 main metering atomizers 12 main air jets with emulsion tubes 13 main fuel jets 14 bracket to secure choke outer cable end 15 adjusting screw secondary barrel 16 stop adjusting screw 17 cap stop 18 primary throttle opening adjusting screw 19 primary throttle spindle and oper
181. enew oil seal 2 Tighten bolts 3 Renew sealings Fig 5 1 Steering 1 track rod 2 drop arm 3 relay rod 4 idler arm 5 adjuster pin 6 lower balljoint 7 right steering knuckle 8 upper balljoint 9 right steering knuckle arm 10 idler bracket 11 upper shaft bearing 12 steering wheel mounting bracket 13 sleeve ignition switch anti theft device 14 steering wheel mounting bracket pipe 15 upper shaft 16 steering box 17 middle shaft 18 column shroud 19 steering wheel 20 pinch bolt 21 underbody chassis arm 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 18 lower ball bearing 19 shims 20 worm bear ing cover lower 21 roller shaft 22 ball bearing 23 worm shaft oil seal B C marks 15 14 13 12 11 LZ LLL e gt a eo c AMAN KZ V ZA gc V D f x S7 AED B PS HA R N9 LL SIDE Gt Pt A 4A NE e SS 10 X AEX COIL a 277 y 77 Yl S Qr 14 22 21 Fig 5 3 Steering components 1 steering box 2 shaft s
182. ent spring 9 detent ball 10 5th reverse selector fork 11 5th reverse fork rod head 12 5th reverse gear unit 13 reverse idler gear shaft 14 reverse idler gear 15 guide plate washer 16 guide plate 17 gear shift lever housing 18 ball socket 19 cap 20 spring 21 thrust washer 22 circlip 69 Fig 3 27 Undoing the fastening bolts of the output shaft idler gear plate with an impact screwdriver The arrow shows the direction of the screwdriver thrust stroke when striking with a hammer Fig 3 28 Withdrawing the input shaft from the transmission casing 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 the crankcase the output shaft in assembly with gears cou plings and synchro unit rings Remove the 3rd 4th synchro unit sleeve from the shaft Dismantle the input shaft fig 3 30 remove circlip 7 baulk ring 6 and spring 5 place the shaft on a press and having fixed the spring washer 2 with tool 41 7816 4069 remove circlip 1 and then the spring washer and bearing 3 Dismantle the output shaft fig 3 31 from the rear end of the shaft remove the 1st synchro gear 11 wit
183. eono aaae i a 96 Chapter 4 Wheel suspensions eeeeeeeeese 100 Front susperislon inerte rn enne tni etnies 102 Rear SUSPENSION siiicar enaere 110 Chapter 5 Steering iecore einen 115 Steering inspection check and adjustment 116 Steering mechanism sess 118 Chapter 6 Braking system ssseeeeeeeene 121 Front Drakes ceteri cic nte a 128 Rear brakes ue pli cepe em rre Cel 130 ANG DAK i 134 Chapter 7 Electrical system 135 Wiring and fUses 5 nre eterne tent 135 nim ange aaeh 136 Astomo6unn BA3 21213 BA3 21214 BA3 21214 20 BA3 21215 PykoBoncTBo no pemMoHTy aBTomobunen l EHEPAJIBHBII I JETIAPTAMEHT PA3BMTMS A O ABTOBA3 Astopbi paspasoTunku Borrua C H Koanos M JI Kocapes C H Nepesog 3 Auwcosoit V CraukoBoii Altetmat r s iicet esae e eta bate dae bes eae ER e 140 SLAMEN IMOLOM E 146 IOMON SYSTEM aici ini anise 149 Lighting and signalling eeeeeeeee 156 Windscreen wiper washetr eeen 159 MISTRUIMONIUS E PT 163 Chapter 8 Bodywork ssseeeee 167 Bodywork repalt sssi error tet irn rere erede 169 isle ce IDOO Siena M I rer Bonnet bumpers Bodywork glazing and windscreen washers 180 Instrument panel seats 181 Heater Nit sess acs iaceo oret pe tun teta tese poi b teret
184. eparator 195 Fig 9 15 Exhaust emission system 1 clasp 2 front exhaust pipe 3 lock plate 4 pin 5 nut 6 gasket 7 oxygen sensor 8 bracket 9 bolt 10 conical string 11 catalytic converter 12 suspen sion loop 13 main silencer 14 clip 15 front silencer 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 spherical surface Downpipe 2 is secured with nuts 5 onto exhaust manifold studs 4 gasket 6 is fitted between them Lock plates 3 are placed under the nuts The other end of the downpipe by means of clasp 1 is secured to bracket 8 fitted to the transmission cover Main silencer 13 is attached to the underbody by two sus pension loops 12 The silencers complete with pipes represent single units and should be renewed as such during repair Electrical system An EMS wiring harness is added to the vehicle electrical sys tem Fig 9 16 to connect the ECU with EMS sensors and actua tors No headlamp wipe wash is fitted to VAZ 21214 20 vehicle Three wires of the EMS wiring harness through a separate plug are connected to the tachometer LT input in the instrument cluster to CHECK
185. epress the throttle lever and smoothly raise the engine speed to 2500 3000 rpm At coolant temperature of 30 38 C EGR valve 5 must be closed while at coolant temperature of 40 48 C it must be open which can be evident through the EGR valve rod upward travel If the Fig 2 92 Exhaust gas recirculation 1 carburettor 2 thermo vacuum switch of EGR valve 3 intake pipe 4 exhaust manifold 5 EGR valve 6 recirculation tube EGR valve does not open check the proper operation of the EGR valve and thermo vacuum switch 2 To check the EGR valve disconnect the thermo vacuum switch Using manual vacuum pump build up vacuum in the EGR valve diaphragm cavity The EGR valve must be closed at 9 3 kPa 70 75 mm Hg With vacuum level over 59 9 kPa 450 455 mm Hg the EGR valve must be fully open which is checked through a sharp vacuum removal the EGR valve closes with a distinct click In both cases no air leaks are allowed within 5 sec onds To check thermo vacuum switch 2 disconnect the hose and EGR valve 5 Using manual vacuum pump build up vacuum of 13 3 kPa 100 5 mm Hg to the thermo vacuum switch At coolant temperature maximum 30 38 C no vacuum leaks are allowed thermo vacuum switch is closed At coolant tempera ture below 40 48 C there should be no vacuum thermo vacuum switch is open 55 Fig 2 93 Exhaust system 1 sealing gasket 2 downpipe 3 bracket to secure downpipe to transmiss
186. er 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 caliper to the pads insert the lever shaft with the head facing the wheel and fix the pins The pads should be changed simultaneously on the right and on the left brakes 130 Rear brakes The design of the rare brake is shown on fig 6 17 Removal and dismantling Lift the rear part of the vehicle and take off the wheel Take care of possible liquid spillage from the tank Using puller 67 7823 9519 fig 6 18 remove the brake drum Disconnect the cable end piece from the shoe manual lever 18 see fig 6 17 remove the cotter pin press pin 21 and remove the lever Using flat nose pliers disconnect the upper 2 and lower 7 return springs Turn the cups of the steady post 17 take them off together with posts springs and bottom cups remove shoes 8 and 16 and expander strut 20 Disconnect from the wheel cylinder 1 pipeline and plug the openings of the cylinder and pipeline Remove the wheel cylinder To replace the brake backplate 4 remove the axle shaft as specified in chapter Rear axle and disconnect the rear cable 13 having turned out two bolts that are fastening it to t
187. er tightening during vehicle servicing 1st step tighten the bolts 1 10 to 20 Nem 2 kgf m 2nd step tighten the bolts 1 10 to 69 4 85 7 Nem 7 1 8 7 kgfem while the bolt 11 to 31 36 39 1 Nem 3 2 3 99 kgf m 3rd step turn the bolts 1 10 to 90 4th step turn again all bolts 1 10 to further 90 WARNING The cylinder head bolts can be re used only when their length is not in excess of 120 mm otherwise renew the bolt Before reassembly immerse the bolts thread and head into engine oil Allow the excess oil drip for at least 30 min utes Remove all entrapped oil from the bolt bores in the cylinder head Fig 2 18 Cylinder head bolt tightening sequence Fig 2 19 Aligning the timing marks on the crankshaft sprocket and cylin der block Fig 2 20 Centering pins for camshaft bearing housing 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 the mark on the bearing housing Fig 2 21 Remove the sprocket and without changing the camshaft position refit the bearing housing to the cylinder head so that the centering pins are in the respective bores of the bearing housing Secure the
188. er 4 rests on limiter 9 Warm up the engine the electric fan blower must cut in Engine stall prevention system Fit 4 mm gasket 8 between lever 4 and limiter Depress stop lever 2 Insert 3 mm pin 3 in lever 10 Set the crankshaft speed at 900 100 rpm by turning limiter 9 Remove gasket 8 and locating pin 3 Fig 9 24 Idle control 1 throttle stop CO adjustment screw 2 stop lever 3 locating pin 4 load lever 5 limiter 6 outer cable tensioner 7 accelerator cable 8 gasket 9 limiter 10 fast idle lever 11 cable tensioner Fig 9 25 Exhaust emission system sion loop 11 main silencer 12 clasp 13 front silencer 1 exhaust gasket 2 gasket 3 exhaust manifold 4 downpipe 5 bracket downpipe 6 bolt 7 helical spring 8 sealing ring 9 catalytic converter 10 suspen 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 feed and speed are sealed at the factory Exhaust emission system Exhaust gases escape from the engine through exhaust man ifold 3 Fig 9 25 front exhaust pipe downpipe 4 catalytic con verter 9 intermediate silencer 13 and front
189. er filler must be used within ten minutes since it usually takes sixty minutes for the filler to harden well through The thick ness of the filler layer should be a maximum of 2 mm Thermosetting plastic is produced as a powder Its elastic properties required for application on a metal panel develop at 150 160 C The surface to be treated must be thoroughly cleaned of rust scale loose paint and other impurities Thermoplastic adheres better to rough metal surfaces Before applying thermo plastic heat up the affected area to 170 180 C and apply a first layer of powder which is to be smoothed down by a metal roller Then apply a second layer and further ones until all surface imper fections are fully covered Each layer is rolled down to achieve a monolithic layer of plastic mass Use your usual treating methods when the layer is hardened well through Use solders of MOCCy 18 2 type or NOCCy 25 2 type to straighten the areas which were earlier filled with solder to build up edges and to eliminate undesirable gaps Severely damaged panels are replaced with new ones using electric inert gas welding Front wing removal and refitting With minor damages small dent scratches etc straighten and paint the wing without removing it from the vehicle Inspect the condition of inner anti corrosion coating restore it when nec essary Always renew the wing in case of major damages or splits Remove the bumper bonnet and front door
190. eration and diagnostics of fuel injection system removal and refiting procedures and methods for engine repair Refer to Repair Manual for Central Fuel Injection System for a more detailed description of the system design repair and diagnostics with the help of specialized tools and diagnostic charts Engine repair description Engine removal and refitting Before removing the engine depressurize the fuel system To do this detach the fuel pump wiring plug from the injection wiring connector start the engine run it for a while then stop the engine and operate the starter motor for 3 seconds to equalize the pres sure in the line Disconnect the battery negative lead Slacken the nuts holding the air cleaner to the central injec tion unit and to the pin in the valve cover detach the relevant hoses and remove the air cleaner Detach the injector wiring then temporarily plug the filler neck of the central injection unit Disconnect the fuel supply return hoses from the pipes on the engine Plug the open ends of the hoses and pipes to prevent dirt ingress or fuel leaking Disconnect the throttle cable from the central injection unit and from the bracket on the intake manifold On the central injection unit disconnect all vacuum hoses to the charcoal canister and MAP sensor detach the crankcase vent hose Disconnect the wiring from all injection related units fit ted to the engine Further steps for removing the engine are
191. ere are any bubbles in the water of the cooling water jacket renew the cylinder block Examine the split face between the cylinder block and cylin der head using a straight edge and feeler blades Position the straight edge diagonally and using a feeler gauge measure at the centre both transversely and longitudinally The flatness to be within 0 1 mm tolerance Cylinder repair Check the cylinders for wear to be maximum 0 15 mm When available use a dial inside gauge to measure the bore diameter Fig 2 27 in four lands both longitudinally and trans versely Fig 2 28 Use tool 67 8125 9502 to set the inside gauge to zero 19 TOY NSSNNNNSNNNN SSS SSS SSSSSSSSSSSSSSSSSSSN AS ISE NNN SSSSSSSSSSNNNSN SSS SS IKII SS SSSSSSSSSSSSSSSSSSSNSSSNSNNSSNNNSSSNSNNNNNNNNNNNNNNS N Ki KW SS SS NSSSSNNNSSNNNN 46 Y x N 24 Fig 2 25 Basic sizes of 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 26 Cylinder size class engraved on the cylinder block 20 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
192. eter The tachometer measures the frequency of voltage pulses in the ignition primary circuit Check the speedometer on a tester unit which simulates the vehicle ignition system Connect the tachometer to the tester cir cuitry as it done in the vehicle set the primary circuit voltage to 14 volts and the spark gap in the tester to 7 mm Turn the dis tributor shaft so that the tachometer needle reaches one of the main graduations of the scale At this moment check the distrib utor shaft speed variation is within 250 to 70 rpm Voltmeter The voltmeter was fitted to the vehicles before 1996 then it was replaced by the low battery warning light refer to Fig 7 4 for the relevant wiring diagram Check the voltmeter by applying a known voltage At voltage below 11 3 0 35 volts the voltmeter LED should light steadily When the voltage is between 11 3 0 35 volts and 16 0 35 volts the LED should not light When the voltage is above 1630 35 volts the LED should flash The voltmeter operates with a 5 second delay Switches and senders Coolant temperature sender The sender has an integrated thermal resistor which resistance alters depending on the coolant temperature The sender specification is shown in Table 7 7 165 Table 7 7 Coolant temperature sender specification Temperature Supply voltage Resistance C 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 warn
193. ettor flange deformation or fit new carburettor 7 Fit new pipe in place of damaged one Engine lacks power and has poor acceleration 1 Partly open throttle 2 Choked air cleaner element 3 Ignition system fault 4 Faulty fuel pump 5 Faulty carburettor faulty accelerator pump blocked main jets partly open choke low fuel level in float chamber leaky throttle enrichment diaphragm 6 Restricted fuel tank vent pipe 7 Incorrect valve clearances 8 Misaligned timing marks 9 Insufficient cylinder compression below 1 MPa 10 kgf cm broken or sticking piston rings poor valve to seat fitting excessively worn cylinders or piston rings 1 Adjust throttle linkage 2 Change filter element 3 Refer to section Ignition system 4 Check pump operation and renew any damaged components 5 Carry out the following check pump operation renew damaged parts blow jets with compressed air adjust choke operation adjust float replace diaphragm 6 Blow pipe with compressed air 7 Adjust valve clearances 8 Adjust timing belt accordingly align timing marks 9 Carry out the following Clean piston rings or grooves from carbon deposits renew damaged com ponents replace damaged valves regrind valve seats replace pistons rebore and hone cylinders Main bearing knocking Typical knocking or thumping noticeable at sudden throttle opening at idle which intensifie
194. f 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 With the worm shaft 11 push out from the box the bearing outer ring 5 and take out the shaft together with bearing cage 6 Remove worm shaft sealing 15 and the pitman arm sealing 16 Using tool 67 7853 9541 take out the top bearing outer ring fig 5 7 Reassembly The reassembly of the steering mechanism is carried out on bracket A 74076 R in sequence reverse to dis mantle The outer ring of the worm upper bearing is press fitted with tool 67 7853 9541 having rearranged the fixture on the tool han dle in reverse order Refit the worm in the steering box and fasten the bottom cover fig 5 8 use dynamometer 02 7812 9501 and head A 95697 5 fig 5 9 to check the worm friction moment it should be within the limits of 19 6 49 N cm 2 5 kgf cm If the moment Fig 5 10 Removing the ballpins will appear less than specified reduce the thickness of shim 2 see fig 5 8 and if more increase After refitting the pitman arm ensure there is no clearance in the roller to worm mesh in position when the worm shaft is turned right and left by 30 from the pitman arm middle position Take up any possible clearance by adjusting screw
195. f the manual give full descriptions of VAZ 21213 vehicle units For general description service and repair procedures applicable to other models refer to Section 9 where you can also find the information on additional and alternative equipment fitted to the vehicles The Manual provides a detailed description of service operations on the base of OEM parts with help ful information on fault diagnosis along with clear indications on removal and refitting dismantling and reassembly adjustment and repair of various vehicle units We recommend to use special tools and working facilities as listed in Attachment No 2 Tighten the thread connections to torques specified in Attachment No 1 Basic adjustments and inspection checks are outlined in Attachment No 3 Refer to Attachment 4 for recommended lubricants and fuels Due to the on going process of vehicle improvement aimed to enhance the VAZ vehicle reliability and performance the manufacturer can make alterations and design changes which may fail to enter this pub lication Such changes and alterations will be incorporated into our manuals at the earliest opportunity The Manual describes the vehicle design as of October 1999 Section 1 General Data Table 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 brakin
196. f window lifter broken Excessive efforts or failure to recline front seat back forward or rearward Excessive friction in seat reclining mechanism Worn components of seat reclining mechanism Damaged welding joints of front seat frame components Failure to fix front seat back in reclined position Disconnected control cable of front seat rake adjuster Broken control cable or fractured outer cable of seat back rake adjuster Renew window lifter 1 Lubricate friction components of seat reclining mechanism and front seat rails with grease Ovon 1 2 Renew worn components lubricate new ones 3 Renew front seat frame 1 Secure control cable on seat recliner hook check for proper operation 2 Renew faulty recliner mechanism components check for proper operation Failure to adjust front seat back rake Faulty retainer of front seat back rake adjuster knob Faulty front seat back rake adjuster 1 Renew front seat back rake adjuster knob retainer check operation of mechanism 2 Renew front seat back frame Front seat position is difficult to adjust Seized runners in tracks due to poor lubrication Misaligned front seat tracks and runners Hot air flow to in Faulty heater tap linkage 1 Lubricate runners with grease Ouon 1 2 Adjust front seat runner using adjusting shims under securing bolts terior compartment 1 Check cable operation secure outer cable renew cable if applicable Heater
197. functions causing jamming 4 Renew linings check for damages on disc surfaces 5 Renew damaged rivets and linings if necessary 6 Renew clutch cover pressure plate assembly Excessive noise at clutch release 1 Worn damaged or dry clutch release bearing 2 Worn front bearing on gearbox primary shaft 1 Renew bearing 2 Renew bearing Excessive noise at clutch engagement 1 Broken or weak damper spring 2 Broken weak or detached clutch release fork return spring 3 Broken pressure plate to clutch cover connecting plates Clutch release drive adjustment The following adjustments are carried out in the clutch release drive the 0 1 0 5 mm gap between the pushrod and the piston of the master cylinder see fig 3 2 is set This gap necessary for comp lete clutch release is adjusted by the clutch pedal limiter bolt 5 The clearance is determined by the pedal free travel equal to 0 4 2 mm 58 1 Renew clutch disc assembly 2 Renew spring or secure 3 Renew clutch cover pressure plate assembly the free travel of the clutch release fork pushrod equal to 4 5 mm is adjusted by bolt 5 fig 3 3 and fixed by locknut 6 The dis tance of the pushrod free travel is controlled by a special pattern After carrying out the above described adjustments the clutch pedal free travel should make 25 35 mm 20 RY 19 18 17 16 1514 13 1211 10 Fig 3 2 Clutch pedal and master cylinder 1 pedal clus
198. g coupling 2 Remove rear cover 31 see fig 3 35 in assembly with the rear axle drive shaft taking care not to damage the sealing Then remove flanges 12 from the input shaft and the drive shafts of the front and rear axles 12 Fig 3 35 Transfer box 11 10 9 8 7 6 27 o5 5 23 24 gt 23 2C CASS 28 21 AN 13 ON CN SE NA 30 12 y 4 f 31 a 32 A 33 3435 2 36 12 SPIR EG an o2 Jg a 6 ewe aN Ne wd TA nt Nil P TTA li NS x A a Y SEZ LENS 5 LX A Sy M V t 5432 1 1 driven gear 2 differential bearing 3 spring washer 4 circlip 5 differential locking coupling 6 differential housing crown 7 front axle drive shaft crown 8 front axle drive shaft bearing 9 oil screen 10 splash guard 11 front axle drive shaft 12 flange 13 oil seal 14 oil drain plug 15 speedometer driven gear 16 speedometer drive gear 17 plug for oil top up and level check 18 transfer box front cover 19 layshaft roller bearing 20 mounting bracket 21 input shaft bear ing cover 22 bearing thrust ring 23 input shaft bearing 24 top gear 25 gear shift clutch hub 26 gear shift clutch 27 transfer box casing 28 low gear 29 low gear bush 30 input shaft 31 rear cover 32 layshaft ball bearing 33 layshaft 34 differential housing 35 rear axle differential gear thrust washer 36 rear axle
199. g distance at GVW and 80 km h on horizontal dry flat asphalt road not greater meters with service braking system applied 40 40 40 40 with emergency system applied either of two service braking circuits 90 90 90 90 Maximum speed in top gear km h with driver and passenger 137 137 137 130 at full load 135 135 135 128 Acceleration time 0 to 100 km h through gear shifting seconds with driver and passenger 19 19 19 22 at full load 21 21 21 24 Engine Model 21213 21214 21214 10 DHW XUD 9SD Type Four stroke Four stroke Four stroke Four stroke petrol carburettor No of cylinders four in line Bore x stroke mm 82x80 Capacity litre 1 69 Compression ratio 9 31 Maximum power as per GOST 14846 net at least KW h p 58 78 9 as per ISO 1585 KW 58 Maximum crankshaft speed at maximum power rpm 5200 Firing order 1 3 4 2 Measured using a special procedure petrol CFI four in line 82x80 1 69 9 3 1 58 78 9 5400 1 3 4 2 petrol sequential injection four in line 82x80 1 69 9 3 1 58 5 79 6 58 5 5000 1 3 4 2 turbo diesel four in line 83x88 1 905 21 5 1 55 74 8 55 4600 1 3 4 2 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 Seco
200. g lugs enter the recesses of the headlight inner rim Front lights Undo two screws and remove the lens then slightly depress the bulb and turn it anticlockwise to remove Direction indicator side repeater To renew a failed bulb first remove the holder complete with the bulb working from the engine bay Interior lamp To renew a blown bulb gently pull the lens up The lamp is held in the recess in the door centre pillar by two spring clips 158 Fig 7 32 Headlight alignment Rear light unit To replace a failed bulb in the rear light unit remove a plastic cap from the inside of the luggage compartment disconnect the terminal connector squeeze the retaining lugs and withdraw the base complete with the bulbs Next depress the bulb turn it anticlockwise and withdraw Number plate light Undo the retaining screws remove the light unit detach the reflector lens and renew a blown bulb Hydraulic headlight adjuster The hydraulic headlight adjuster system consists of the mas ter cylinder fitted to the instrument panel working cylinders on the headlamps and connecting pipes The cylinders and pipes are filled with non freezing hydraulic fluid The hydraulic adjuster is not serviceable and has to be renewed as a complete unit together with the cylinders and pipes in the event of a failure When the beam setting is disturbed and alignment by means of the adjustment screws on the headlight has failed check the cy
201. g plate to the axle beam and using a pusher remove the axle shafts from the differ ential box disconnect the propeller shaft from the driving gear flange and move the shaft aside using a dynamometer check the driving gear moment of resistance to rotation and note hold the flange with a special key undo the driving gear flange fastening nut and remove the flange with the washer remove the driving gear sealing grease the seal working surface with JIWTOJT 24 and press fit with a mandrel into the reduction gear casing on depth of 2 0 3 mm between the end face of the reduction gear casing and the sealing outer surface fit the flange with a washer on the driving gear hold it with a special key and tighten the flange fastening nut controlling the moment of resistance to rotation by a dynamometer from time to time If the initial value of moment of resistance to rotation was 58 8 Necm 6 kgf cm or more the new one should exceed the initial by 9 8 19 6 Necm 1 2 kgf cm If the initial moment of resistance to rotation was less than 58 8 Necm 6 kgf cm the flange fas tening nut should be tightened to 58 8 88 2 Necm 6 9 kgf cm If the moment of resistance to rotation was exceeded when tightening the nut dismantle the reduction gear renew the dis tance sleeve then reassemble the reduction gear and adjust as described in chapter Assembly and adjustment The reassembly of the rear axle is carried out in seque
202. g rings of fuel pipes Dismantling and reassembly Undo the retaining screws and remove throttle position TP sensor 10 Fig 9 4 injector 6 fuel pressure regulator vacuum hose manifold housing 13 and idle air control valve 14 Undo two retaining screws and disconnect the fuel supply part from the throttle housing Reassembly is a reverse of dismantling Examine the seals renew if applicable When refitting the TP sensor align the throt tle shaft flats with the TP sensor pickup lever Examination and repair Injector is a one piece unit When removing the injector take care not to damage the wiring plug or atomizer head WARNING Never clean or wash the injector with petrol or other cleaners Renew the injector seals In the event of deposits on the injector filters the major diameter filter is a purge filter while the minor diameter filter is an intake filter blow the filters with com pressed air then flush the fuel tank and fuel pipes Apply sealant on the retainer screw thread when refitting the injector Fuel pressure regulator Remember that the spring under the regulator cover is compressed so exercise care when unscrewing the cover When the regulator is removed examine the valve seats use a magnifying glass if necessary The seat must not show any pit ting dents or surface irregularities otherwise renew the fuel sup ply housing of the central injection unit It is recommended to renew the valve di
203. greater thickness If the specified clearance Fig 3 67 Removing the drive gear rear bearing inner ring using puller A 40005 1 7 1 puller 2 drive gear 3 bearing ring 4 fixture A 45008 Fig 3 68 Removing the differential housing bearing inner ring using puller A 40005 1 6 1 puller 2 bearing inner ring 3 differential housing 4 rest A 45028 90 27 206 25 24 B 2 Fig 3 69 Rear axle reduction gear components 21 20 19 1 drive gear flange 2 oil seal 3 oil deflector 4 front bearing 5 rear bearing 6 drive gear adjusting ring 7 axle shaft gear support washer 8 axle shaft gear 9 pinion 10 pinion shaft 11 driven gear 12 differential housing 13 differential housing bearing 14 adjusting nut 15 stop plate securing nut 16 stop plate 17 stop plate 18 driven gear fastening bolt 19 drive gear 20 cover securing bolt 21 spring washer 22 gasket 23 reduction gear securing bolt 24 reduction gear housing 25 distance sleeve 26 flat washer 27 drive gear flange securing nut 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 ag
204. h bush 12 hub 3 with 1st 2nd synchro sleeve 4 2nd speed gear 10 together with baulk ring 5 place the output shaft with tool 41 7816 4069 on a press fig 3 32 place two thrust half rings 3 under 3rd speed gear and by pressing the spring washer with the mandrel remove the circlip 2 then spring washer 4 3rd 4th sleeve hub and 3rd speed gear If necessary dismantle the lever and the gear selector mech anism Proceed as follows take off rubber boot 10 fig 3 33 thrust ring 6 and circlip 7 spring 5 and cap 4 from the gearshift lever 70 Fig 3 29 Withdrawing the output shaft from the transmission casing Fig 3 30 Input shaft components 1 circlip 2 spring washer 3 bearing 4 input shaft 5 synchro unit spring 6 synchro unit baulk ring 7 circlip 8 bearing 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 carried out in reverse sequence Pay attention that the reverse idler gear shaft is fitted before refitting the shafts in the transmission casing with torque to 78 Nem 7 8 kgf m before refitting the 5th reverse fork rod in the crankcase refit the spacer the inner
205. h the gasket next withdraw the inlet and exhaust manifolds the hot air intake is withdrawn at the same time Remove the water jacket return pipe and coolant to heater return pipe Unscrew the spark plugs and coolant temperature sender Undo the securing nuts and remove the bearing housing complete with the camshaft Undo the nuts holding the thrust flange to the bearing housing Remove the flange and lift out the camshaft from the bearing housing Release springs 12 and remove valve rocker levers 11 Fig 2 43 Remove the rocker lever springs Slacken lock nuts 14 undo adjuster bolts 13 and bushes 15 Position tool A 60311 R as shown in Fig 2 44 compress the valve springs and release the collets A stationary tool 02 7823 9505 can be used instead of tool A 60311 R Remove the valve springs together with lower and upper seats Turn the cylinder head over and remove the valves from the underneath Take off the outer caps from the valve guides Reassembly Reassemble the cylinder head in the reverse order Before assembly begins always oil the outer caps and valves with engine oil Before refitting the camshaft bearing housing check the cen tering pins are in the position Fin 2 21 Tighten the bearing housing securing nuts in the sequence as shown in Fig 2 23 Ensure the centering pins are positioned in the bearing housing recesses without sheering The valve clearances are adjusted only after the cylinder head has been ref
206. haft flange Refer to Fig 2 14 Moving the crankshaft up and down using screwdrivers for instance check the crankshaft endfloat to be within 0 06 0 26 mm If not adjust accordingly and replace the old thrust washers with new ones or fit thicker thrust washers Locate the rear oil seal housing gasket on the crankshaft flange insert the front clutch housing cover bolts into the respec tive bores Fig 2 15 Place the oil seal housing on tool 41 7853 4011 and slide it to on the crankshaft flange next secure it to the cylinder block with the bolts Locate front clutch housing cover 6 Fig 2 10 over two cen tering pins Fig 2 16 Secure the cover to the rear oil seal hous ing with nuts Fig 2 13 Marks on the main bearing caps bearing are numbered from the engine front end Fig 2 14 Checking the crankshaft endfloat 15 Fig 2 15 Crankshaft rear oil seal housing The lugs arrowed for centering the housing against the crankshaft flange 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 A 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 WARNING The hole for gudgeon pin in the piston is 1 2 mm set off so the arrows on the piston cr
207. haul damaged components to remedy the situation No load test Disengage the tester ring gear from the starter motor pinion Operate the starter motor measure the current flow and armature shaft speed to be respectively maximum 60 amps and 5000 1000 rpm at 11 5 12 volts across the starter motor terminals If the amperage and drive shaft rpm readings differ from the values specified the possible causes are likely to be the same as those for the test described above Solenoid test Insert a shim of 12 8 mm between stop collar 21 Fig 7 13 and pinion and operate the solenoid The solenoid cut in voltage with the pinion resting against the shim should not exceed 9 volts at ambient 20 5 C Any higher voltage indicates the solenoid or drive failure Starter motor relay The relay cut in voltage should not exceed 8 volts at 23 5 C When higher it is an indication of a failed relay or drive Starter overhaul Dismantling Undo the nut on the lower solenoid terminal bolt and discon nect the stator winding lead Undo the solenoid retaining nuts and remove the solenoid Remove the end cap Fig 7 16 from the pinion end cover Unscrew and remove protective case 8 Recover lock ring 9 undo clamp bolts 12 and separate yoke 11 with housing 5 from housing 1 with armature 13 Unscrew the brush holders from the stator winding leads then separate the yoke from the commutator end housing Extract springs 7 and brushes 6 Undo the co
208. he atomizer hole and carefully swivel the atomizer to direct the fluid jet where desired Instrument panel seats Instrument panel removal and refitting Disconnect the battery negative lead Remove the windscreen pillar trim steering column shroud instrument panel surround 14 Fig 8 28 instrument cluster Refer to section Electrical equipment disconnect the wiring connectors and wiring plugs Remove the instrument lighting switch knob undo the retain ing nut and push the switch down behind the instrument panel Undo the retaining screws remove front parcel shelf 9 and radio support panel 13 disconnect the wiring from the radio cig arette lighter headlight wipe wash switch hazard warning flash er switch Undo the retaining screws and withdraw glovebox housing 4 Remove the knobs of the heater control levers To do this at the knob lever connection point prise out the lower part of the top knob with some flat and sharp tool while for the middle and lower knobs prise out the upper part Undo the four screws arrowed in Fig 8 29 holding lower instrument panel 3 Fig 8 28 to the front cross member then working through the apertures of the glovebox and instrument panel binnacle undo four nuts holding the top panel to the front end next remove the instrument panel Fig 8 29 Instrument panel attachment points arrowed 181 21 8Fig 8 30 Seats 1 seat back 2 headrest
209. he brake plate 4 Assembly and refitting Assembly and refitting is carried out as follows Fit and fix the wheel cylinder on the brake backplate attach it to the pipeline and fully tighten the connector nut Attach the shoe manual lever 18 see fig 6 17 and refit the brake shoes with expander strut 20 then insert posts 17 with springs and bottom cups put the upper springs and fix them on racks by turning one or other way Ensure that the shoe ends have correctly settled down in the support jacks on the wheel cylinder pistons and on the backplate Attach the rear cable end piece 15 to lever 18 Fit the brake drum previously having greased the landing shoulder of the axle shaft with graphite lubricant or greasing JICLI 15 and fully tighten the drum fastening bolts Wheel cylinders dismantle and reassembly The dismantle and reassembly of the wheel cylinders is car ried out as follows Remove protective caps 2 fig 6 19 then press out from the cylinder body 3 pistons 4 in assembly with the components of the automatic shoe drum clearance adjuster Place the piston in assembly with the automatic adjuster on a special tool so that the ledges of the tool will cover the head of the thrust screw 3 fig 6 20 Using a screwdriver and by turning pis ton 9 turn out thrust screw 3 from the piston Remove sealing 8 with support cup 7 and retainers 5 from the screw Separate thrust ring 4 and thrust screw 3
210. he cylinder The arrow of the piston must face the timing belt end of the engine Gudgeon pin is of steel hollow floating type i e freely operates in the piston bosses and connecting rod bush The gud geon pin is secured in the hole with two circlips As to the outside diameter the gudgeon pin are of three classes in step of 0 004 mm The class is paint marked on the gudgeon pin face 1st class blue paint 2nd class green paint 3rd class red paint Piston rings are of cast iron The top compression ring has a chromed barrel face The bottom compression ring is of the scraper type The oil control piston ring features chromed work ing edges and has a coil expander spreader ring The oversize rings are marked as 40 or 80 which corre sponds respectively to 0 4 or 0 8 mm step in the major diameter Connecting rod is of forged steel The connecting rod is machined together with the big end cap therefore they are inter related The cylinder number 6 in Fig 2 30 is stamped on the caps and connecting rods to prevent confusion when refitting into the cylinders During reassembly the figures on the connecting rod and cap should face the same side p NNNM Esel NY AS Fig 2 29 Basic dimensions of pistons and connecting rods 21 The connecting rod small end features a pressed in steel bronze bush As to the diameter of the bush the connecting rods a
211. he 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 desired clockwise for advance and anticlockwise for retard when viewed from the distributor cap end Tighten the nuts and recheck the ignition timing For easier ignition timing adjustment there provided the respective graduations and marks on the distributor flange A graduation on the distributor flange corresponds to eight degrees 8 of the crankshaft turn Another effective way for checking the ignition timing is to use an oscilloscope analyzer when this tool is available Refit the distributor as following turn the crankshaft to the position of compression beginning at No1 piston then still turning the crankshaft align mark 4 with mark 1 remove the distributor cap turn the rotor arm so that its exterior contact faces the No1 piston contact on the distributor Cap holding the distributor driveshaft stationary insert it to the cylinder block so that the axial line through the spring clamps is nearly parallel to the engine axial line locate the distributor to the cylinder block refit the distribu tor cap reconnect the wiring check and adjust timing ignition Ignit
212. he event the injection system has failed do not blame the high pressure pump first check the following fuel tank and fuel level delivery and return fuel lines fuel filter injectors glow plugs engine stop solenoid resistance Examine the engine since higher flash point temperature depends on compression valve and piston ring condition Inspect the air cleaner battery starter motor check the oil level Major faults and remedial actions 1 Engine does not start emitting no smoke check fuel level in fuel tank set engine manual stop device to normal position check fuel delivery pipes in case of leaks tighten connections or replace pipes check engine stop solenoid for resistance wiring conductivity and fuel inflow If engine still fails to start after all these checks and remedial actions remove high pressure pump and test it using specialized equipment 2 Engine does not start emitting black smoke when engine speed is below 150 rpm check condition and fitting of bat tery terminals and starter motor battery charge oil grade and oil level when engine speed is over 150 rpm start engine without using air cleaner when no smoke is evident renew filter element check proper mounting of air cleaner housing check injection timing is correct check fuel injectors are sound check valve adjustment and compression in cylinders Should smoke persists despite all rem
213. he following check and renew faulty contact part of ignition switch or ignition relay check wire I and its connec tions between ignition switch and ignition relay check wire 4 and its connec tions between ignition relay and earth Warning light does not light up when ignition is switched on and does not stay on during engine operation Instruments operate Battery is discharged 1 Blown warning light bulb or loose holder to PCB contact 2 Broken circuit between instru ment cluster and alternator termi nal 61 3 Brushes worn or binding slip ring oxidized 4 Voltage regulator damaged break between Lll terminal and earth 5 Lead from voltage regulator B terminal disconnected 6 Short circuit in positive diodes 7 Field winding leads discon nected from slip rings 8 No contact between voltage regulator terminals B and LL and brush terminals for pre 1996 alternators 1 Renew failed bulb bend holder contacts or replace bulb holder 2 Check wire Kb and its connec tions between alternator and instru ment cluster 3 Renew brush holder with brush es clean slip rings with fuel moist ened cloth 4 Renew voltage regulator 5 Reconnect wire 6 Renew diode plate 7 Solder pins or renew alternator rotor 8 Clean voltage regulator terminals B LU and brush output bend voltage regulator pins Warning light is bright or half bright with engine running Batte
214. her within one wiring harness Always ensure the spark control unit is reliably earthed through the retaining dowels or its trouble free operation will be affected With ignition switched on never disconnect the leads from the battery posts and never remove the connector from the spark control unit since it may result in higher voltage to some components and damaged control module Ignition timing adjustment Refer to Attachment 3 for the advance angle BTDC at crank shaft speeds of 750 800 rpm To check the ignition timing there provided three marks 1 2 and 3 Fig 7 18 on the timing cover and mark 4 in the crankshaft pulley which corresponds to TDC of pistons No1 and No4 when aligned with mark 1 on the timing cover The ignition timing is best checked and adjusted by means of a stroboscopic timing light Follow the procedure below connect the timing light positive clamp to the battery positive post earth terminal clamp to the battery negative post connect the timing light terminal to No1 cylinder HT lead Highlight in chalk timing mark 4 on the crankshaft pulley Fig 7 18 Ignition timing marks 1 TDC mark 2 5 advance timing mark 3 10 advance timing mark 4 TDC mark on crankshaft pulley Fig 7 17 Wiring diagram of ignition system 1 ignition switch 2 ignition solenoid 3 spark control unit 4 ignition coil 5 ignition distributor 6 spark plugs 151 start t
215. hey are badly damaged at the contact point with the contact plate Reassembly Assemble the starter motor in reversal of the dismantling pro cedure Before reassembly lubricate the armature shaft splines and freewheel hub pinion and housing bushes with motor oil Lubricate drive guide ring with Litol 24 grease Protect the clamp bolt passing under the stator coils with an insulating plastic tube Select shim 10 thickness Fig 7 16 to ensure maximum armature axial play of 0 5 mm On reassembly bench test the starter motor Ignition system General description The ignition system is breakerless It comprises ignition dis tributor 5 Fig 7 17 spark control module 3 ignition coils 4 spark plugs 6 ignition switch 1 with relay 2 113 3747 10 model and high tension HT leads The spark control module monitors the supply circuit of the ignition coil primary winding Control pulses to the control module are generated by the Hall sensor housed in ignition distributor 6 149 Fig 7 16 Exploded view of starter motor 1 drive end housing with intermediate ring 2 rubber plug 3 operating lever 4 solenoid 5 commutator end housing 6 brush 7 brush spring 8 protective case 9 stop ring 10 adjusting shim 11 yoke 12 clamp bolt 13 armature 14 insulating pipe 15 overrun clutch with pinion 16 stop collar Ignition distributor is of 3810 3706 model four event sparking rate non shielde
216. ibutor removed from the engine the sensor can be tested as illustrated in Fig 7 24 at supply voltage of 8 14 volts While slowly rotating the distributor shaft measure the output using a voltmeter The voltage should change sharply between the low level 0 4 volt maximum and the high level which must be maximum 3 volts below the supply voltage The Hall sensor can be tested in the vehicle as shown in Fig 7 23 Adapter 2 and a voltmeter are connected across the distributor connector and wiring harness connector Switch on the ignition and measure the sensor output with a voltmeter while slowly rotating the crankshaft with a special tool The out put voltage readings should meet the specification Ignition coil Check resistance of the winding and insulation For the ignition coil of 27 3705 model the resistance at 25 C should be 0 45 0 05 Ohm for the primary winding and 5 0 5 kOhm for the secondary winding For the ignition coil of 8352 12 model the resistance of the primary winding is 0 42 0 05 Ohm while that of the secondary winding is 5 1 kOhm Fig 7 24 Wiring diagram for Hall sensor test on the removed ignition distributor 1 ignition distributor 2 2kOhm resistor 3 voltmeter of minimum 15 v scale and minimum 100 kOhm internal resistance 4 view on the ignition distributor connector 153 i A B 123456 _ 3B Fig 7 25 Checking the spark control module
217. ichment economizer operates when cer tain vacuum level is maintained on throttle body 5 Fig 2 84 Fuel is fed from the float chamber through ball valve 8 Valve 8 remains closed as long as the diaphragm is held retracted in the intake pipe by means of the vacuum With wide open throttle the vacuum decreases allowing diaphragm 7 spring to open the valve Petrol which flows through part throttle enrichment jet 9 is added to fuel passing through main fuel jet 4 providing a richer mixture Full throttle enrichment econostat operates at full engine load at high close to maximum speeds and wide open throttles Petrol from the float barrel through jet 3 Fig 2 84 is delivered to the fuel pipe and further through injection tube 13 into the sec ondary barrel resulting in a richer mixture Accelerator pump is of diaphragm type mechanically oper ated by cam 6 Fig 2 85 on the primary throttle spindle With the throttle valve closed the spring retracts diaphragm 3 thus filling the pump with petrol through ball valve 8 As the throttle opens the cam operates lever 5 whilst diaphragm 3 forces fuel through ball valve 2 and atomizer 1 into the barrels enriching the air fuel mixture The pump capacity is invariable and is determined by the cam profile only Choke control unit Choke lever 4 Fig 2 86 has three pro files Its outer edge 4 3 operates throttle lever 11 through adjuster screw 10 to start the engine when cold and to further ris
218. icle on the lift or over an inspection pit clean the breather from dirt and inspect undo the control plug check the oil level in the axle casing top up if necessary Fig 3 80 Bearing pattern in final drive gear mesh front side Il rear side a and b improper contact in gear mesh move the drive gear away from the driven gear by reducing the shim thickness c and d improper contact move the drive gear closer to the driven by increas ing the shim thickness e right contact in gear mesh clean the casing filler neck from oil and wipe dry raise the rear axle and put it on supports start the engine engage the fourth gear and at speed of 90 100 km h warm oil up to 80 90 C approximately during 15 min utes with the fourth gear engaged at speed of 100 km h deter mine the amount of oil leakage during 15 minutes Oil leak exceeding 5 drops in 15 minutes will indicate a bad sealing Damaged sealing can be replaced without removing the reduction gear from the vehicle if no replacement of other parts of the reduction gear is required The procedure of seal replacement is the following drain oil from the rear axle casing loosen the rear wheels fastening nuts put blocks under front wheels and raise the rear axle release the handbrake and place the gear shift lever in neutral take off the wheels and brake drums undo the nuts that are fastening the brakin
219. in accordance with the established procedure Refitting is the reverse order of removal On completion adjust the accelerator cable and check the operation of fuel injection sys tem as recommended in Repair Manual for Central Fuel Injection Engine dismantling and reassembly Remove bracket 3 Fig 9 1 with ignition module 4 then plug 2 with gasket and detent 1 with the sealing ring Disconnect and remove the supply return pipes from the cen tral injection unit and from the bracket on the valve cover Undo the retaining pins and remove the central injection unit withdraw the gasket from the intake pipe surface Remove intake manifold 2 Fig 9 2 with preheater 1 When applicable on a work bench detach the preheater complete with the gasket and sealing ring from the intake manifold Unscrew the crankshaft position sensor mounted on the tim ing cover Further dismantling of the engine is carried out in the usual order as outlined in section 2 Reassembly is the reversal of dismantling There is a dispos al gasket under the central injection unit always remember to renew it during reassembly Fig 9 1 Removing the original components from the front left hand side of the engine 1 detent 2 plug 3 bracket 4 ignition module 185 Central Injection Unit Removal and refitting Select the neutral position of the gearchange lever and apply the handbrake Since after the engine is stalled f
220. in outer gear to feed oil to chain 13 camshaft 14 oil recess camshaft centre bearing journal 15 cam lobe oilway 16 oilway camshaft bearing journal 17 cylinder head vertical oil passage to valve timing gear 18 oil gallery 19 oil pressure warning light sender 39 ms 2 y h Fig 2 68 Basic dimensions of the oil pump components and associated parts zz D aA 5 d NET A e d f 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 Refitting is the reversal order of removal Dismantling and reassembly Position the oil pump in vice taking care not to damage the pump housing then undo the bolts and remove the intake manifold complete with the oil pressure relief valve remove cover 3 Fig 2 69 and withdraw the pump shaft complete with the inner and outer gears from the housing To reassemble the pump position the pump in vice and carry out the following operations refit the inner gear with the shaft then the outer gear refit the pump cover pressure relief valve with the spring and bolt the intake manifold assembly to the pump body Note On completing the pump a
221. ing 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 position if the bearing inner ring turns against the axle shaft land ing shoulder renew the stop ring bearing fastening plate and oil screen have no damages axle shaft is not deformed and the landing surfaces are not damaged the axle shafts runout measured in centers on the seal journal does not exceed 0 08 mm Before fitting in the centers carefully clean the centering apertures on the axle shaft from dirt and rust In case of wear or damage of parts fitted on the axle shaft renew them following the below guidelines and using special tools An insignificant bending of the axle shaft core can be cor rected by straightening After straightening the runout of the Fig 3 60 Rear axle beam straightening 1 hydraulic cylinder 2 clamping bar 3 flange A 70172 4 try square 5 press table 6 rest 7 indicator post flange end face measured in the centers should not exceed 0 05 mm if the runout is above the specified value but no more than 0 08 mm it can be lathed to eliminate runout The reduction of flange thickness due to turning should be no more than 0 2 mm Stop ring removal The axle shaft bearing stop ring is removed and i
222. ing cases to exclude wrong readings when the electrolyte level is not as required when electrolyte is too hot or too cold the optimum temper ature to measure electrolyte specific gravity is 15 27 C immediately after the battery replenishment Leave the bat tery for some time to let the electrolyte mix up it may take up to several hours if the battery has been fully discharged after a number of start up attempts It is advisable to wait until electrolyte in the battery cell is homogeneous in terms of density when electrolyte is boiling Wait to see bubbles rising to the surface in the electrolyte sampled with a hydrometer Battery charging Remove the battery from the vehicle and clean it carefully especially its top Check the electrolyte level and replenish if applicable The battery is recharged at a rate of 5 5 amperes with the caps undone Charge the battery until intensive gas escape is observed and consistent voltage and electrolyte specific gravity is achieved within three hours The electrolyte density of the charged battery at 25 C should be as shown in Table 7 4 When recharging the battery frequently check the electrolyte temperature to keep it below 40 C When 40 C is reached then either halve the charging current or stop recharging to cool the battery down to 27 C Stop charging the battery in case of intensive gas escape from the battery cells and when the last three measurements taken h
223. ing collet 8 from cap nut 1 Check collet 8 core 3 and plunger 6 for scores check the mating surfaces of the tensioner shoe and plunger for deep scores Always renew any damaged components 34 The spring tension should be within the range specified in Fig 2 57 otherwise renew the spring Check to see the shoe and chain damper do not have excess wear renew them when applicable Refitting is a reversal of removal Once the plunger is refitted center punch housing 2 at three points B Make certain the pro jections caused by centre punching do not contact the surface A during the plunger stroke Note The spring ring is used in some vehicles instead of centre punching Camshaft timing chain Wash the chain in kerosine exam ine the chain links Check to see there are no scores cracks or other damages In the course of the engine operation the chain lengthens The chain deems operable as long as the tensioner ensures its proper tension i e the chain length is maximum 4 mm longer Check the chain length with the help of tool 67 7824 9521 Fig 2 58 having 2 special type wheels 1 on which the chain is located Using counterweight 3 the chain is extended through applying force of 294 N 30 kgf or 147 N 15 kgf Use adjuster nut 2 to ensure the counterweight axis is parallel to the tool base Apply force 294 N 30 kgf with the counterweight in the extreme right position then decrease the force by 147 N 15 kgf moving the
224. ing 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 Fuel gauge sender The sender unit is located in the fuel tank and is secured by nuts The sender has an alternating Ni Cr wire resistor The resistor slide contact is operated by the float lever Another slide contact fitted to the shorter end of the lever triggers the fuel reserve warning lamp when only 4 to 4 6 litres of petrol are left in the tank The sender resistance should be 250 12 Ohm for an empty tank 66 6 Ohm for a half filled tank and 20 3 Ohm for a full tank Handbrake on warning lamp relay The relay of PC 492 model is intended for intermittent light of the handbrake on warning lamp It is fitted to the wires on the left hand side beneath the instrument panel The number of the relay ons offs per minute should be in the range of 60 120 at 10 8 to 15 volts within 40 to 40 C The wind ing resistance is 26 Ohm The relay of PC 492 model is out of use starting from 1995 therefore when the handbrake is applied the warning lamp lights steadily Carburettor solenoid control Electronic control unit testing Sound electronic control unit 4 Fig 7 41 should cut off sole noid 5 when the engine speed reaches 2100 rpm and operate it when the engine slows down to 1900 rpm if the idle switch is earthed Fig 7 42 Control unit check 1 control unit 2 adapter and vol
225. ing outer race Handle to washers for pressing out wheel hub inner bearing outer race Tool for pressing in front wheel hub bearing outer race Washer for pressing out wheel hub bearing inner race oil seal Tool for checking geometry of front suspension cross member REAR SUSPENSION Tool kit replacement of rear suspension rod silent blocks STEERING Separator tool for pressing out steering joints from drop arm and idler arm Removal tool drop arm Repair tool steering box Bracket for securing steering box to be attached to tool A 74076 1 Tool for pressing in out drop arm shaft bush Tool for pressing out worm shaft bearing outer race Reamer steering box bushes Wrench steering rod coupling Puller steering link balljoints Tool for pressing out in worm upper bearing outer race Tool for checking steering wheel free play BRAKING SYSTEM Spanner brake pressure regulator cover plug Installation tool rear brake pressure regulator Puller brake drum ELECTRICAL SYSTEM Removal tool alternator pulley BODYWORK Removal tool window lifter handle locking clip Tool kit to be supplied to the customer is defined separately 217 Attachment 3 Adjustment and checking DATA Valve clearances cold engine 18 20 C mm Inlet ValVes 5 xut etin dea te ee a Qo adio sae ioo d aM o pta sd es a rtc ae ld 0 15 exhaust valVes croc eo mim R3 s E oou Sill ee ol caedis im heen Er stt ea ie tas e aee 0 20 Coolant temperature warm engine a
226. ing ring 7 stop screws 8 piston return springs 9 spring cup 10 seal holding spring 11 spacer ring 12 inlet port A compensation port clearances between seal 6 ring 11 and piston 5 N 5 7 nb j 4 277A HR ds 126 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 1 96 N 1 3 0 2 kgf 80 mm under load of 117 5 5 88 N 12 0 6 kgf 160 mm The clutch pedal return spring has the length of 130 mm under load of 36 26 30 38 N 3 7 3 1 kgf and 155 mm under load of 49 49 42 63 N 5 05 4 35 kgf Length of the clutch servo unit spring under load of 219 52 180 32 N 22 4 18 4 kgf should be 120 mm and under load of 645 82 529 22 N 65 9 53 9 kgf 152 mm Servo unit Removal and refitting When removing the servo unit do not disconnect the brake hydrodrive master cylinder from the hydraulic system to avoid air penetration The order of removal disconnect the servo unit push rod from the pedal undo the nuts fastening the master cylinder to the unit remove it from pins and move aside disconnect the hose from the servo unit undo the nuts fastening the se
227. int Test 3 If no vibrations was diagnosed during tests 1 and 2 go to test 3 Accelerate the vehicle to the speed at which vibra tion occurs and place the transfer and gearbox levers in neutral position If vibration persists the reason should be looked for in the front or rear propeller shaft out of balance jammed joints or interaxial differential is not balanced Transfer box removal refitting and centering Removal Place the vehicle over an inspection pit or on a lift Release the handbrake and place the gear and transfer box levers in neutral position Undo the fastening screws of the gear lever surround and remove it Remove the handles and gaiters from the levers Undo the fastening screws and remove the cover cap and the bellows 74 Disconnect the speedometer cable from the transfer box and the wires from the differential lock warning lamp sensor Turn the driveshafts and disconnect the driveshaft flanges from the trans fer box shafts and the layshaft flange from the gearbox output shaft flange Unscrew nuts 3 fig 3 37 on the transfer box mounting bracket 1 fastening bolts and remove it together with brackets and shims 5 which are placed under the brackets in assembly with the layshaft Mark each shim so that to refit them in the same amount Refitting and centering the transfer box is done in the fol lowing order ensure proper refitting of engine support pads in brackets the centering washers of the
228. inward Should you experience any difficulties to fit it check the aperture size using the windscreen without the seal Rectify any deviations in the aperture size as applicable Side and rear window glasses replacement To withdraw the glasses remove the molding then depress at the bottom glass corners and force the glass out Ask your assistant to support the glass from falling outside Refitting of the side and rear window glasses is similar to that of the windscreen Washer system The washer system is shown in Fig 8 25 A separate washer container for the tailgate washer is pro vided in the luggage compartment Removal and refitting of windscreen headlamp washer pump Detach the wiring from motor 1 Fig 8 26 and remove the tube from the washer pump connection unit Turn cover 2 with motor anticlockwise and withdraw the pump from the fluid container Refitting is a reversal of the removal sequence Dismantling and reassembly of windscreen headlamp washer pump The pump and motor Fig 8 26 are secured with the screws and nuts to cover 2 To dismantle the pump undo the screws remove the motor and cover detach pick up tube 4 Pick rim 8 edge to prise it out Fig 8 25 Glass washer system 9 8 7 1 tailgate washer jet 2 pump to jet hose 3 tailgate washer reservoir 4 windscreen washer jets 5 headlight washer pump 6 hose to headlight jet 7 T piece 8 windscreen headlight washer reservoir
229. ion 4 connection clasp 5 suspension ring main silencer 6 main silencer 7 front silencer 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 2 is secured with nuts to the exhaust manifold studs and in addition to bracket 3 mounted on the gearbox cover The lock plates are used under the manifold retaining nuts The nuts and gasket 1 are of disposal type Rear silencer 6 is secured to the underbody with the help of two suspension rings 5 The silencers and associated pipes are made as a one piece unit so in the event of their failure they are renewed as a unit 56 Chapter 3 Power train Clutch 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 d CS SS xX ES SI gt G amp S SSS SS D M SS Fig 3 1 Clutch assembly 19 1 bleeder 2 central diaphragm spring 3 diaphragm spring rivet 4 pressure plate 5 clutch disc 6 flywheel 7 clutch bellhousing 8 bellhousing to flywheel bolt 9 gearbox input shaft 10 clutch release bearing assembly 11 clutch release fork 12 release fork ba
230. ion components bench testing Ignition distributor The distributor of 3810 3706 model is shown in Fig 7 19 Functional test Mount the distributor on the tester intended for checking electrical devices Connect it to a variable speed motor Connect the distributor terminals to the ignition coil spark con trol module and battery of the tester similar to the wiring in the vehi cle Connect four terminals of the distributor cap to the spark box with adjustable gaps Set the spark gap to 5 mm switch on the tester motor and operate the distributor driveshaft clockwise for some minutes at 2000 rpm Increase the gap to 10 mm and check for internal dis charges in the distributor These can be recognized by specific sounds or weak or intermittent sparking in the tester spark box No noise should be produced by the ignition distributor at any driveshaft speed Automatic ignition advance control Mount the ignition dis tributor on the tester and connect it to terminals 3 5 and 6 of tester control module 1 Fig 7 20 Connect control module ter 152 Fig 7 19 Ignition distributor 3810 3706 model 1 shaft 2 oil screen collar 3 connector 4 vacuum advance housing 5 diaphragm 6 vacuum advance cover 7 vacuum advance operating rod 8 bearing plate centrifugal advance unit 9 ignition distributor rotor 10 side electrode and terminal 11 cover 12 centre electrode and terminal 13 centre electrode carbon
231. is maintenance free To exclude air leaks resulting in higher fuel consumption remember to check the pipes are properly tightened Injectors In case of difficult engine start or black smoke form the silencer remove check and if necessary renew the injectors 202 When refitting the injectors always renew both copper and steel washers Fuel filter is one stage with a replaceable filter element a built in water separator and a sludge discharge cap Undo the central bolt remove the housing and clean it in diesel fuel Renew the filter element and oil seals Air cleaner has a replaceable filter element made of special cardboard and a gauge strainer from synthetic cotton WARNING Fuel accessories high pressure fuel pump fuel injectors fuel filter must be repaired at specialist maker s workshops This manual does not cover the relevant dismantling repair and reassembly procedures Idle adjustment No adjustments of maximum fuel supply and speed are pos sible The adjustments can only be done by specialist dealers Idle speed can be adjusted Any changes in adjustments can result in rapid engine wear and ensued loss of guarantee Fast idle setting With the cold engine lever 10 Fig 9 24 should touch limiter 9 when necessary tighten cable 7 by ten sioner 11 The cable movement should be more than 6 mm Accelerator setting Fully depress the accelerator pedal lever 4 should touch limiter 5 Make sure that at idle lev
232. isional cap WARNING Never secure the carburettor or tighten its retaining nuts when it is warm 18 Fit the valve cover complete with the gasket and fuel piping bracket Fit the air cleaner to do this secure the hoses to the air clean er housing fit the filter housing complete with the gasket to the carburettor then fit the mounting plate and secure the housing with nuts Locate the filter element and secure the air cleaner COVer Reconnect the HT leads to the distributor and spark plugs Fill the engine with motor oil through the oil filler in the valve cover Fig 2 24 Refitting the oil pump 1 oil pump 2 drain pipe lock 3 oil separator drain pipe 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 mating compo nents pipe connections or gaskets oil pressure and oil leaks through gaskets ignition timing idle speed carburettor intake pipe tightness abnormal knock In case of any malfunctions or unknown rattle stop the engine eliminate the faults then continue the tests In case of oil leaks through the gasket between the valve cover and cylinder head or through the
233. ith 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 circlip from the spindle and withdraw the spindle complete with the gear and washers On completion blow the inside of the dismantled motor with compressed air to remove any carbon deposits always inspect the brushes and commutator The brushes should slide freely without sticking in the brush holders the springs should be good and sufficiently tense The commutator should be sanded with fine emery paper then wiped with a cloth moistened in petroleum jelly If the commutator is badly burnt or worn it is advisable to renew a complete motor Inspect the armature shaft ends for any traces of jamming Sand them with fine emery paper if applicable When reassembling make sure the brushes are well clear off the commutator to prevent possible edge chipping or damage Refit the armature into the motor housing with a particular care avoiding hitting the magnets On completion align the bearings by tapping the motor hous ing with a wooden mallet then check the motor on the tester Wiper motor specification Maximum operative drive spindle torque Nem kgfm 2 0 2 Consumption current at 1 Nem 0 1 kgf m D eden AMPS c5ncesbenbteeee iu 2 8 Motor drive spindle speed at 1 Nem 0 1 kgfem atleast rom eee 50 Starting torque of motor
234. ith torque to 6 86 Nem 0 7 kgf m make a mark B on the washer fig 4 5 then undo the nut by 20 25 until the first edge will meet the A mark fix the nut in this position by pressing the cups on the jour nal into the grooves on the outer joint race tail end After adjustment the bearing clearance should be within the limits of 0 01 0 07 mm Front wheel hub bearing renewing the greasing To renew the greasing do the following from both sides of the vehicle raise the front part of the vehicle and take off the wheel unbend the edge of the brake front splash guard undo the fastening bolt of the brake pad carrier and remove the brake caliper from the brake disc by moving it aside Do not disconnect the brake hoses to avoid air penetration in the hydraulic system and do not leave the caliper to hang on the hoses ACTES SS SES SY x num VA Fig 4 4 Checking the axial gap in the front wheel hub bearings 1 indicator 2 fixture 67 7834 9507 3 lever 67 7820 9521 Fig 4 5 Tightening and adjusting the front wheel hub bearings A nut edge B mark on the nut use tool 67 7823 9514 to remove the wheel hub cap undo the adjusting nut and remove bush 21 see fig 4 1 carefully so that not to damage sealing 25 remove hub 19 in assembly with the brake disc put a support under the suspension lower arm 4 and slight ly lower the front part of the vehicle to compress spring 9
235. ition distributor shaft speed rpm 133 267 400 533 00 200 300 400 Fig 7 22 Ignition distributor vacuum advance map A advance degrees P vacuum gPa mm Hg E ER Gr Fig 7 23 Wiring diagram for Hall sensor in vehicle test 1 ignition distributor 2 adapter with voltmeter of at least 15 v scale and inter nal resistance of minimum 100 kOhm 3 view on ignition distributor connector 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 driveshaft at 1000 rpm Watching the tester graduated disc note the angle at which one of the four sparking events occurs Smoothly increase the vacuum through every 26 7 gPa 20 mm Hg and make note of the advance angle with respect to the initial value Compare the resulting advance pattern with that in Fig 7 22 Note the Hall sensor mounting plate invariably returns to its original position after vacuum has been removed Hall sensor The Hall sensor produces the output voltage if there is a steel vane in the air gap The output is around zero volts when there is no vane in the gap With the distr
236. itted to the engine Inspection and overhaul Cylinder head Thoroughly wash the cylinder head and clean the oilways Scrape away all carbon from the combustion chambers and from the exhaust valve ports with a wire brush Examine the cylinder head Look to see there is no cracking in the cylinder head Check the cylinder head for leakage when suspicious as to possible oil contamination with coolant To do this plug the cooling water jacket holes using plugs from tool A 60334 Fig 2 45 then pump water into the cylinder head water jacket at 0 5 MPa 5 kgf cm No water leak should be evident within 2 minutes The cylinder head tightness can be checked with compressed air Plug the water jacket holes using the same plugs from tool A 60334 immerse the cylinder head into the bath with water of 60 80 C for 5 minutes Next pump the compressed air into the cylinder head at 0 15 0 2 MPa 1 5 2 kgf cm No air bubbles must be seen from the cylinder head within 1 1 5 minutes Valve seats The valve seat chamfer shape is shown in Fig 2 46 and Fig 2 47 Check the working chamfers of the valve seats valve contact area for pitting corrosion or deterioration Minor irregularities of the seats must be recut Remove as little metal as possible Both manual and machine grinding is permit ted Valve regrinding is carried out as follows Position the cylinder head on a mounting base Insert cen tering tool A 94059 in the valve guide and cle
237. jacket return pipe thermostat expansion tank or intake pipe 1 Repair or renew radiator 2 Renew damaged hoses or gaskets tighten hose clips 3 Renew tap or heater matrix 4 Renew seal 5 Renew cap 6 Renew gasket 7 Check oylinder block and cylinder head for leakage renew damaged com ponents in case of evident cracking 8 Check for leaks renew components in case of fissures minor leaks can be cured by adding a radiator sealant such as HAMCC 1 11 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 carburettor Disconnect the throttle linkage and choke cable Disconnect the wires from the fuel cutoff solenoid idle switch oil pressure sensor coolant temperature sensor ignition distribu tor alternator and starter motor Drain coolant from the radiator cylinder head and heater unit To do this shift the heater tap control lever to the right undo the caps on the cylinder block left side and radiator right hand fluid cooler screw instead the return hoses connectors then undo the caps of the expansion tank and radiator Separate the fan cowl halves and remove the fan blower cowl Disconnect the coolant supply and re
238. kgf m and bend it up at one point before refitting the gas generator make certain there are no knocks or sticking check the steering wheel rotates smoothly lock to lock swing the steering wheel to see there is no radial or axial steering wheel play eliminate all defects found fit the gas generator to the steering wheel adapter with your right hand Position the gas generator in the adapter recesses and turn clockwise about 40 to the full lock A click should be heard the hole in locking tab 4 Fig 9 39 should coincide with the hole B in the steering wheel adapter In this position the gas generator is set to working order During installation turn the gas generator by hand only The gas generator should never be forced into the position working from the outside of the vehicle place the airbag module to the gas generator unit while matching the A fixture Fig 9 38 on the module with the hole B Fig 9 39 in the steer ing wheel adapter tighten airbag module 13 securing bolts Fig 9 38 to 7 11 Nem do not cut drill or pierce any part of the SRS 40 system under any circumstances 211 ATTACHMENTS Attachment 1 TORQUE WRENCH SETTINGS Part Thread Tightening torque N m kgf m ENGINE Main bearing cap bolt M10x1 25 68 31 84 38 6 97 8 61 Oil pump bolt M6 5 10 8 20 0 52 0 85 Breather cover retaining stud M8 12 7 20 6 1 3 2 1 Breather cover nut M8 12 7 20 6 1 3 2 1 Cylinder he
239. l up the fuel emulsion ducting When excessively dirty clear the jets with the help of a soft wood en needle soaked in acetone Carburettor housing Clean the housing from dirt or oil Wash the passages with acetone or petrol blow dry with com pressed air Where applicable use special tools for cleaning the ports and emulsion tubes Examine the sealing surfaces of the housing when found damaged or distorted renew the housing with a new one Accelerator pump Clean out the pump components wash in petrol and blow dry with compressed air Check to see the ball in the atomizers and moving parts lever diaphragm compo nents operate smoothly There must be no seizures or sticking The diaphragm should be intact and undamaged Examine all sealing surfaces and gaskets Always renew any damaged com ponents 53 Fig 2 90 Setting the fuel level in float barrel 1 float 2 carburettor cover 3 gasket 4 gauge to check the float position 5 needle valve 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 following The float must freely turn on its pivot pin there should be no conflict with the barrel walls The need
240. ld be at least 16 mm The starter motor test temperature should be 25 5 C The brushes must slide smoothly on the commutator Functional test By closing switch 5 Fig 7 15 operate the starter motor three times from a 12 volt source at different braking conditions eg at the braking moments of 2 6 and 10 Nem 0 2 0 6 and 1 kgf m The starter motor should be switched on for no longer than 5 seconds with minimum 5 second intervals in between If the starter motor fails to turn the tester ring gear or pro duces unusual noise dismantle the starter motor and examine its components Fully locked ring test Lock the tester ring gear operate the starter motor and measure the current voltage and braking moment to be maximum 550 amps 7 5 volts and at least 13 7 Nem 1 4 kgfem respectfully Do not switch on the starter motor for over than 5 seconds When the braking moment is below while the current is over the values specified the likely reason is an internal short circuit of the stator or armature winding or earthed winding When the braking moment and current are below the values specified the possible cause is an oxidized or dirty commutator severely worn brushes or weak springs sticking brushes loose stator winding terminals eroded or burnt solenoid terminal bolts At fully locked condition the starter armature must not turn when otherwise the one way clutch is faulty Dismantle the starter motor replace or over
241. le valve must freely operate in its seating without warping or seizure the tightening torque for the needle valve seat is 14 7 Nem 1 5 kgf m The tightening torque for the solenoid cutoff valve is 3 68 Nem 0 4 kgf m 54 Fig 2 91 Throttle stop screw 1 throttle stop screw 2 idle mixture adjustment screw 3 sealing ring 4 adjusting screw cap Check the jet marking and consult Table 2 2 to prevent the jet confusion when refitting Before refitting pivot pit 19 Fig 2 88 apply sealant YI 9 on the pivot end and over 1 1 5 end turns of thread To reassemble the accelerator pump first hand start the cover retaining screws press the lever full way to stop tighten the screws and release the lever Carburettor adjustment and checks Setting fuel level in float chamber The adequate fuel level for proper carburettor operation is ensured by correct fitting of good cut off valve components Correct fitting of float 1 Fig 2 90 is checked with gauge 4 To do it locate it normal to cover 2 which should be held hori zontally with the floats up The clearance between the gauge over its contour and floats must be 1 mm as a maximum When necessary adjust by means of bending the float tab or levers The locating tab face must be normal to needle valve 5 pivot and have no evident dents or cuts Choke control unit adjustment When turning lever 4 Fig 2 86 of choke 5 control unit full way anticlockwise
242. level is for 20 C and 101 3 kPa 760 mm Hg Reset the crankshaft speed to 750 800 rpm by means of throttle stop screw 1 When applicable restore CO level to the maximum 1 5 On completion sharply depress and release the throttle pedal check to see the engine speeds up without any gasps and does not stall at lower rom Should the engine stops use throttle stop screw 1 to increase the engine speed to 750 800 rpm Refit new plastic cap 4 to idle mixture adjustment screw 2 Checking the secondary barrel locking linkage Turn the choke lever anticlockwise to fully close the choke Next turn spin dle 19 lever Fig 2 89 to wide open primary throttle 23 sec ondary throttle 24 must remain closed Turn the choke lever fully clockwise turn throttle lever 19 to wide open the throttle If the secondary throttle fails to open elim inate the fault The fault can be caused by seized secondary lock lever 20 or disconnected lock lever spring 21 Exhaust gas recirculation system The vehicle is fitted with the exhaust gas recirculation EGR system which comprises thermo vacuum switch 2 Fig 2 92 and EGR valve 5 with the relevant port and recirculation tube 6 in intake pipe 3 When coolant is over 40 48 C the thermo vacuum switch triggers to build up vacuum in the EGR valve the valve opens to reintroduce small amount of exhaust gas from exhaust manifold 4 into the intake pipe and inside the engine Checking EGR system operation D
243. lignment angle 3 Wrong roller to worm clearance 4 Excessive torque applied to slave arm shaft adjusting nut 5 Low pressure in front wheel tyres 6 Damaged balljoint components 7 No oil in steering box 8 Damaged upper shaft bearings 1 Renew deformed components 2 Check wheel alignment angle and adjust 3 Adjust clearance 4 Adjust nut tightening 5 Ensure normal pressure 6 Inspect and renew damaged parts 7 Check oil lever and top up Renew oil seal if necessary 8 Renew bearing Noise rattle in the steering mechanism 1 Excessive clearance in front wheel hub bearings 2 Loose nuts on tie rod ballpins 3 Excessive gap between slave arm shaft and bushes 4 Slackened slave arm shaft adjusting nut 114 1 Adjust clearance 2 Check and tighten nuts 3 Replace bushes or bracket in assembly 4 Adjust nut Diagnosis Remedy 5 Wrong clearance in roller to worm mesh or in worm bearings 6 Excessive gap in tie rod balljoint 7 Loose steering box fastening bolts or slave arm shaft bracket 8 Loose knuckle arm fastening nuts 9 Loose steering shaft fastening bolts 5 Adjust clearance 6 Renew ball joints or tie rods 7 Check and tighten bolt nuts 8 Tighten nuts 9 Tighten nuts Shimmy 1 Improper tyre pressure 2 Wrong front wheel alignment angle 3 Excessive clearance in front wheel hub bearings 4 Wheels out of balance 5 Loose tie rod ballpin nuts
244. linders and pipes for leaks Remove the working cylinders and check the rod travel to be 7 0 5 mm To replace a faulty headlamp adjuster detach the pipe clips from the wiring clamps remove the control knob from the master cylinder and undo the mounting nut Detach the working cylinders from the headlight units and push them together with seals into the passenger compartment Refit a new headlamp adjuster using the reversal of the removal procedure Steering column combination switch The steering column switch is secured to the steering column support bracket with the help of the retaining strap Observe the following procedure when removing the steering column combination switch remove the steering wheel remove both steering column shrouds remove the instrument cluster and disconnect the steering column switch wiring release the retaining strap and withdraw the steering column switch 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 direction indicators blown bulb or broken bulb circuit the direction indi cator and relevant facia warning light start flashing faster The relay is secured under the facia by the bolt welded
245. ll washers and shims will be properly replaced Disconnect the engine mounting rubber pads from the cross member brackets Place a hydraulic jack with a fixing tool under the suspension crossmember support the engine with arm 67 7820 9514 or hoist disconnect the recoil bumper bracket 47 and the cross member from the body chassis Remove the crossmember 1 in assembly with lower arms 4 The installation of suspension parts and units is done in reverse order The springs on the suspension should be installed only of one class class A not marked or has marks by white paint class B with black marks on the outer surface of the coils It is permissible to install springs of A class on the front suspen sion if B class springs are fitted on the rear suspension After reassembly and suspension refitting check the wheel alignment angles and toe in Suspension units dismantle and reassembly Dismantle f the suspension repair requires complete dis mantle of the units it is more convenient to begin directly on the vehicle after removing the crankcase protective plate and the splash guard Proceed as follows undo the upper balljoint 41 see fig 4 1 pin nut and remove the clips from hoses unbend the protective casing blades turn out the fastening bolt of the caliper carrier and move the whole assembly aside ATTENTION To avoid damaging the hoses do not leave the caliper to hang on hoses using tool 67 7823
246. ll socket 13 clutch release bearing 14 pressure plate thrust flange 15 clutch release fork boot 16 clutch release fork spring 17 pressure plate fulcrum ring 18 clutch cover 19 clutch release fork pushrod 20 adjusting nut 57 21 locknut 22 protective cap 23 clutch release cylinder slave cylinder 24 fork return spring 25 return spring bracket 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 flange to clutch cover connecting plates 7 Air in clutch hydraulic drive system 8 Liquid leak from hydraulic drive system through connections or dam aged pipelines 9 Leaking master cylinder or clutch release cylinder 10 Plugged opening in reservoir cover causing underpressure and vac uum leak in cylinder through sealings 11 Vacuum leak due to fouling or wear of front sealing ring in master cylinder 12 Skew or buckling of pressure plate 1 Adjust clutch release drive 2 Straighten or replace disc 3 Renew linings or clutch disc assembly 4 Renew linings check disc runout 5 Clean splines apply grease JICL 15 or Ouon 1 Ovon 2 In case of badly worn splines causing seizure
247. lly noises appear and dis appears at same speeds both at acceleration and deceleration Fig 3 65 Reduction gear 1 drive gear 2 driven gear 3 pinion 4 axle shaft gear 5 pinion shaft 6 differential housing 7 bearing cover securing bolts 8 bearing cover 9 stop plate 10 bearing adjusting nut 11 reduction gear housing 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 it may activate the anti theft system Noise noticed during this test and corresponding to the one noticed at the first test does not originate from the final drive drive gears as they do not make any noise without load And on the contrary noise marked during the first test and which was not repeated at the second one can proceed from the reduction gears or the driving gear bearing or the differential Test 3 On a parked vehicle with the handbrake set switch on the engine and by gradually increasing the revolutions com pare the arisen noises with those noticed in the previous tests Noises similar to those indicated in test 1 do not originate from the reduction gear and are likely to be caused by other units Test 4 Noise n
248. lower beam Using adjustment screws 1 and 7 Fig 7 31 align the beams first on the right hand headlamp while the other is covered with a piece of cardboard or dark cloth and then on the left hand headlamp with the right hand one screened To adjust the headlight beam in the vertical plane turn screws 1 and 7 simultaneously in the same direction and to the same number of turns The difference in turns between the screws with the other screw intact should not exceed 3 turns Horizontally the headlights are adjusted by means of screws 1 and 7 turned in opposite directions If one screw is turned one turn clockwise the other should be turned one turn anticlockwise Some vehicles can be fitted with the headlights without the hydraulic beam adjuster and have an alternatively mounted adjuster screws when the horizontal adjuster screw is on the left while that for vertical adjustment is fitted at the top If the headlights are correctly aligned a cut off at the top of the beam patterns must be at line 2 Fig 7 32 while the inter section points of horizontal and angled lines should coincide with reference points E Bulb replacement Headlight units To replace a bulb undo securing screws 5 and remove trim 4 Fig 7 31 slacken screws 3 securing the headlight optical unit rim turn the rim anti clockwise to remove it withdraw the headlight optical unit and renew a failed bulb refit the optical unit so that the retainin
249. lternator components 1 voltage regulator complete with brush holder 1996 on alternators 2 voltage regulator and brush holder pre 1996 alternators 3 supplementary diode connector 4 insulating bushes 5 diode plate 6 contact bolt 7 stator 8 rotor 9 spacer 10 inner washer for bearing attachment 11 drive end housing 12 pulley 13 outer washer for bearing attachment 14 clamp bolt 15 front rotor ball bearing 16 bush 17 slip ring end housing 18 buffer bush 19 hold down bush 20 suppression capacitor 145 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 B Avoid damaging the brushes so remove and refit the regulator with the brush holder as described earlier in sections Alternator dis mantling and Alternator reassembly In case of 1996 on alternators with one piece regulator brush holder unit renew the complete brush regulator holder assembly Before refitting the voltage regulator with new brush holder blow its locating place in the alternator clean from carbon dust and wipe off any oil contamination Rotor bearings renewal To remove a failed bearing from the drive end housing undo the nuts of screws holding the bearing retaining washers remove
250. lve guide bores using tool A 90310 1 for the inlet valve guides and tool A 90310 2 for the exhaust valve guides Valve stem oil caps must always be renewed during the engine overhaul Any damaged oil caps are renewed on the cylinder head removed Use special tool 41 7853 4016 to push the oil seals on the guide Springs Check the springs are not cracked and are ade quately tense load test the springs to reveal any deformation Fig 2 52 283 225 H 283 58y MEE 492 2251 461 25er 50 53 7 a Fig 2 52 Basic lengths to check the valve outer a and inner b springs 1362 H 15 9 HE ec 39 2 29 7 20 27 2187 H 281514 c 31 For lever springs Fig 2 53 the size A spring unloaded must be 35 mm whereas the size B 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 bolt When replacing the bolts take care not to fit similar bolts from other VAZ engines of the same type 2101 21011 2103 2107 2121 but made of different steel The 21213 engine bolts have the threaded area of 70 mm 30 mm for other engines in addition the 21213 engine bolts do not have a distinctive mark a 7 5 mm diameter recess for wrench Valve rocker levers Check the c
251. lves To remove the cylinder head carry out the following operations Apply the handbrake remove the spare wheel and discon nect the battery negative lead Remove the air cleaner and protect the carburettor with the provisional plug Drain the coolant from the radiator and cylinder block 28 Fig 2 43 Valve components 1 valve 2 circlip 3 valve guide 4 oil cap 5 lower spring seat outer spring 6 locking washer inner spring 7 inner spring 8 outer spring 9 upper spring seat 10 collets 11 valve rocker lever 12 valve lever spring 13 adjuster bolt 14 lock nut adjuster bolt 15 bush adjuster bolt 16 lock ing plate valve lever spring Fig 2 44 Removing the valve spring 1 tool A 60311 R 2 mounting base Fig 2 45 Checking the leak proofness of the cylinder head on tool A 60334 1 2 4 plugs 3 tool plate 5 flange with water supply connector 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 exclude pos sible fuel leaks Detach the vacuum hose from the carburettor Disconnect the hoses from the intake pipe from the outlet pipe of the cooling w
252. m fer width of 1 9 2 mm Valves Scrape away carbon from the valves Check the valve stem for deformation check the valve disc for cracking Always renew the damaged valve Examine the valve working chamfer Reface the valve in case of minor damages maintaining the chamfer angle at 45 30 5 Note that the distance between the bottom valve seat face and base diameter 36 and 30 5 must be as shown in Fig 2 50 Valve guides Check the valve guide to stem clearance by measuring the valve stem diameter and valve guide bore The clearance for new guides is 0 022 0 055 mm for the inlet valves and 0 029 0 062 mm for the exhaust valves the maxi mum permissible clearance in case of wear is 0 3 mm provided no excessive noise is produced in the valve train 30 Fig 2 48 Regrinding the valve seat working chamfer with spindle A 94058 I II Fig 2 50 Limit sizes for valve chamfer regrinding inlet valve Il outlet valve Fig 2 53 Valve spring checking diagram A dimension in free state B dimension under load Fig 2 51 Pressing out the valve guides 1 tool A 60153 R When a new valve fails to take up clearance between the valve guide and the valve rim renew the valve guides using too A 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 va
253. m loosely fits into backlash H it is necessary to remove ring 1 and insert in this gap a ring with thickness of 1 67 mm and repeat all specified operations Note It is recommended to carry out the gap measurement from the side of the pipe The circlips are provided in eight size sets according to their thickness each of them has a certain colour 1 45 not painted 1 48 yellow 1 52 brown 1 56 dark blue 1 60 black 1 64 1 67 1 40 colors are not designated and their thickness is determined by measuring After inserting the circlips hit the yoke forks with a hammer with plastic head After the impact the backlash between the bearing bottom and the circlip will be taken up and formed between the bearing housing and spider thorn end faces within 0 01 0 04 mm After reassembly check for easy rotation of the U joint yokes and the shaft balance To reassemble the layshaft U joint follow the procedure described in chapter Front wheel drive When reassembling install retainer 7 see fig 3 49 with the chamfer facing the trans fer box input shaft and grease the U joint with 20 cm of Longtern 00 from Dow corning Shaft balance The front and rear propeller shafts are balanced on special machines by welding metal plates At speed of 5500 min the shaft misalignment checked on surfaces A and B fig 3 53 should not exceed 1 72 N mm 175 grf mm and at the balance check 2 16 Nemm 220 grf mm The laysh
254. mer on a dry degreased sur face Using a brush apply BlIM 1 type sealant on the areas pre pared When the vehicle is in use no longer than 1 1 5 years it is recommended to have a minimum overlapping of a new sealant over an old layer In the event of a longer field service with this underbody protection apply the sealant over the entire under body and wheel arches surfaces In cold weather before use store sealant paste in a warm room to warm it up to at least 20 C When thick thin sealant with ksylol to 396 as a maximum Clean the paintwork of excessive sealant using a cleaning cloth moistened in white spirit Body sealing and tightness The body tightness is ensured by use of rubber seals Fig 8 9 pastes bodyfillers sealants rubber plugs in provisional holes and thorough levelling of adjoining parts When removing or refitting seals with metal reinforcement take care not to crumple the metal frame or seal Weld seams do not offer an absolute tightness between the parts so corrosion is encouraged when water or moisture gets in between the welded parts Use 1 4A type plastisol on weld seams to guard off moisture and dirt apply the 51 7 wet type sealant Fig 8 10 and Fig 8 11 on angle joints and clearances between the sidesills and bulkhead passenger compart ment side between the bulkhead and front pillar panel and battery tray between the front chassis arms and radiator support bulk head
255. meter drive housing 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 shaft front bearing and the inspection hatch cover Remove the gear switch lever bracket 13 see fig 3 36 in assembly with the lever After removing the lock washer take out the shaft and remove lever 14 Undo the locking bolt of the gear shift fork 17 close the detent socket with a finger and carefully take out rod 12 and the detent components UU Fig 3 40 Removing the transfer box front cover 1 layshaft 2 drive shaft 3 differential 4 front cover 77 Fig 3 41 Drive shaft and layshaft components 1 flange 2 oil seal 3 bearing thrust ring 4 front bearing 5 drive shaft 6 top gear 7 hub 8 coupling 9 low gear 10 bush 11 rear bearing 12 bearing set ring 13 layshaft bearing 14 layshaft Fig 3 42 Differential exploded view 1 circlip 2 spring washer 3 bearing set ring 4 differential housing bearing 5 driven gear 6 differential front housing 7 front axle gear 8 pinion shaft circlip 9 pinion 10 differential rear housing 11 washer 12 rear axl
256. mounting bracket 15 axle fferential housing bearing 19 bearing cover 20 breather 21 pinion 22 driven gear e shaft gear washer 36 differential housing 37 suspension mounting bracket 38 axle Fig 3 55 Pressing out the axle shaft 1 axle shaft 2 knockout tool 67 7823 9516 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 fig 3 58 check the normality of the reduction gear fastening surface vs the seating surface of flange A 70172 The 0 2 mm feeler gauge should not fit Make a 90 turn of the axle beam and place it on V blocks A try square applied to the outer surface of the flange fig 3 59 should adjoin with no gaps otherwise check the size of deforma tion by a feeler gauge The 0 2 mm gauge should not fit 85 Fig 3 56 Checking for vertical deformations of the rear axle beam using a try square on the outside surface of flange A 70172 Fig 3 58 Checking the reduction gear mounting If deformation exceeds this size straighten the beam follow ing the procedure given below After straightening carefully wash the beam clean the mag neti
257. mpers 5 fuse 16 amperes Table 9 3 Instrument cluster pin assignment Pin No Pin assignment Connector X1 red or amber To ignition switch terminal 15 Spare To instrument cluster lighting switch To alternator terminal W To housing To ignition switch terminal 50 To handbrake warning light switch To seat belt relay To fuel gauge terminal W 20 Gg 160 o 180 AN DoF c n ps amp 9TI rer T5T9 HE To differential lockup sensor n5 To low oil pressure sensor Fig 9 35 Instrument cluster To brake fluid level sensor 49 207 Fig 9 36 Wiring diagram for instrument cluster 1 digital tachometer 2 coolant temperature gauge 3 fuel level gauge 4 instrument illumination light 5 engine overheating warning light 6 heated rear window warning light 7 rear fog light warning light 8 high beam warn ing light 9 exterior lighting warning light 10 direction indicator warning light 11 low battery warning light 12 resistor 50 Ohm 5 W 13 brake failure warning light 14 low oil pressure warning light 15 differential lock up warn ing light 16 fuel reserve warning light 17 seat belt reminder 18 handbrake on warning light Connector X1 is red or orange Connector X2 any colour except red and amber 1 s To high beam relay To exterior lighting switch To indicators flasher relay
258. n nected cigarette lighter To restore the cigarette lighter operation eliminate the cause of its lengthy operation dismantle the cigarette lighter remove the melted washer and fit a new safety washer Heater blower motor It is a motor of M3 255 model DC on permanent magnets The motor wiring diagram is shown in Fig 7 38 For slower speeds there is supplemental resistor 4 The resis lor is retained by two spring washers in the heater blower fan cowl The resistance value is 1 5 Ohms at 20 C Always renew a faulty motor with a new one The only repair possible is the commutator cleaning To dismantle the motor undo the retaining screws to remove the cover Then retrieve the lock washer from the armature shaft and withdraw the armature from the housing The reassembly is carried out in the reverse order to the dismantling Inspect the motor in the way similar to that for the windscreen wiper motor Fig 7 38 Wirhg diagram for heater blower motor 1 ignition switch 2 fusebox 3 heater blower switch 4 supplemental resistor 5 heater blower motor 162 Blower motor specification Shaft speed with fan impeller load at 12 v and 25410 C rpm ee eee 30004150 Consumption current at the load and rpm as above ampere not greater 008 4 5 to zero by pushing the reset knob in the instrument cluster Reset the trip counter only on a stationary vehicle turning the knob clockwis
259. n refitting the crossmember tie rods the inner nut should be tightened until the clearance between the washer and the bracket 3 see fig 4 6 will be taken up and the outer one with torque specified in the appendix To avoid wrong force distribution in silent blocks the arm shaft nuts should be tightened under vehicle static load of 3140N 320 kgf Then check and adjust the wheel alignment angles and toe in Inspection Balljoint Ensure the integrity of the balljoint boots no breaks cracks rubber peeling from the metal fixture traces of grease leaks are permissible Check for wear of balljoint working surfaces by manually turning the ballpin No free play or pin jamming is allowed A more profound check of the balljoint radial and axial clear ances is carried out on fixture 02 8701 9502 Place the balljoint 1 fig 4 8 A in the fixture bezel and fix with screw Fit in the fix ture bracket indicator 2 so that the indicator leg will rest against the side surface of the balljoint housing the indicator arrow should point to zero Fit the dynamometer 3 in the fixture bezel and apply torque of 196 Nem 20 kgf m in both directions determine by indicator 2 the total radial clearance in the balljoint If it exceeds 0 7 mm renew the joint Make the similar check of the balljoint axial clearance previ ously having changed its fastening in the fixture as shown on fig 4 8 B The axial clearance in the joint should not excee
260. n the camshaft sprocket with the mark on the bearing housing which corresponds to the end of the compression stroke of the cylinder No4 Now in this position adjust the clearance at the cylinder No4 exhaust valve No8 cam and cylinder No3 intake valve No6 cam Slacken the valve lever adjuster bolt nut between the valve lever and cam place a flat feeler blade A 95111 of 0 15 mm for the intake valve 0 2 mm for the exhaust valve and using a spanner tighten or slacken the bolt with further 27 U SS PO NE Ne TON 5 d Fig 2 42 Checking the clearance between the rocker levers and cam lobes 1 feeler blade A 95111 2 adjuster bolt 3 lock nut 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 adjustment Crankshaft angle Cylinder No Valve cam No degrees end of compression stroke 0 4 8 amp 6 180 2 4 amp 7 360 1 1 amp 3 540 3 582 Cylinder head removal and refitting The cylinder head is removed from the engine in the vehicle when no complete stripping of the engine is required or when carbon deposits should only be removed from the combustion chamber and va
261. n the rear end of the gearbox output shaft the design of the following parts was changed instead of a metal centering ring 26 see fig 3 31 and circlip 1 a rubber centering bush is installed instead of sealing 25 with spring 24 a sealing without a spring is installed lock washer 22 is replaced with a spring washer nut 23 is sealed with YI 9 or YI 10 Fig 3 19 Removing the gear selector mechanism Remove circlip from the gearbox output shaft end fig 3 16 Unbend the lock washer undo the nut by several turns to move the coupling centering ring and again turn in the nut Using a puller A 40006 1 with tool A 40005 4 remove the flexible cou pling centering ring from the output shaft end fig 3 17 Remove the coupling centering ring seal with spring from the output shaft end undo the nut and using tool A 40005 3 9B 9C remove the flexible coupling flange fig 3 18 Before removing the rear cover place the gearshift lever in neutral position undo the gear selector mechanism fastening nuts and remove the gearshift lever fig 3 19 in assembly with the selector mechanism One of the cover fastening nuts is undone from the inside of the transmission casing with the bottom cover being removed When removing the rear cover it is neces sary to move it not only backwards but also to turn it to exclude hitting the fifth speed reverse gear unit After removing the output shaft rear bearing inner ring 43 s
262. nce reverse to dismantle 95 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 3 Low oil amount in axle case 4 Worn or destructed inner joint bearing axle shaft 1 Renew worn components adjust differential bearings 2 Isolate problem in reduction gear repair or replace 3 Top up oil check for oil leak from front axle casing 4 Replace bearing Noise at vehicle acceleration and engine braking 1 Incorrectly adjusted final drive gear mesh at reduction gear repair 2 Wrong side gap in final drive gear mesh 3 Excessive gap in driving gear bearing due to loose flange fas tening nut or worn bearings 1 Adjust gear mesh as described in subsec Rear axle 2 Adjust clearance as described in subsec Rear axle 3 Adjust clearance as described in subsec Rear axle replace bear ing if necessary Knock at the beginning of movement 1 Worn differential pinion shaft opening in differential housing 1 Replace differential housing and pinion shaft if necessary Oil leak 1 Worn or damaged oil seal 2 Worn inner joint casing oil seal 3 Loose inner joint casing bear ing cover fastening o
263. ncorporating a double winding solenoid Body 17 Fig 7 13 houses four poles 18 with field windings three of which are series and one is parallel Covers 7 and 15 and starter housing 17 are held together by two bolts The armature features a face type commutator The armature shaft runs in sin tered shells 14 press fitted to cover 6 and 15 The starter motor wiring diagram is shown in Fig 7 14 When the starter motor is switched on the battery voltage is supplied through supplementary relay 4 113 3747 10 model to both sole noid windings plunging winding Il and holding winding The plunging winding shuts off when the solenoid contacts close Fault diagnosis Cause Remedy At starter motor switch on armature fails to rotate solenoid inoperative 1 Battery defective or fully dis charged 2 Battery terminal posts and lead ends severely corroded end loose 3 Solenoid faulty internally earth ed or broken 4 Starter motor relay defective 5 Starter relay winding power cir cuit open 6 Ignition switch contacts 30 and 50 fail to close 7 Starter solenoid power leads broken 8 Stuck starter solenoid 1 Charge or renew battery 2 Clean battery posts and lead ends tighten and apply a coat of petroleum jelly Vaseline 3 Renew solenoid 4 Clean relay contacts Renew faulty relay 5 Check wires and connections between ignition switch terminal 50 and relay terminal 86 6 Renew ignition swi
264. nd gear 2 10 2 10 2 10 2 10 third gear 1 36 1 36 1 36 1 36 fourth gear 1 00 1 00 1 00 1 00 e fifth gear 0 82 0 82 0 82 0 82 reverse gear 3 53 3 53 3 53 3 53 Transfer case two gear lockup differential Gear ratio top gear 12 1 2 1 2 1 2 bottom gear 2 135 2 135 2 135 2 135 Transfer case differential Drive line from transmission to transfer case from transfer case to front and rear axles from front axle to wheels Final drive ratio front and rear axles gear ratio differential Front suspension Rear suspension Wheels wheel rim Tyres size cross ply tyres e radial ply tyres bevel gears two pinion gears flexible coupling and CV joints two universal joints on needle bearings with grease nipples and yokes open with CV joints bevel hypoid 3 9 3 9 3 9 3 9 bevel two pinion gears Suspension and wheels independent lower track control arms wishbones coil springs hydraulic telescopic shock absorbers anti roll bar rigid axle beam with Panhard rod and four trailing arms coil springs hydraulic telescopic shock absorbers pressed steel disc 127J x 406 5J x 16 tubed cross ply or radial ply 175 x 406 6 95 x16 175 80R16 Features VAZ 21213 VAZ 21214 VAZ 21214 20 VAZ 21215 Steering mechanism Steering linkage Service braking system front brakes rear brakes brake operation line Handbrake Wiring diagram Voltage volts Batte
265. nd wear gloves when working with the gas generator or airbag module 2 Always keep on the lateral side of the steering wheel when working with the gas generator or airbag module Never place anything on the steering wheel or between the steering wheel and a worker 3 Never use the gas generator unit when it happened to fall from over 1 meter height or has evident damages 4 Do not store the gas generator at temperatures above 52 C 5 When handling the gas generator always keep the holes outward on any surfaces position the holes upward never put anything on the gas generator Fig 9 39 Steering wheel A e YY OE Fg 1 adapter for inflator unit fitting 2 lock spring 3 horn button 4 locking tab A device for setting system to ready position D shaped lug B hole in adapter 210 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 there are solid chemicals being poisonous inflammable and potentially health hazardous 8 To exclude any misuse of the SRS 40 system do not employ impact tools on steering elements Removal Open the bonnet and disconnect the battery nega tive lead Position the front wh
266. nd while turning it check the runout which should not exceed 0 5 mm in 50 mm from the end weld seams 0 3 mm in the middle part If the runout exceeds the specified values straighten the shaft under a press or renew 81 Fig 3 47 Driveline assembly 1 front propeller shaft 2 layshaft 3 transfer box 4 rear propeller shaft Fig 3 48 Front propeller shaft exploded view 1 U joint flange 2 grease cup 3 circlip 4 spider 5 sliding yoke 6 seal 7 seal retainer 8 propeller shaft 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 bearing housing needles and thorns of the spider seals end face washers 17 16 15 14 13 12 Fig 3 49 Layshaft 1 gear box output shaft 2 output shaft flange 3 coupling insert 4 flange fastening bolt 5 coupling flange 6 boot 7 cage 8 ball 9 CV joint hous ing 10 plug 11 transfer box input shaft 12 circlip 13 joint race 14 boot cover 15 clamp 16 centering bush 17 balancing washer If any of the components are damaged renew the spider in assembly with the bearings The diameter of the yoke
267. nder head and withdraw it complete with the exhaust manifold and intake pipe 13 Fig 2 7 Removing the camshaft thrust flange 1 thrust flange 2 camshaft 3 bearing housing 4 thrust flange securing stud Fig 2 8 Removing the oil pump shaft 1 thrust flange 2 flange securing bolt 3 oil pump shaft 4 wrench Remove thrust flange 1 Fig 2 8 of the oil pump drive shaft and take the shaft out of the cylinder block Using picker A 40005 1 7 kit A 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 rod main and big end bearing shells for position to facilitate the reassembly WARNING When removing the pistons and conrods do not press out the connecting rod bolts Fit tool 5 Fig 2 10 undo bolts 3 remove washer 4 and the flywheel from the crankshaft Remove the front clutch housing cover Using tool A 40006 take the input shaft bearing out from the crankshaft Fig 2 11 Remove the crankshaft oil seal retainer Unbolt the main bearing cap bolts remove them complete with the lower bearing shells then lift out the crankshaft top bearing shells and rear bearing thrust washers Engine reassembly Follow the engine reassembly procedure as below Locate a clean cylinder block and screw in any missing dow els Oil the crankshaft
268. ndicator arrow calculate the meaning of the clearance in the upper balljoint by summing the values of deviations from zero the total indicator readings should not exceed 0 8 mm X1 A A 54 5556 57 5859 60 aD a 13 12 111098 7 654 3 2 1 Fig 4 1 Front suspension 1 front suspension crossmember 2 lower control arm shaft 3 lower arm silent block 4 lower control arm 5 lower control arm shims 6 lower control arm shaft bush 7 crossmember bracket 8 coil spring lower seat 9 coil spring 10 compression buffer mounting strut 11 compression buffer 12 compression restrictor 13 shock absorber mounting bracket lower 14 shock absorber 15 anti roll bar 16 rubber pad 17 anti roll bar securing clamp 18 lower balljoint 19 wheel hub 20 wheel and brake disc securing bolt 21 taper bush 22 cap 23 outer CV joint housing tail 24 oil seal bush 25 oil seal 26 splash guard ring 27 wheel hub bearings 28 wheel disc 29 steering knuckle 30 front brake splash guard 31 ballpin 32 boot 33 bearing 34 ballpin liner race 35 ballpin bearing housing 36 anti roll bar securing plate 37 washers 38 tie rod 39 tie rod mounting bracket 40 body chassis arm 41 upper ball joint 42 shock absorber rod mounting pad 43 shock absorber rod 44 washer 45 shock absorber mounting bracket 46 upper control arm 47 recoil buffer bracket 48 recoil buffer 49
269. nected first to the power supply of 12 volts and then to that of 15 16 volts With the sound voltage regulator the lamp illuminates in the first case and goes out in the second case If the lamp illuminates in both cases there must be a break in the voltage regulator when the bulb fails to light in both cases the regulator circuit is broken or brush to regulator connection is loose for pre 1996 alternators Capacitor testing The suppression capacitor is intended to protect the on board electronic equipment against voltage surges in the ignition system along with suppression of radio interference A damaged capacitor or its loose fitting to the alternator poor ground is recognizable through increased radio interference with the engine running A simple way of testing the capacitor is to use a megohm meter or a tester scaled as 1 10 MOhm In case of a sound capacitor when its contacts are closed via the instrument the needle should first deflect towards a lower resistance values and then gradually return to the initial position The capacitance mea sured with a special device should be 2 2 microfarad 20 Alternator overhaul Alternatzor dismantling Clean the alternator and blow dry with compressed air Release the clip to disconnect air intake 3 Fig 7 11 from hous ing 4 Undo two screws 1 and nut from contact bolt extension 5 Fig 7 10 Checking the voltage regulator a 1996 on voltage regulator b
270. new shoes if the friction lining thickness is less than 1 5 2 mm 131 N eo Ti aN ps m prd dg e Me st Fig 6 19 Wheel cylinder 1 shoe abutment plate 2 cap 3 cylinder body 4 piston 5 seal 6 backing cup 7 spring 8 retainers 9 thrust ring 10 thrust screw 11 bleed screw A slot in thrust ring Fig 6 20 Wheel cylinder components 1 piston assembly 2 cylinder body 3 thrust screw 4 thrust ring 5 retainers 6 spring 7 backing cup 8 seal 9 piston 10 cap 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 turning and polishing is 1 mm These dimension limits should be strictly observed otherwise the durability of the drum and the efficiency of braking will be decreased due to reduction of drum rigidity Rear brake wheel cylinder test bench inspection Position cylinder 2 fig 6 21 on the test bench attach the pipeline from the manometers and bleed the system Adjust rests1 so that the wheel cylinder pistons are rested against them Check for liquid leak Connect a low pressure manometer 4 Slowly rotate flywheel 8 to obtain liquid pre
271. ng 5 pin 6 bolt 7 rear engine support cross piece 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 During engine operation water warmed up in the water jack et through the drain pipe flows to the radiator or thermostat depending on the thermostat valve position Then water is sucked by the pump and returned to the water jacket Fig 9 20 Cooling system 1 expansion tank vapour discharge pipe 2 expansion tank cap 3 engine vapour discharge hose 4 radiator delivery hose 5 expansion tank 6 radi ator vapour discharge pipe 7 radiator 8 top radiator mounting rubber 9 electric fan blower 10 bottom mounting rubber 11 return hose 12 filler hose 13 thermostat 200 The cooling system is fitted with a built in double acting ther mostat the valve opening temperature is 83 C Coolant level and density check With the cold engine 15 20 C the level of water in the expansion tank must be 25 30 mm above the MIN mark WARNING It is recommended to check the water level on the cold engine since on heating up water expands so the fluid level can rise signific
272. ng Ignition system Direction indicators Instruments Heater unit Heated rear window Wipers windscreen rear window headlight Il Starter motor 30 INT 30 1 15 Refer to position I 30 50 Starter motor Ill Parking 30 INT 155 Fig 7 28 Wiring diagram for headlight and foglight 1 headlights 2 main fusebox 3 low beam relay 4 ignition switch 5 exterior light switch 6 warning lights high beam left and fog lamp right 7 rear fog light 8 fog light switch 9 complementary fusebox 10 headlight switch 11 high beam relay 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 A to illumination lamps for instruments switches and heater controls l i Fig 7 30 Wiring diagram for direction indicators and hazard flashers 1 direction indicators in headlights 2 side repeat indicators 3 ignition switch 4 ignition relay 5 fusebox 6 direction indicators in rear light cluster 7 direction indi cators warning light in instrument cluster 8 indicators flasher relay 9 hazard warning flasher switch 10 direction indicators switch 156 General desc
273. ng nuts and bolts or damaged engine supports 6 Bended bolts and layshaft flex ible coupling flange 1 Renew or repair propeller shafts 2 Renew or repair differential 3 Repair joints or replace shafts 4 Inspect boot and joint Renew joint in case of damage 5 Tighten mounting nuts and bolts or renew engine mounts 6 Renew bolts or layshaft Noise at cornering or wheel slip 1 Hard rotation of differential pin ions on shaft 2 Jammed axle drive gears in dif ferential housing 3 Damaged differential pinion working surface 4 Large axial clearance of axle drive gears in differential housing 1 Renew worn or damaged parts 2 Renew worn or damaged parts 3 Renew worn or damaged parts 4 Use shims to adjust clearance to 0 0 10 mm Hard gear switching or differential lock up 1 Jammed coupling on hub Splines or on differential housing splines 2 Dents on smaller crown teeth on top or lower gears on clutch teeth and on splines of front axle drive shaft 3 Bended fork or rod 4 Deformed transfer box drive levers 5 Jammed drive levers on shafts 1 Rectify burrs dints scores renew bad parts 2 Rectify burrs scores renew bad parts 3 Straighten deformed parts 4 Straighten levers renew if neces sary 5 Remove levers clean shafts and bushes Renew bad parts 73 Spontaneous gear or differential lock disengagement 1 Worn teeth on gears and cou plings 2 Weak detent spring or
274. ng the layshaft pay attention to the condition of the gear unit and the speedometer drive gear No chipping or excessive wear of teeth is allowed Renew bad parts Gears When inspecting the gears check the condition of teeth and landing surfaces No teeth chipping or excessive wear is allowed There should be no scuffings or wear on gears land ing surfaces that may cause large gaps Check the gear mesh clearance the mounting gap should be 0 10 mm maximum allowed 0 20 mm The mounting gap between the low gear and bush and 80 between the input shaft and top gear should be 0 05 0 10 mm maximum allowed 0 15 mm If wear exceeds the limits renew the gears Bearings Ball and roller bearings should have no damages on races cages rollers or balls and no cracks and choppings on rings The bearing radial gap should not exceed 0 05 mm When turned a clean dry bearing should not knock It should run smooth without jamming Renew damaged bearings Rods forks No deformation of forks and jamming of rods in the casing apertures is allowed In case of jamming renew the detent components Weak springs should be replaced The spring length under load of 99 15 114 85 N 10 2 11 8 kgf should be 19 mm when let free 23 3 mm Ensure there are no traces of jamming on the gear shift clutch hub and especially on the clutch sliding surfaces and also on the differential housing splines Scuffings and burrs can be smoothed with a file S
275. njection system protective fuses Fuse Circuits protected 1 2 Fuel pump on relay contacts Electric fuel pump Fuel injector 34 Oxygen sensor Vehicle speed sender Canister valve Intake manifold preheater relay winding 5 6 ECU Ignition control module 7 8 Reserve In addition to fuses there is a fusible link at the end of the red wire connected to the battery This fusible link represents a length of black wire of 1mm cross section whereas the main red wire is of 6 mm cross section laa E LIII nggu WI 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 purge valve 13 spark plugs 14 ignition module 15 electronic control unit plug 16 intake manifold preheater fuse 17 fusebox injection system 18 crankshaft position sensor 19 instrument cluster with tachometer and CHECK ENGINE light 20 main fusebox 21 ignition relay 22 fuel pump cut in relay 23 intake manifold preheater relay 24 intake manifold preheater A to battery terminal B to ignition switch terminal 15 189 VAZ 21214 20 vehicle The VAZ 21214 20 vehicle is fitted with a 1 7 L engine
276. nstalled on a hydraulic press First bend out bolt retainers 39 see fig 3 54 that are fas tening plate 38 with the oil screen and the brake plate and take out the bolts Straddle the bearing with tool 67 7823 9529 and place the axle shaft vertically so that the half rings are rested on the thrust ring Place the axle shaft under the press fig 3 61 and apply gradually increasing force to the spline end of the axle shaft until the bearing stop ring will be removed The bearing stop ring should be renewed Ensure that the landing surface of the axle shaft has no marks or damages renew if necessary Axle shaft reassembly Place the axle shaft vertically and rest the flange on ring 7 fig 3 62 of tool 67 7823 9530 Bolt together the axle shaft bearing oil screen and the bear ing fastening plate with a seal and refit the assembly on the axle shaft fit the axle shaft ball bearing Fit a new stop ring into special retainer 3 place into heater and warm the ring up to approximately 300 C so that at the moment of press fitting its temperature will be 220 240 C The stop ring is press fitted on the axle shaft with tool 1 on a press with force of 58 8 kN 6000 kgf so that the bearing inner ring is fixed between the stop ring and the axle shaft collar 87 Fig 3 62 Press fitting the axle shaft bearing stop ring 1 tool 2 axle shaft 3 race 4 stop ring 5 bearing 6 oil deflector assem bly and
277. nstruments fault diagnosis Coolant temperature gauge If the gauge needle constantly stays at the low end of scale switch on the ignition disconnect the lead from the gauge and connect its end to earth through a resistor of 20 50 Ohm If the needle swings the gauge is faulty and must be renewed If the needle does not move remove the instrument cluster and without disconnecting its wiring pull out the red con nector then with the ignition switched on earth terminal 13 Fig 7 39 of the instrument cluster white connector through the 20 50 Ohm resistor The needle swings if the gauge is sound but the wire between the sender and the instrument cluster is dam aged When the needle does not swing renew the coolant tem perature gauge or the complete instrument cluster When the needle stays in the red area then with the ignition switched on disconnect the sender wire The sender is faulty if the needle returns to the low end of scale If the needle remains in the red area then either the lead is earthed or the gauge is damaged The gauge can be checked through disconnecting the white terminal connector from the instrument cluster With the ignition switched off the needle should be at the low end of the scale Fuel gauge The checking procedure for the fuel gauge is similar to the one described earlier If the needle stays at the low end of the scale and does not move when the pink wire is disconnected from the gauge and ea
278. nt supply pipe from the heater From the pump and exhaust manifold disconnect the coolant supply pipe from the heater Use tool A 60312 to undo the oil filter with seal remove the oil filter and seal Fig 2 4 Unscrew the oil pressure warning lamp sender Remove the crankcase vent breather cover crankcase and oil pump Remove the oil separator drain pipe catch and take out the oil separator To remove the crankshaft pulley secure the flywheel using A 60330 R Fig 2 10 and undo the nut using tool A 5012 Fig 2 5 Withdraw the valve cover and timing cover Unbolt the Fig 2 5 Releasing the crankshaft nut using tool A 50121 Fig 2 6 Removing the chain tensioner and damper 1 camshaft timing chain 2 shoe retaining bolt 3 tensioner chain 4 ten Sioner retainer nut 5 tensioner housing 6 tensioner cap nut 7 chain damper securing bolts 8 oil pump shaft sprocket retaining bolt camshaft and oil pump drive shaft sprockets Slacken chain tensioner cap nut 6 Fig 2 6 undo nut 4 hold ing it to the cylinder head remove the tensioner then unbolt and remove chain tensioner shoe 3 Undo the chain stop pin remove the oil pump and camshaft sprockets then take off the chain Loosen studs 4 nuts Fig 2 7 Remove the camshaft bearing housing Undo studs 4 nuts remove thrust flange 1 and withdraw the camshaft exercising maximum care not to damage the camshaft bearing housing surface Unbolt the cyli
279. nt sgk the facia and release the top catches No sharp bends of the drive cable should be evident after undo the two securing nuts and withdraw the instrument refitting The permitted drive cable bending radius is 100 mm as ja a maximum cluster from the facia 2 3 4 5 1 uy LL tT EEDE EET ca 11 12 13 i 15 13 2 0 7 9 8 7 A M HA oun E39 e s so Os Um gee Fig 7 40 Wiring diagram for 1996 on instrument cluster rear view 1 tachometer 2 voltage stabilizer 3 instrument illumination bulb 4 coolant temperature gauge 5 fuel gauge 6 warning light exhaust emission system 7 heat ed rear window warning light 8 foglight warning lamp 9 high beam warning light 10 external light warning lamp 11 direction indicators warning light 12 voltmeter 13 low brake fluid warning light 14 low oil pressure warning light 15 differential lockup warning light 16 fuel reserve warning light 17 seat belt reminder 18 handbrake on warning light D1 D2 diodes IN4002 R1 resistor 470 Ohm 0 25 W R2 resistor 51 Ohm 5 W 164 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 I
280. nt suspension arms 3 Renew deformed arms Excessive gap in balljoints 1 Worn balljoint rubbing surfaces as a result of fouling due to leaks in 1 Replace ball joint and boot shroud or its damage 100 Diagnosis Remedy 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 tread inner path 7 Low tyre pressure large wear on tread edge 8 Excessive tyre pressure large wear in tread middle part 9 Low front wheel toe in wear of tread inner path 10 Excessive front wheel toe in wear of tread outer path 1 Low down speed 2 Repair suspension 3 Balance wheels 4 Adjust braking system 5 Renew shock absorbers or repair 6 Align wheel camber 7 Adjust to normal pressure 8 Adjust to normal pressure 9 Adjust wheel toe in 10 Adjust wheel toe in Wheel runout 1 Wheel out of balance uneven tread wear displacement of balance weights and tyres at installation deformed rim damaged tyres 2 Excessive gap in wheel hub bearings 1 Do the following balance or replace wheels balance wheels rectify rim or replace balance wheels replace tyre and balance wheels 2 Adjust clearance
281. o maintain the sizes of 4 5 4 8 mm and 67 mm maximum see fig 6 19 for free landing of the brake drum before refitting the components in the cylinder body thickly grease them with brake liquid After reassembly check the movement of each piston in the cylinder body They should freely move within the limits of 1 25 1 65 mm The last established in place is the protective cap 2 Component inspection Wheel cylinders Ensure the cleanness of working surfaces of the cylinder pistons and thrust rings The surfaces should be absolutely smooth without roughness to avoid liquid leak and premature wear of sealings and pistons The defects on the cylin der mirror can be eliminated by lapping or polishing However no increase of the cylinder inner diameter is allowed Inspect screw 3 see fig 6 20 spring 6 thrust cup 7 and retainers 5 If necessary renew damaged components Renew sealings 8 Inspect protective caps 10 and renew if necessary Shoes Carefully check the shoes for damages or deforma tions Check the tension of the upper and lower return springs if necessary renew The springs should have no residual deformations when stretched with effort of 350 N 35 kgf for lower springs and 420 N 42 kgf the upper ones Check the linings for dirt or traces of greasing if necessary carefully clean with metal brush and wash with white spirit besides check for leaks of greasing inside the drum eliminate malfunctions Re
282. o the steering worm shaft Undo the bracket 6 fastening bolt fig 5 3 and remove the steering shaft with the bracket Undo the nuts that are fastening the ballpins on the side and middle tie rods to the arm and use puller A 47035 to press out the ballpins from the arm apertures Remove the steering box prior having undone the bolts that are fastening it to the body chassis arm Take out the steering shaft sealing from the opening in the car front Refitting Insert sealing 2 see fig 5 3 into the opening in the car front match the sealing ridges with the grooves in the open ing place the steering box on the chassis arm but do not tighten completely the nuts on the steering box fastening bolts Using a special fixture situate the steering box so that angle Qt fig 5 4 does not exceed 32 and the clearance between the shaft and the brake pedal will be no less than 5 mm Then com pletely tighten the steering box fastening nuts Place the steering pitman arm in middle position To do this match the labels on the steering box and on the worm shaft see fig 5 2 Temporarily refit the steering wheel on the shaft so that the spokes are located horizontally and in this position connect the intermediate shaft U joint with the worm shaft paying special attention that the fastening bolts pass through the worm ring groove Then attach the steering shaft bracket to the body Remove the steering wheel and refit the combination swi
283. ociated components are damaged or badly worn renew the actuator assembly Stator Using megohmmeter or a 220 v test lamp check the stator winding is not earthed The test lamp voltage is supplied to the common winding ter minal and starter housing When the bulb is lit up or megohm meter resistance reading is below 10 kOhm or if the windings have evidence of overheating blackened insulation renew the housing complete with the windings Housings Inspect the housings for cracks If this is the case replace the housings with new ones Examine the bushes When they are worn renew the com plete housings or only the bushes When the new bushes are pressed in ream them to 12 015 0 03 mm Make sure the brush holders are properly secured on the commutator end housing The positive brush holders must not be earthed The brushes should slide smoothly in the holder slots Renew the brushes worn to 12 mm in height but first run them in to the commutator Using the dynamometer check the spring load at the brush es to be 9 8 0 98 N 1 0 1 kgf for new brushes renew the spring when applicable Solenoid Check the solenoid armature for smooth opera tion Using ohmmeter check the closing of the solenoid terminal bolts via a contact plate When there is no contact the solenoid should be dismantled and the terminal bolts to be sanded with fine emery paper or a superfine flat file You may turn the terminal bolts 180 C in case t
284. of any other engine noise since the valves are operated by camshaft rotating at half the crankshaft speed 1 Excessive valve clearances 2 Broken valve spring 3 Excessive valve to guide clearance 4 Worn camshaft lobes 5 Loose locknut of adjuster bolt 1 Adjust clearances 2 Renew spring 3 Replace worn parts 4 Renew camshaft and levers 5 Adjust clearance between lever and cam tighten locknut Excessive noise of camshaft operation line Noise from camshaft operation line is caused by clearances between engagement elements and becomes noticeable in general engine noise at low crankshaft speed 1 Loose chain caused by general wear 2 Broken chain tensioner shoe or damper 3 Seized chain tensioner plunger rod 1 Tighten chain 2 Renew tensioner shoe or damper 3 Eliminate seizure Insufficient oil pressure at warm engine idle 1 Foreign particles entrapped under oil pump relief valve 2 Seized oil pressure relief valve 3 Worn oil pump gears 4 Excessive main bearing running clearance 5 Excessive camshaft bearing journal to bearing housing clearance 6 Incorrect oil grade or inappropriate oil quality 1 Clean valve from foreign particles and flash clean oil pump 2 Renew valve 3 Repair oil pump 4 Turn journals and renew bearing shells 5 Renew camshaft or bearing housing 6 Change oil as recommended in Attachment 4 Excessive oil pressure on warm engine 1 Seized oil pressure relief valve
285. of the handbrake lever quadrant was changed the first tooth of the sector became double and thus the order of adjustment marked below in the text with a sign has changed If the handbrake does not hold the vehicle on a slope up to 25 when moving the lever by 4 7 2 8 teeth of the quadrant adjust the handbrake in following order shift the handbrake lever to the lowest position and then lift by 1 2 teeth of quadrant this operation is carried out only for the gear sector of the old design slacken locknut 5 fig 6 4 and by turning the adjusting nut 6 take up cable 1 check the full travel of the handbrake lever which should be 4 5 2 4 teeth on the quadrant then tighten locknut 5 Apply the brake pedal several times to ensure that the lever travel does not change and wheels rotate without jamming at fully lowered lever Note If the cables were renewed depress the brake pedal two or three times applying force on the lever of approx 392 N 40 kgf Thus the cables will be stretched Pressure regulator serviceability check Position the vehicle on a lift or over an inspection pit clean the pressure regulator and protective cover from dirt Carefully remove the protective cover from the pressure reg ulator remove the remains of greasing and clean the torsion to piston connection 123 mum SSS SON AAAA AAA Fig 6 4 Handbrake linkage 1 front cable 2
286. omponents 1 cover 2 front cable 3 lever 4 pushbutton 5 tie rod spring 6 lock tie rod 7 rear cable guide 8 distance sleeve 9 return spring 10 expander strut 11 manual shoe operating lever 12 rear cable 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 from the brackets on the floor and the cable sheath from the brackets on the rear axle beam and remove the rear cable 12 Remove the lever protective cover and then the lever assem bly and the front cable Take out the pin and remove the thrust washer disconnect the front cable from the handbrake linkage lever The handbrake is refitted in reverse sequence with subse quent adjustment see Handbrake adjustment When refitting grease with JIMTOJT 24 or JICLI 15 the rear cable guide the handbrake lever shaft and the front cable end Check and repair Carefully inspect the components of the handbrake mechanism If breakage or wire scuffing is detected renew the cable Make sure that the quadrant teeth and handle lock are not damaged worn components should be replaced Check the condition of the spring It should provide the lever return to the released
287. on After refitting bleed the brakes and adjust the main and handbrake systems as direct ed in section Brakes Fill the rear axle with transmission oil through oil fillers Rear axle dismantling and reassembly Dismantling Disconnect the pipe ends from the brake cylin ders and remove the pipeline with the brake system tee from the axle Place the axle on a repair bench and drain oil After removing the brake drum and undoing the braking plate fastening nuts with pusher 67 7823 9516 fig 3 55 take out the axle shaft in assembly with the oil screen the bearing fastening plate the bearing and a stop ring Remove the braking plate and the sealing ring If necessary to renew take out the sealing ring from the axle beam flange Do the same on the other end of the beam then remove the reduction gear The reassembly of the rear axle is carried out in reverse sequence grease the threads of the reduction gear fastening bolts with a sealant previously having degreased them and the threaded connections in the rear axle beam grease the axle shaft bearing seal with JINTOJI 24 before refitting and use tool A 70157 to refit the seal in the beam flange grease the landing shoulder of the axle shaft and the drum mating surface of the flange with graphite or JICLI 15 The brake drums are installed after refitting the rear axle on the vehicle and fastening the cable ends to the handbrake link age levers Rear axle beam
288. on system secondary barrel conventional flow fuel jet conventional flow air jet Full throttle enrichment econostat conventional flow fuel jet Part throttle enrichment economizer fuel jet marking spring compression 9 5 mm length N Accelerator pump atomizer marking delivery 10 full strokes cc cam marking Starting clearances choke valve clearance B mm e throttle valve clearance C mm Diameters mm crankcase vent drilling vacuum advance unit orifice needle valve bore fuel return orifice to petrol tank 32 24 107 5 150 ZD 39 140 40 45 3 0 14 12 Jet marking is flow related Flow rate is measured with a micrometer calibrated against the reference jets Conventional flow through the jet is determined against the reference jet under a special procedure in operation no control is required Starting clearances are as shown in Fig 2 86 14 5415 1 2 1 8 0 70 32 24 117 5 135 ZC 70 140 70 47 ja ae GOIN A WN SA E NS A ZZA N CZz DN N NARINI IN N C SANIN Y s S N N N N L 3X KSS NE 8K 6 S RECEN RE WII Zz e LUZ Vz 7 e a 7 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 n
289. on the steering wheel Refit the ballpins of the middle and left tie rods on the pitman arm and fix them with nuts Adjust the front wheels toe in and check the effort on the steering wheel which should not exceed 196 N 20 kgf 245 N 25 kgf measured on the wheel rim when tested on a smooth metal plate Note It is possible to assemble the steering column with the combination switch separately and then to refit the unit on the vehicle To fix the unit establish the steering wheel spokes horizon tally and connect the worm shaft to the lower end of the interme diate shaft paying attention that the lock bolts pass through a ring groove on the worm shaft and the wheel shaft Prior to completely fastening the bracket bolts rotate the steering wheel in both directions several times and only then tighten the bracket fastening bolts Steering mechanism dismantle and reassembly Dismantle Drain oil from the steering box Fix it on bracket A 74076 R with support A 74076 1 Undo the pitman arm fastening nut 2 fig 5 5 take off the spring washer and using puller A 47043 remove the arm fig 5 Fig 5 8 Installing the steering worm 1 bearing cover 2 shim 3 worm Fig 5 9 Checking the worm friction moment using a dynamometer 1 worm 2 head A 95697 5 3 dynamometer 02 7812 9501 4 test bench bracket 5 steering box 6 Undo the fastening bolt take off cover 12 see fig 5 5 o
290. ondition of the lever oper ating surfaces which mate the valve stem cam lobe and adjuster bolt spherical end Always renew the rocker arm when its surfaces are chipped scored or scuffed Renew the lever adjuster bolt bush or the bolt itself in case of any deformation or damages found Camshaft and timing gear Design description Camshaft is cast iron of five bearings operates in the alu minium bearing housing fitted to the cylinder head Basic dimensions of the camshaft and bearing housing are shown in Fig 2 54 The flanks of the cams are chilled for better wear resistance In order to eliminate the camshaft endfloat the camshaft is supported by the thrust flange held in the front journal groove Camshaft is operated through crankshaft sprocket 5 Fig 2 55 and double row roller chain 2 The chain also operates sprocket 4 of the oil pump shaft The chain drive has semi auto matic tensioner 8 with shoe 7 and chain damper 3 with rubber covers In the cylinder bottom there is stop pin 6 to prevent the chain dropping into the crankcase when camshaft sprocket 1 is removed Chain tension adjustment Loosen nut 1 Fig 2 56 of the tensioner This releases rod 3 and the chain is tightened by means of shoe 7 Fig 2 55 which is loaded by spring 7 Fig 2 56 Turn the crankshaft 1 1 5 turns progressively By doing that the tensioner spring operating the shoe automatically adjusts the chain tension Tighten tensioner nut 1
291. oolant Coolant change Change coolant at the intervals recommended or after the engine overhaul Fill the cooling system as described below undo the radiator and expansion tank caps open the heater tap disconnect the heater hose top from the union on the vehi cle body pour coolant 10 7 litre to the radiator up to the upper filler edge until it starts flowing from the hose and heater union reconnect the heater hose with the union and refit the radi ator cap Top up the remaining coolant into the expansion tank refit and tighten the filler cap to remove air pockets start the engine run it idle until the coolant temperature reaches the temperature of the thermostat opening 80 2 C Check to see the radiator inlet and return pipes are hot Leave the engine to cool and check the coolant level When the level is below that required while there are no evident sys tem leaks top up coolant as necessary i aozozo ays oso OS OT TAT zo El Bons O H S ZOZ o o pz ZO r1
292. opening for the needle bearing should not exceed 28 021 mm In case of damage or if wear of working surfaces of the layshaft U joint components exceeds 0 1 mm renew the U joint assembly Flexible coupling Inspect the rubber components of the flexible coupling In case of cracks or peelings of rubber from the metal inserts renew the flexible coupling Flexible coupling flange Inspect the centering bush on the flexible coupling flange Renew in case of damage or wear Reassembly The reassembly is a reversal of dismantle providing the fol lowing evenly grease the spline joints with 3 4 gr of MOJT 1 or QAOJT 2Y match the marks on the dismantled parts after reassembling the spline joint apply axial load to press the seal by 0 3 0 5 mm and crimp the retainer on the yoke groove The reassembly of the U joint is carried out in the following Sequence remove old greasing lubricate the inner surface of the bear ing housing with grease Ne 158 or GWOJT 2Y 0 8 1 2 gr on each bearing Do not grease the spider thorns to avoid an air plug during reassembly Mount the spider into fork apertures Insert a bearing in one of the yoke openings and place circlip1 fig 3 52 with thickness of 1 56 mm in the yoke groove Insert a bearing in the other yoke opening until the opposite bearing will thrust against the circlip end face The pressing force should not exceed 15000 N 1500 kgf ISSS Sz N N N N
293. oticed at the first test and which were not repeated at the subsequent originate from the reduction gear for confirmation lift the rear wheels start the engine and engage the fourth gear Thus it is possible to ensure that noise indeed orig inates from the reduction gear and not from the other units for example suspension or car body Reduction gear removal If itis necessary to remove only the reduction gear drain oil from the rear axle beam raise the rear part of the vehicle place it on supports and remove wheels and brake drums undo nuts fastening the braking plate to the beam and pull out the axle shafts so that they come out from the differential box disconnect the propeller shaft from the reduction gear put a support under the reduction gear casing turn out the bolts fas tening it to the rear axle beam and take out the reduction gear from the beam pay attention not to damage the sealing Reduction gear refitting Before refitting the reduction gear carefully clean the axle beam from oil Place a sealing on the mating surface fit the reduc tion gear into the beam and fix with bolts Grease the bolt threads with a sealant Before greasing the bolts and connections in the beam carefully degrease all surfaces Connect the propeller shaft to the reduction gear Install the axle shafts and brake drums Install a wheel with a tyre and fasten without tightening the wheel nuts After refitting both wheels rem
294. otionless brake pedal Sticking of the pro tective cap 13 to the valve housing tail and hissing of inleaking air will indicate insufficient tightness of the servo unit In these cases the unit should be renewed Brake drive adjustment The free travel of the brake pedal with engine not working should be 3 5 mm This size is received by adjusting the position of the stoplight switch 7 fig 6 3 If the stoplight switch is too close to the pedal it does not come back to the initial position valve 18 see fig 6 2 being pressed to housing 21 separates cavities A and B and it results in incomplete release of wheels when the pedal is let off To adjust the stop light switch position slacken nut 8 and by rotating nut 9 see fig 6 3 position the switch so that its buffer will slightly touch the pedal rest thus the pedal free travel should make 3 5 mm After adjustment tighten nut 8 ATTENTION The brake pedal free travel adjustment is made with the engine not working If the adjustment of the stoplight switch fails to remedy the brake mechanism disconnect the master cylinder from the servo unit and check the protrusion of the adjusting bolt 4 see fig 6 2 in relation to the fastening plane of the master cylinder flange size 1 25 This size can be established by holding with a spe cial key the end of rod 3 and with the other key screwing in or undoing bolt 28 Handbrake adjustment Note In the end of year 1995 the design
295. ourly show no changes in voltage and specific gravity If at the end of the recharging procedure the electrolyte spe cific gravity after temperature correlation differs from that spec ified adjust it accordingly In case of higher specific gravity remove some electrolyte and top up distilled water while in case of lower specific gravity remove some amount of lower specific gravity electrolyte and add some higher specific gravity elec trolyte 1 4 g cm After the electrolyte specific gravity has been duly adjusted continue to charge the battery further 30 minutes for better elec trolyte mixing Next disconnect the battery and after 30 minutes check the electrolyte level in all cells When electrolyte is below the level required pour in elec trolyte of the specific gravity which is recommended for that cli mate Refer to Table 7 4 When electrolyte level is above that required remove excessive amount using a rubber bulb Table 7 4 Electrolyte specific gravity at 25 C g cm Climate average Season Fully discharged Battery discharged January temperature C battery by 25 by 50 Very cold from 50 to 30 Winter 1 30 1 26 1 22 Summer 1 28 1 24 1 20 Cold from 30 to 15 All seasons 1 28 1 24 1 20 Moderate from 15 to 8 All seasons 1 28 1 24 1 20 Warm and damp from 0 to 4 All seasons 1 23 1 19 1 15 Hot and dry from 15 to 4 All seasons 1 23 1 19 1 15 139 Alternator Specific
296. ove the supports and lower the vehicle then tighten the wheel nuts with a torque wrench Fill the axle beam with oil through the filler previously having cleaned and screwed in the drain plug Reduction gear dismantle Fix the reduction gear on a bench Remove lock plates 9 see fig 3 65 turn out bolts 7 and remove covers 8 of the differential box bearings adjusting nuts 10 and outer rings of the roller bear ings Make marks on covers 8 and bearing outer rings so that to refit them on former places Take out from the reduction gear casing 11 the differential box together with the driven gear 2 and bearing inner rings To remove gear 1 and its components turn the reduction gear casing with the filler neck upward fig 3 66 hold driving gear flange 3 with tool 1 and undo the flange fastening nut with wrench 2 remove the flange and take out the driving gear with the adjusting ring rear bearing inner ring with distance sleeve take out the seal the oil screen and the front bearing inner ring from the reduction gear casing using tool A 70198 press out the outer rings from the front and rear bearings remove the distance sleeve from the driving gear and with the help of a universal puller A 40005 1 7 and tool A 45008 fig 3 67 take out the inner ring from the rear roller bearing remove the driving gear adjusting ring To dismantle the differential remove inner rings 2 fig 3 68 from the differen
297. overhaul of the motor is restricted to replace ment of gears cleaning of commutator and adjustment of limit switch To remove the windscreen wiper withdraw the blades complete with the arms open the bon net and disconnect the leads from the battery and wiper motor undo the connector nuts and remove them together with washers and shims undo the motor bracket retaining nut withdraw the wiper When necessary take the motor off the bracket and disman tle the linkage on the work bench Refitting is a reversal of the removal procedure 34 Fig 7 34 Wiring diagram for windscreen wipe wash 1 windscreen washer motor 2 windscreen wiper motor 3 ignition switch 4 ignition relay 5 fusebox 6 windscreen wipe wash switch 7 pin assignment of switch connector 8 windscreen wiper relay 9 pin assignment of wiper relay and motor connectors Fig 7 35 Windscreen wiper motor components 1 cover 2 panel 3 drive gear 4 steel washer 5 tekstolite washer 6 retainer 7 housing 8 armature 9 crank 10 circlip 11 protective cap 12 spring wash er 13 sealing ring 14 shim 15 thrust washer 16 motor cover 160 Wiper motor dismantling reassembly and inspection Commence to dismantle the motor by undoing cover 1 Fig 7 35 retaining screws Remove the cover complete w
298. ower longitudinal arm 2 rubber bush 3 bracket 4 spacer sleeve 5 upper longitudinal arm 6 additional compression buffer 7 spring 8 spring seat upper 9 compression buffer 10 spring insulating gasket upper 11 shock absorber 12 spring insulating gasket lower 13 transverse am Fig 4 16 Rear suspension mounting 1 chassis arm 2 transverse arm bracket 3 rear axle beam X 152 mm 3432H 350krc 434 278 Fig 4 17 Main parameters for checking the rear suspension spring 111 N N N o gt co oo Y rT lee E TITT TIIRI TIITII IILI PPPS ITIL LLLI NAPPING STII IEE LIJAR L IIIT L IL IIIT ILILILILIL IISI EEN A recoil valve discs 13 piston ring cylinder rod 21 restricting plate 19 tank 20 oa Ss LE recoil valve cap 12 17 by pass valve spring 18 26 rod oil seal 27 gasket 28 rod guard ring 29 tank nut 30 shock absorber eye 32 spring washer 33 washer 34 pad 35 distance sleeve 36 shock absorber casing 10 shock absorber piston 11 LS WY 36 Fig 4 18 Front and rear suspension shock absorbers lower eye 2 compression valve body 3 compression valve discs 4 compression valve throttling disc 5 compression valve spring 6 compression valve holder 1 recoil valve spring recoil
299. own must face the timing belt end of the engine when inserting the pistons into the cylinders Press the big end bearing shells into the connecting rods and caps Guide the conrods and big end caps onto the crankshaft journal then tighten the connecting rod bolts The big end caps must be positioned so that the cylinder number on the cap is against the cylinder number on the connecting rod big end Refit the crankshaft sprocket Locate the oil pump shaft and secure it with the thrust flange Insert two centering pins into the cylinder block Fig 2 17 and locate the cylinder head gasket over them WARNING Always fit the new cylinder head gasket Never re use the old gasket Before refitting the gasket remove any oil from the mat ing surfaces of the block and cylinder head Make sure the gasket is perfectly clean and dry Avoid any incidental oiling of the gasket Turn the crankshaft so that the pistons are midway in the cylinder bore Refit the cylinder head complete with the valves exhaust manifold and intake pipe over the centering pins 16 NW t Amt iit my Fig 2 16 Clutch dowels arrowed black and clutch housing centering pins arrowed white Fig 2 17 Fitting the pistons complete with piston rings using ring com pressor centering pins of the cylinder head arrowed Tighten the cylinder head bolts in the established procedure Fig 2 18 in four steps to ensure a reliable fit and exclude furth
300. ownward 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 suspension and car body To do this turn the wheels fully right and left until the steering pitman arm will rest against the steering mechanism housing fastening nuts Front wheel hub bearing gap check and adjustment To check the gap remove the cap and slacken the wheel fas tening nut lift the front part of the vehicle rest it on a support and take off the front wheel Remove the front brake caliper with brake pads Do not allow the caliper to hang on high pressure hoses Fix tool 67 7834 9507 with indicator fig 4 4 on the steering knuckle so that the indicator leg will rest against the wheel hub as closely as possible to the adjusting nut Turn the hub in both directions and simultaneously move it with lever 67 7820 9521 along the steering knuckle shaft forward and backward Measure the size of shift gap by the indicator If the gap is more than 0 15 mm adjust it in the following order undo the adjusting nut from the outer joint housing tail fit a new or used but on other vehicle nut and tighten with torque to 19 6 Nem 2 kgf m simultaneously turning the hub in both directions 2 3 times for self setting the roller bearings Slacken the adjusting nut and again tighten w
301. p 2 spring washer 3 synchro unit hub 4 synchro unit sleeve 5 baulk ring 6 spring 7 washer 8 3rd speed gear 9 output shaft 10 2nd speed gear 11 1st speed gear 12 gear bush 13 bearing 14 key 15 reverse gear 16 5th speed gear 17 oil deflector washer 18 spacer 19 output shaft rear bearing 20 oil seal 21 coupling flange 22 lock washer 23 nut 24 seal spring 25 seal 26 centering ring 71 Fig 3 32 Refitting the circlip on the output shaft 1 tool 41 7816 4069 2 circlip 3 support half ring 4 spring washer 5 press rod Fig 3 33 Gear change mechanism and lever 1 gear change lever 2 gasket 3 ball socket 4 cap 5 spring 6 ring 7 circlip 8 flange 9 collar 10 rubber boot 11 lever knob 12 lever exten sion 13 pad 14 rubber bush 15 spacer 16 securing collar 17 gear change lever housing 18 sealing ring 19 guide plate washer 20 guide bar 21 spring 22 guide plate 23 reverse lock plate 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 the cover are not aligned against each other replace th
302. partly pull out the regulator from the alternator leaving the brush holder in place Next swing and withdraw the regulator complete with the brush holder from the alternator Undo the retaining screw and remove suppression capacitor 20 Undo clamp bolt 14 nuts remove alternator housing 11 and rotor 8 Undo the bolt nuts connecting diode ends to stator wind ing terminals withdraw stator 7 from alternator housing 17 Undo contact bolt 6 nut disconnect the supplementary diode wire terminal from connector 3 remove diode plate 5 Alternator reassembly The reassembly of the alternator is the reverse of the dis mantling procedure In case of pre 1996 alternators with detachable regulator brush holder unit in order to avoid damage to the brushes before refitting the regulator complete with the brush holders do not fully insert the brush holder into the regulator it should be pushed in place only partly then insert the assembly as such into the alternator After the brush holder is refit into the alternator housing press lightly the regulator into the alternator Out of concentricity for the holes in the alternator housings must not exceed 0 4 mm Therefore during reassembly always insert a special gauge into these holes The taper spring washer of the pulley must be assembled with the convex side facing the nut Tighten the pulley securing nut to a torque of 38 4 88 Nem 3 9 9 0 kgf m 20 19 18 17 16 Fig 7 12 A
303. pecial attention should be payed to the clutch teeth end faces if their damage interferes with the clutch sliding when shifting the gears renew the clutch Differential Check the differential pinion shaft surface and the apertures in the differential housing in case of insignificant damages smooth the surfaces with fine sandpaper and at major damages renew Check the surfaces of axle drive gear journals and their mounting apertures in differential housings and also the adjust ing washer surfaces and mating end face surfaces on the axle drive gears and housings The detected damages can be removed by fine sandpaper or velvet file renew the parts in case of major damages or wear With spring washer 15 being removed see fig 3 42 ensure there is no radial movement of circlip 8 in shaft grooves 14 Replace circlips in case of free play Drive line Design of propeller shafts is shown on fig 3 47 3 48 3 49 Fault diagnosis Diagnosis Remedy Knock in shafts at pull away at hard acceleration or gear switching 1 Loose fastening bolts and nuts 1 Tighten nuts to torque specified on flexible coupling and U joint in Appendix flanges 2 Excessive backlash in spline 2 Check gap on spline middle joints of front or rear propeller diameter if it is more than 0 30 mm shafts renew worn parts 3 Worn U joints 3 Repair joints and renew worn parts Noise and vibration of propeller shafts 1 Deformation of front or rear
304. pletely the inner joint The race should be taken out in the direction of the larger diameter of the cage The reassembly of the inner joint is carried out in reverse sequence It is necessary to match the labels made before dis mantle The elongated cone part of the cage should be facing shaft 4 When reassembling fill 150 cm of LUPYC 4 into the joint Use tool 67 7853 9537 to refit the joints protective covers If there are no knocks and vibrations the shrouds are in good condition the dismantle of the front wheels drive is not recom mended 99 Chapter 4 Wheel suspensions Fault diagnosis Diagnosis Remedy Noise and knock in suspension at vehicle movement 1 Faulty shock absorbers 1 Replace or repair shock absorbers 2 Loose anti roll bar fastening bolts 2 Tighten securing nuts and bolts in case of rubber pad wear replace 3 Worn arm silent blocks 3 Renew silent blocks 4 Loose shock absorber fastening or worn shock absorber eye rubber 4 Tighten fastening bolts and nuts renew bushes in shock absorber eyes bushes 5 Worn arm balljoints 5 Renew ball joints 6 Excessive gap in wheel hub bearings 6 Adjust clearance or replace bearings 7 Wheels significantly out of balance 7 Balance wheels 8 Deformed wheel discs 8 Replace discs 9 Set down or broken springs 9 Renew spring 10 Worn rear suspension bar rubber bushes 10 Renew rubber bushes 11 Knock in stiff suspension due to damaged buffers 11 Replac
305. pliers Press out the bearing housing from the U joint yoke Proceed as follows place the propeller shaft so that one of the yokes will be based on rest 1 fig 3 50 Move the other yoke pos 3 with the help of the press rod through special bush 2 down until it will be pressed against the spider turnover the yoke repeat the described operations i e move the other end of the yoke down to press against the spider When performing these operations the opposite spider bearing will partially leave the yoke aperture and in the formed gap between the yoke and spider it will be possible to place bush 1 fig 3 51 with a side notch for further complete dismantle place bush 1 see fig 3 51 on the spider stud move the U joint yoke down to press out the bearing using the above specified procedure press out the other spider bearings Layshaft Disconnect the flexible coupling from flange 5 see fig 3 49 Note the amount and location of the coupling and bal ance washers 17 on the flange so that to refit them in place In case of damage of the protective cover 6 or shroud 14 when it is required to inspect the joints and the quality of greas ing note the location of the U joint in relation to the flexible cou pling flange and dismantle the U joint using the procedure described in subsection Front wheel drive Inspection Eccentricity check Place the front rear propeller shaft between the centers on a special bench a
306. position 134 Inspect the rear cable sheath and the fastening of end pieces on the sheath and ensure that the cable freely moves inside the sheath Replace the cable in case of sheath damage and loose end piece fastening 135 136 Chapter 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 cigarette lighter inte rior lamps inspection lamp hazard warning flashers exterior lighting and main beam Most of the vehicle electrical circuits are protected by fuses which are located beneath the facia at the left hand side of the steering column Fig 7 2 There are no fuses for battery charg ing ignition and engine start up starter and alternator circuits main dipped beam relay Extra fuses 11 12 14 16 are provided in the additional fusebox to be used for alternative vehicle speci fications Before renewing a blown fuse isolate and remedy the cause Before attempting to diagnose any electrical fault refer to Table 7 1 to study the relevant wiring diagram protected by a failed fuse Table 7 1 Fuse protected circuits Fuse No Circuit protected 1 16 A Heater blower motor Headlight wiper
307. pota et ea 183 tional equipment 2 ca rene ein 185 VAZ 21214 vehicle eese 185 Engine repair description essssseeeees 185 Central Injection Unit 186 VAZ 21214 20 vehicle eeseseseeeese 189 Engine 21214 10 ie tee 190 VAZ 21215 10 vehicle eeseseseseseess 197 Cooling SVStem wes ont enter orte eniin Re n 200 Lubrication system ees 202 Fuel System ente ee aint 202 Exhaust emission system seeeeee 203 Electrical SyStetri eei eee extet 203 Steering with BREED SRS 40 driver s airbag in the steering wheel 209 Ait chitierits ote eren 212 Maker opurunan waroroBneH BKM YNABP AO ABTOBAS Kownbtorepuas B pcrka n ocopunenve B Anaes B WlekoB B Mwrpodpauos Ten 8482 22 54 19 Mag Ne 0021311 2 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 model with 1 7 litre Central Fuel Injection Engine VAZ 21214 20 model with 1 7 litre Sequential Fuel Injection Engine VAZ 21215 model _ with Turbo Diesel Engine The chapters o
308. pre 1996 voltage regulator 1 battery 2 voltage regulator earth 3 voltage regulator 4 voltage regulator terminal LL 5 voltage regulator terminal B 6 warning light 7 voltage regulator terminal b 144 Fig 7 11 Removing the alternator protective case 1 securing screw 2 bushes 3 air intake 4 protective case 5 extension alternator terminal 30 6 wire alternator terminal 61 7 alternator 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 consists of two steel half rings inserted into the pulley The half rings are of the same cross section area as the alternator drivebelt At one end they are connected by means of the joint at the other end they have levers to be compressed by hand when removing the pulley Disconnect the wire from the alternator terminal B Disconnect the voltage regulator and capacitor leads from alter nator terminal 30 undo regulator 1 retaining screws Fig 7 12 and withdraw it In case of pre 1996 alternators to prevent dam ages to the brushes when removing the brush holder Insert a screwdriver between regulator 2 housing and brush holder then
309. pressure 7 reservoir 8 flywheel 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 the distance of 150 5 mm see Pressure regulator position adjustment between the end of arm 2 and underframe side member is obtained Raise protective cap 3 see fig 6 22 and by turning the reg ulator on the fastening bolts obtain a slight contact between the arm end and the regulator piston Fix the regulator in this position fully tighten the fastening bolts then apply a layer of greasing 11 1 or MTOP on shaft 2 and the protruding part of the piston Refit rubber cap 3 having applied 5 6 gr of the same greasing Remove tool 67 7820 9519 and reconnect the arm end to tie rod 7 previously having covered the bushes of the rod to arm connection with greasing 1 1 or QUTOP Attach the gas release system pipelines to the car body Bleed the brakes to expel air from the rear brakes Dismantle and reassembly Use key A 56124 to turn out the plug remove lining 5 fig 6 23 take out piston 10 distance sleeve 2 sealing 7 plate 8 spring 9 and thrust washer with seal ing ring 3 When reassembling which is carried out in reverse sequence
310. pressure regulator and adjustments 1 7 regulator securing bolts 2 piston 3 thrust washer bracket 4 pressure regulator control arm 5 shaft 6 cap 8 tie rod 9 pressure regulator X 150 5 mm 124 Fig 6 6 Installing tool 67 7820 9519 to adjust the position of the rear brake pressure regulator 1 tool 67 7820 9519 2 pressure regulator control arm 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 11 1 on shaft 5 and the work ing part of piston 2 Fill 5 6 gr of the same greasing in rubber cap 6 and refit Remove tool 67 7820 9519 and reconnect the arm end with tie rod 8 Hydraulic system bleeding Air that got into the brake hydraulic system during replace ment of pipelines hoses sealing rings or due to system leak causes increase of brake pedal free travel its softness and con siderably reduces braking efficiency Before bleeding the brake system ensure the leak proofness of all system units and their connections check and if necessary fill the tank with brake liquid up to normal level Then carefully clean from dirt and dust the bleeding connectors and remove the protective caps Fit a rubber hose on the connector fig 6 7 for liquid drain and place
311. procket and bearing maximum 0 04 mm surface mating the oil seal maximum 0 05 mm Measure the diameters of the main bearing journals and 4788 4785 4758 7025 47 59 ag 435 880 4735 47 08 05 47 10 100 46 83 46 85 Fig 2 36 Basic crankshaft dimensions 0127 230 Aem 2 36 487 50739 5089 morum 02550569 7 956 t 50299 050 50319 fey pps 50049 2199 075 9 us Z 50 069 2208 Um 49799 aan 23M 100 qaa 490 ys 34 992 Thy 34 960 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 ovality and taper for the main bearing journals and big end bearing journals after regrinding must not exceed 0 005 mm On a reground crankshaft the vertical offset of the crankpins axes must be 0 35 mm Fig 2 37 To check this place the crank shaft on V blocks and position the crankshaft so that No1 crankpin axis is in the horizontal plane passing through the main bearing journal axes Using a dial gauge check the vertical off set of crankpins No 2 No 3 and No 4 against crankpin No 1 After regrinding the journals and crankpins polish them using the diamond paste or
312. r 20 surround 21 shaft 1 escutcheon 2 window lifter handle 3 window lifter mechanism 4 cable 5 top roller 6 sliding glass 7 sliding glass holder 8 cable retainer 9 cable sleeve 10 glass holder bracket 11 bottom roller 12 tensioner 13 window lifter housing 14 barrel and driven gear 15 pinion 16 support 17 brake spring 18 spring 177 Fig 8 15 Front left door lock 1 inner door handle 2 escutcheon 3 pivot shaft 4 inner door bracket 5 inner door operating link 6 door locking knob 7 locking knob rod 8 inner control lever 9 lock body 10 spring 11 thrust block 12 rotor 13 central shaft support 14 striker housing 15 exterior drive lever 16 exterior drive lever spring 17 ratchet 18 ratchet spring 19 lock release shaft 20 lock release link 21 lock operating lever Fig 8 16 Front door lock attachment 1 door locking knob 2 locking knob rod 3 lock securing screws 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 cable at the barrel output with a wire clip Withdraw the window glass through the lower door
313. r casing covers damaged sealings Removal and refitting 1 Renew oil seal 2 Renew oil seal 3 Tighten nuts and bolts replace gaskets Place the vehicle on the lift or over an inspection pit and raise the vehicle front part Remove the anti roll bar the suspension crossmember tie rods and the crankcase protective cover Disconnect the shock absorbers from the lower suspension control arms and the input propeller shaft from the front axle reduction driving gear flange Compress the suspension spring disconnect the balljoint from the lower arm and take off the spring having smoothly unloaded it Disconnect the steering tie rods from the steering knuckle arms Remove the wheel cap and undo the wheel hub bearing nut Do the same on the other end of the suspension 96 Loosen the muffler to front exhaust pipe clip disconnect the pipes and muffler brackets in the rear part of the vehicle and on the gearbox Using key 02 7812 9500 undo the front exhaust pipe to exhaust manifold fastening nuts and remove the pipe downward Undo the nuts that are fastening the engine front mounting pads to the suspension crossmember brackets Support the front axle and undo the bolt fastening the right bracket 22 see fig 3 81 to the engine and two fastening nuts of the front axle from the left side Raise the engine by 25 30 mm remove the front axle in assembly with the front wheel drives Refitting of the front axle on th
314. r ring is on the side opposite to the ring gap Inspection Scrape away all traces of carbon from the piston and remove all carbon deposits from the piston connecting rod oilways Thoroughly examine the components Make sure there are no cracks of any sort on the piston piston rings gudgeon pin connecting rod or big end cap Renew the bearing shell if there is obvious scoring or scuffing The piston ring to groove wall clearance is checked using feeler blades as shown in Fig 2 34 fitting the ring into the respec tive groove For new components the design clearance rounded off to the nearest 0 01 mm is 0 04 0 07 mm for the first com pression ring 0 03 0 06 mm for the second compression ring and 24 0 02 0 05 mm for the oil control ring When worn the tolerance must not exceed the specified maximum of 0 15 mm The piston ring gap should be checked with a feeler gauge via inserting the rings into the gauge Fig 2 35 with the bore equal to the piston ring nominal diameter 0 003 mm Use gauge 67 8125 9502 for the normal 82 mm rings The gap for all new piston rings should be within 0 25 to 0 45 mm The maximum permitted gap for worn rings is 1 mm Crankshaft and flywheel Design description Basic dimensions of the crankshaft are shown in Fig 2 36 Crankshaft is cast iron of five bearings The crankshaft journals can be reground during the engine overhaul when the diameter is reduced by 0 25 mm 0 5 mm 0 75 mm and 1mm
315. r trim 7 cover 8 door aperture seal 9 gas filled strut Front door lock adjustment To ensure a trouble free operation of the lock slacken the securing bolts and align the position of door striker housing 14 Fig 8 15 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 aperture Lower down the striker if the door goes up when closing door sagging in the open position When the door is difficult to open with inner handle 1 adjust the handle position accordingly To do this slacken the securing screws and move the handle and bracket to the optimum posi tion On completion tighten the securing screws Tailgate removal refitting and alignment The tailgate is hinged to the body two hinges 2 Fig 8 18 and is locked In the open the tailgate is held by two solid gas filled struts 9 Disconnect the struts from the door by removing the pins from the welded nuts Disconnect the wiper wiring and washer tube undo the nuts holding the door to the hinges and withdraw the door When refitting the door make appropriate alignments within the body aperture via the oval holes for the hinge studs then finally tighten the
316. rature 20 5 C After checking remove the shock absorber from the test bench overhaul or renew the components if necessary Repeat the tests to ensure the shock absorber efficiency Shock absorber dismantle and reassembly After washing fix the shock absorber in vice Note Special grips 67 7824 9513 001 are used to fasten the shock absorber and its components in vice Fully extend the shock absorber rod undo tank nut 29 see fig 4 18 with key A 57034 R take out from the tank the slave cylinder 21 in assembly with the rod and compression valve 2 Remove the tank from vice and drain liquid Using key 67 7824 9513 005 take out the rod guide bush 23 from the slave cylinder Take out from the cylinder rod 20 com plete with piston 10 and drain the liquid Carefully using a spe cial tool punch out from the cylinder the compression valve 2 housing in assembly with other components Place the rod in assembly with the piston in grips fix in vice and undo the recoil valve nut 8 Remove piston 10 with valves bypass and recoil rod guide bush 23 rod sealing 26 sealing race 25 and other components Note To facilitate the inspection of the rod in the front sus pension shock absorber it might be helpful to press off the cover from the rod To dismantle the compression valve first remove race 6 and then sequentially take out from case 2 spring 5 plate 7 and valve discs 4 and 3 The reassembly of the shock absorber is car
317. raw the seat complete with the adjuster mech anisms Refitting is a reversal of removal Rear seat Release catches 9 Fig 8 30 holding the seat back undo the bolts securing the seat cushion straps to the floor cross member then withdraw the seat Refitting is a reversal of removal Front seat rails dismantling and reassembly For dismantling remove the seats from the vehicle Raise handle 2 Fig 8 31 up move tracks 10 forward remove the front rest on the tracks move the tracks rearward until rollers 9 go out of end stop 7 withdraw the tracks To reassemble relocate the rollers with the stop into the slid er groove force the track fully forward and restore the rests mechanically Lower down handle 2 and u check the slides for smooth operation Heater unit Removal and refitting To remove the heater unit perform the following operations fully shift rightward knob 6 Fig 8 33 of heater tap 17 and drain coolant from the engine cooling system disconnect the battery negative lead undo the securing screws remove the facia shelf and radio panel disconnect the relevant wiring slacken the clips and detach the rubber hoses from heater supply return tubes 16 working from the engine bay side undo the two retaining bolts and remove the heater radiator pipe grommet loosen the bolt of tap outer cable retaining clamp then remove the cable from the tap remove the heater blower motor switch and dis
318. re 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 are paint marked on the connecting Fig 2 30 Marking on the piston and connecting rod 1 arrow on piston crown for orientation in cylinder 2 oversize 3 piston class 4 class of gudgeon pin hole 5 connecting rod class as to gudgeon pin hole 6 cylinder No rod The engine must always be fitted with the connecting rods of the same weight class The connecting rod weight can be adjust ed by removing excess metal from the bosses on the small end or big end up to the minimum size of 16 5 mm or 35 5 mm Fig 2 31 Fig 2 31 Locations of possible metal removal subject to adjusted con necting rod small end and big end weights 22 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 51943 A white 186 2 52513 B blue 53143 C red 51913 D black 19042 52543 E violet 53143 F green 519 3 G yellow 19442 52543 H brown 53143 orange Selecting piston to cylinder The design clearance between the piston and cylinder bore for new parts is 0 025 0 045 The condition must be ensured through prior measurements of the associated parts and fitting of the pistons whi
319. re factory treated with PVC plasticate Plastisol 1 11A of 1 1 5 mm thick ness over epoxy 9 083 primer Ta6nuua 8 1 Corrosion inhibitors for bodywork protection Description Grade Viscosity sec Solvent thinner Drying conditions at 20 C as per B3 4 Temperature C Time min Automotive sill rust inhibitor Mosunb Mosunb 2 15 40 white spirit petrol 20 20 30 Protective non drying grease HTM MJ1 45 white spirit 20 15 Protective skin HI 2165 18 22 white spirit petrol 20 20 Bitumen type sound proof sealant BMN 41 high viscosity ksylol solvent 100 110 30 PVC plasticate Plastisol 4 11A Detto 130 30 Plasticate Plastisol 4A Detto 130 30 Non drying sealant ST Detto 174 Fig 8 8 Underneath view of the body Inner cavities of 1 front chassis arms 2 front chassis arms connections 3 middle chassis arms 4 middle chassis arms connectors 5 rear floor cross member 6 rear chassis arms 7 rear end cross member When only the 1 11A plastisol coating is affected while the primer is intact scour any dirt from the relevant areas then on a dry surface apply bIIM 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 C within 30 minutes In the event of major damages of protective layers and dam aged primer clean of dirt and rust the area affected to the bare metal then apply 073 type pri
320. record the reading of az Define thickness S of the driving gear adjusting ring which is an algebraic difference between a and b Sza b Where a average arithmetic distance from the tool 1 face fig 3 64 to the differential bearing journals a a a 2 b deviation of the driving gear from the nominal position in terms of mm The size of deviation is marked on the driving gear fig 3 73 in hundredth of a millimeter with a plus or minus sign When finding the thickness of the adjusting ring pay attention to the b sign and unit of measurement Example We presume that size a determined by the indi cator is equal to 2 91 mm size a is always positive and on the driving gear after the serial number the deviation of 14 is shown To get size b in millimeters we multiply the specified size by 0 01 mm b 14 0 01 0 14 mm Determine the thickness of the driving gear adjusting ring in millimeters S a b 2 91 0 14 2 91 0 14 3 05 mm 91 M2 CO Fig 3 71 Defining the thickness of the drive gear shim 1 indicator 2 fixture A 95690 3 drive gear rear bearing 4 tool A 70184 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 ATTE
321. remove excessive electrolyte using an ebony tipped rubber bulb Battery charge level checking Always measure the battery charge with a hydrometer are ometer during servicing or in the event of the battery failed in operation At the same time measure the temperature in order to account for temperature correlation Table 7 3 of hydrometer readings Table 7 3 Temperature correction values to hydrometer readings for measuring electrolyte density Electrolyte temperature C Correction value g cm 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 C the correction value is added to actual hydrometer readings When electrolyte tem perature is below 20 C the correction value is subtracted The correction value is not applied when electrolyte temperature is within 20 to 30 C Once you have measured the electrolyte specific gravity in each battery cell determine the state of the battery charge using Table 7 4 Withdraw the battery from the vehicle for re charging when it is discharged in excess of 25 percent in winter time or 50 percent in summer time When measuring electrolyte density take care not to drip electrolyte on the battery cover case body or other parts Electrolyte contains hazardous sulfuric acid which causes corro sion current leaks etc Do not measure the electrolyte specific gravity in the follow
322. ressure regulator 8 Faulty pressure regulator in cylinder renew damaged com ponents if necessary 3 Renew or clean tube bleed sys tem 4 Adjust pressure 5 Adjust angles 6 Clean braking mechanism com ponents 7 Adjust position 8 Adjust or renew Excessive pedal effort at braking 1 Plugged air filter 2 Jammed servo unit valve hous ing 1 Renew air filter 2 Renew servo unit 3 Damaged hose between servo 3 Renew hose or tighten clips unit and engine inlet pipe or its loose fastening on connectors 4 Oxidation of brake pedal metal 4 Renew worn parts or greasing bushes or dry greasing in pedal bushes Scratch or squeal of brakes 1 Loose shoe return spring 2 Ovality of drums 3 Excessive oil on friction linings 4 Worn linings or trapped detri mental inclusions 5 Excessive disc runout or non uniform wear 1 Inspect return spring replace if necessary 2 Remachine brake drum 3 Clean pads using metal brush with warm water and washing liq uid Eliminate cause of liquid or lubricate ingress 4 Renew pads 5 Grind disc in case thickness is less than 9 mm renew Inspection and adjustment Pipelines and connections inspection To prevent any occasional failure of the braking system care fully inspect all pipelines metal pipelines should have no dents or cracks and should lie far from sharp edges that can damage them brake hoses should have no cracks on
323. rew 4 indicator bracket 5 retaining screw 6 driven gear EE w ES E Ex y ow a i S SS wi 2774 Sd Mea MN Fig 3 79 Checking the differential housing bearing preload D distance between two covers of the differential bearings 1 2 shims 94 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 will have to be dismantled to make the adjustments of the driving gear and replace the adjusting ring After reassembly repeat all operations on the driving gear roller bearings preload check the moment of resistance to rota tion the preload of the differential housing roller bearings and the adjustment of the final drive mesh side gap Replacing the driving gear sealing The necessity of seal replacement is determined by the drop of oil level in the rear axle casing due to oil leak through the sea ling to the level which might affect normal operation of the reduc tion gear Misting of the casing filler neck and even oil drops in the amount not exceeding the below norms do not indicate oil leak In case of heavy drop formation inspect the sealing put the veh
324. ried out in reverse sequence paying attention to the following after the reassembly of the compression valve ensure the free play of plate 7 and valve discs race 6 is press fitted on case 2 with special tool the compression valve is press fitted in the cylinder using tool 67 7824 9513 004 to facilitate the reassembly of components located on the rod use guide 67 7824 9513 003 the throttle disc 15 of the front shock absorber has two grooves on the outer diameter and the rear shock absorber throttle disc three the recoil valve nut is tightened with torque of 11 76 15 68 Nem 1 2 1 6 kgf m the tank nut is tightened with key 67 7824 9513 002 to torque 68 6 88 2 N m 7 9 kgf m Inspection of components Wash the metal components and dry wipe the rubber com ponents with clean cloth and wash in warm water Carefully inspect the components paying attention to the fol lowing the compression and feedback valve discs and the bypass valve plate should not be deformed the nonflatness of the bypass valve plate is allowed no more than 0 05 mm the working surfaces of the piston the piston ring the rod guide bush cylinder and the valve components should have no scuffings and dents that might affect normal operation of the shock absorber the recoil and compression valve springs should be tense enough and not damaged the compression valve discs should not be damaged and should have no significant
325. ring of the bearing is press fitted on the 5th reverse gear unit and the outer one in the rear cover socket the output shaft rear bearing is press fitted on the shaft to facilitate the installation of the rear cover the reverse idler gear 1 see fig 3 23 gear 3 and fork 4 are installed simultaneously when reassembling the gear switch lever apply grease JICLI 15 or JIMTOJT 24 on the ball or the cap of the ball socket the gear unit fastening bolt is tightened with torque to 78 Nem 7 8 kgf m when refitting the clutch housing with the transmission cas ing front cover the opening in the front cover should be located as shown on fig 3 15 grease the oil seals with IMTONI 24 before refitting use tools 41 7853 4028 41 7853 4032 41 7853 4039 to install the sealings and bearings Inspection Cleaning Before inspection carefully clean all gearbox com ponents Brush or scrape all deposits or residues clean the bores and splines then wash down to dissolve and remove all traces of oil Blow the parts with compressed air and carefully wipe them Especially carefully blow the bearings directing the air jet so that to exclude fast rotation of rings Gearbox casing and covers There should be no cracks on the casing and no wear or damage should be evident on the bearing housings Fig 3 31 Output shaft exploded view a 17 18 19 20 21 22232425 26 1 circli
326. rips tack the panel by gas welding in the locations arrowed in Fig 8 5 Weld the roof panel by resistance welding with a step of 40 50 mm and by electric COe arc welding or gas welding with a step of 50 60 mm over the earlier drilled holes of 5 6 mm diameter To avoid deformation start welding from the middle of the seam rightward and leftward Finish the seams with an electric or pneumatic grinding tool Paintwork Polishing To preserve paintwork and maintain it as long as possible select the polishers to suit the condition of the paintwork Strictly adhere to recommendations for application The basic maintenance routine for the bodywork within the first two or three months is just regular washing with cold water Over further three years move to non abrasive polishers for new coatings to restore the brilliance of shine After three to five years of vehicle operation use the auto motive polishers intended for weather affected paintwork which contain a small amount of abrasive After five years of intensive use select the polishers for aged paintwork To prevent the polisher drying off work on small areas buff ing them manually with a clean flannel cloth To rectify minor paintwork defects it is recommended to use polishing pastes of IMA 1 or IMA 2 type Hand pads or power tools with lambskin discs or flannel discs can be used for pol ishing Prior to use thoroughly mix the paste dilute it with water when thick Af
327. ription The headlight wiring diagram is shown in Fig 7 28 Turn signal self canceling device inoperative 1 Cancelling mechanism seized 2 Combination switch guide ring 1 Renew 3 stalk switch 2 Detto 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 briefly switched on by pulling combination switch 10 for light signalling By doing this stalk switch 10 terminal is energized directly from the power source bypassing the ignition switch Some vehicles are fitted with the hydraulic headlight adjuster to align the headlight beam depending on the vehicle load The external light wiring diagram is shown in Fig 7 29 The sidelights in the front and rear lights are operated by means of exterior light switch 3 Number plate lamp 6 instruments and switch illumination lamps sidelight warning lamp 5 are powered at the same time The wiring diagram for direction indicators hazard warning flashers is shown in Fig 7 30 The left hand and right hand direction indicators are operat ed with the help of steering column combination switch 10 When operated hazard flashing switch 9 activates all direc tion indicators Flashing is enabled by relay 8 Fault diagnosis Cause Lights do not com
328. rminal through a test bulb to the alternator terminal 30 while minus to one of the diode plate securing bolts Fig 7 8 Ill The illuminated bulb advises about a short circuit in one or more positive diodes Discontinuity in the diodes can be traced without dismantling the alternator either by means of an oscilloscope or a tester through a significant output current drop 20 to 30 percent against the specification If the alternator windings supplemen tary diodes or voltage regulator are sound whilst the diodes are not shorted the cause of the output current drop is discontinuity in the diodes Supplementary diodes testing To check the supplementary diodes for short circuit without removing and dismantling the alternator make connections as shown in Fig 7 9 Similarly to the diode checking disconnect the battery and alternator leads remove the alternator housing dis connect the lead to the voltage regulator terminal B Connect the battery positive post through a test bulb 1 3 watt 12 volts to the alternator terminal 61 while the negative post to one of the diode plate securing bolts 143 Fig 7 9 Checking the supplementary diodes 1 battery 2 warning light 3 alternator 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 supplementa
329. rojections arrowed for cover centering against crankshaft pulley hub 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 specified Fit the alternator and oil pump pulley then secure it with the nut Fit the oil filter complete with the gasket manually screw it to the union on the cylinder block Refit the crankcase vent oil sep arator breather cover and secure the oil separator drain pipe with the clip Fit oil pump 1 Fig 2 24 then fit the oil sump with the gasket Fit the coolant pump alternator bracket and alternator Fit the belt around the pulleys and adjust the belt tension Fit the heater matrix supply pipe and cooling water jacket out let pipe to the cylinder block Secure the heater matrix drain pipe to the coolant pump and outlet pipe Fit the instrumentation sensors Fit the oil pump distributor gear followed by the ignition dis tributor Insert the spark plugs place spanner 67 7812 9515 on the spark plugs and tighten the spark plugs with a torque wrench to the torques specified Fit the fuel pump as outlined in section Fuel system Fit the carburettor and reconnect the hoses Cover the car burettor with a prov
330. rojections of exposed panels or detachable parts against the adjoining panels must be properly realigned and readjusted 15 14 Fig 8 1 Bodywork panel 1 front bonnet reinforcement 2 bonnet panel 3 diagonal bonnet reinforcements 4 rear bonnet reinforcement 5 roof panel 6 rear end cross member 7 outer tailgate panel 8 inner tailgate panel 9 side panel 10 outer front door panel 11 inner door panel 12 door bar 13 front door extension 14 front wing 15 front Deformed surfaces repair The repair of any damaged body parts is carried out by means of stretching ding and dent straightening cutting out of irreparable areas making of maintenance patches from the body rejects or metal sheets by shaping them into a suitable part Deformed panels are restored as a rule manually with the help of specialized tools metal hammers plastic or wooden mal lets various mandrels and accessories Heating up is recommended to contract settle down heavily stretched panel surfaces Heat up to 600 650 C cherry red colour to prevent a sharp belling out of the panel or degrading of physical properties The heated area should not exceed 20 to 30 mm Contracting of surfaces is carried out as described below using a carbon electrode of a semi automatic welder or a gas burner heat up the metal sheet starting from outside to cen tre of the damaged area and restore the original shape by ham mering out
331. roken stator winding 142 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 test bulb and battery The wire insulation should show no signs of overheating caused by short circuit in the diode plate Always renew the stator with a damaged winding Finally using a special growler check the stator winding for internal short circuit Diodes testing A sound diode allows current only in one direction A faulty diode can either prohibit the current flow a broken circuit or allow it in both directions a short circuit The complete diode plate must be renewed if any diode is found damaged The diode plate can be checked for a short circuit with the alternator in the vehicle For this disconnect leads from the bat tery and alternator and remove the slip ring end housing Also the lead to the voltage regulator terminal B should be disconnect ed In case of the alternator with an old voltage regulator do not forget to disconnect the voltage regulator terminal b from the alternator terminal 30 An ohmmeter or a test bulb 1 5 watt 12 volts and battery can be used as shown in Fig 7 8 Note For easier diode fitting thr
332. rotate under its own weight It should turn under force of 9 8 19 6 N 1 2 kgf applied to its end If nut 4 was tightened too much undo it raise washer 6 and tighten again Fix the bracket on the chassis arm with self locking nuts and flat washers tighten them with dynamometer Connect the tie rod ballpins to the idler arm 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 1 Renew bad components of wheel cylinder wash and dry shoes and drums bleed braking mechanism 2 Expel air from system 3 Renew seals and bleed system 4 Renew hoses Spontaneous braking at working engine 1 Air inleak in servo unit between 1 Replace servo unit valve housing and protective cap Incomplete brake release on all wheels 1 No brake pedal free travel due to wrong position of stop signal switch 2 Projection of servo unit adjusting bolt in relation to fastening surface of master cylinder exceeds 1 25 mm 3 Jammed servo unit valve hous ing 4 Plugged compensation aperture in master cylinder 5 Swollen master cylinder rubber sealings due to penetration of petrol mineral oils and etc in liquid 6 Jammed mas
333. rs at start up and when wiper arms pass initial position Headlight wiper relay contacts Headlight washer motor 15 16A Cigarette lighter Pre 1996 vehicles were fitted with a voltmeter protected by fuse No2 instead of the relevant warning light in the instrument cluster In all wiring diagrams covered by chapter Electrical sys tem the letters are used to denote the respective colour code the first letter stays for the wire colour code while the second let ter for the tracer colour code Table 7 2 Table 7 2 Fuse colour codes Colour rc o 15 White Blue Yellow Green Brown Orange Red Pink Grey Black WARNING Always disconnect the battery negative lead when making repairs on the vehicles or its electrical system When replacing fuses or checking wiring never use fuses other than those specified for a particular vehicle model as it may damage current tracks in the fuse and relay box f OTAOAOKANND 135 4 Tt A zc ee et i HOT x Wein SE EE ER REPERI P t D auxiain t EPA Bee se eee eee BY TA p 3H Ba O ie Te sl ec CF e l 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
334. rsal of removal Check the position of the sealing grommet between the radi ator cowling and body ensure the rubber hoses securing straps are reliably tightened After the hoses have been refitted and reconnected fill the engine cooling system with coolant and check the connections for leaks 184 Heater unit dismantling and reassembly To dismantle the heater unit remove two spring clips 16 Fig 8 34 and remove the electric blower fan from shroud 4 Undo impeller securing nut 14 and detach it from motor 15 Undo clasp 8 nut holding the supply and return pipes remove the clasp and detach heater matrix 11 from housing 5 Undo the clip retaining nuts and lift off air intake cover 7 Undo the clip retaining nuts and remove air distributor cover 1 of the blower shroud The reassembly is a reversal of removal 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 fed to the intake manifold and further to the engine cylinders The fuel injection system and catalytic converter in the exhaust system help reduce exhaust emission and improve vehi cle performance This chapter provides a brief description of design features op
335. rthed check the fuel gauge To do this remove the instrument cluster disconnect the white wiring connector then with the igni tion switched on earth terminal 11 of the instrument cluster white connector through a resistor of 20 50 Ohm If the gauge is sound the needle moves If the needle always stays at the high end of scale check the gauge through disconnecting the instrument cluster white con nector If the gauge is sound the needle returns to the low end of scale with the ignition switched on Instruments checking Coolant temperature gauge The gauge is associated with a sender in the cylinder head At 700 Ohm the needle should be at the low end of the scale while at 77 89 Ohm it should stay at the beginning of the red area of scale Fuel gauge The gauge is coupled with a sender in the fuel tank The sender is used to operate the fuel reserve warning light when only 4 to 6 litres of petrol are left in the fuel tank The sender resistance of 238 262 Ohm corresponds to the empty reading 59 71 Ohm to the half filled tank reading nee dle is in the middle of the scale while 7 23 Ohm to the full reading mark 1 Speedometer Check the speedometer by rotating its drive shaft at various speeds The speedometer specification is shown in Table 7 6 Table 7 6 Speedometer checking data Drive shaft Speedometer speed rpm reading km h 500 31 35 1000 62 66 5 1500 93 98 2000 124 130 2500 155 161 5 Tachom
336. rvo unit bracket to the body front and remove the unit in assembly with the bracket Refitting of the servo unit is carried out in reverse order Master cylinder The design of the master cylinder is shown on fig 6 9 Removal and refitting Disconnect the flexible hoses from the master cylinder and close the openings of hoses and con nectors on the cylinder to prevent liquid leak from reservoir and penetration of dust dirt or foreign matters Undo the tube nuts and disconnect from the master cylinder the steel pipelines that are carrying liquid to wheel cylinders of front and rear brakes Remove the cylinder having undone the nuts that are fas tening it to the servo unit Refitting of the master cylinder is carried out in reverse sequence After refitting the cylinder bleed the hydraulic system to expel air Dismantle and reassembly Remove connectors 2 fig 6 10 with connecting bushes 3 turn out lock bolts 5 and take out all components in order specified on fig 6 10 The reassembly of the cylinder is carried out in reverse sequence Grease all components with brake liquid When reassembling use tool 67 7853 9543 Fig 6 10 Master cylinder components 1 oylinder body 2 connector 3 connector bush 4 sealing washer 5 lock bolt 6 9 sealing rings 7 rear brake front additional drive piston 8 distance ring 10 sealing ring holding spring 11 spring cup 12 piston return spring 13 wa
337. ry Alternator Starter motor Type Steering globoidal worm double crest roller steering ratio 16 4 three links relay rod and two steering rods drop arm idler arm and swing arms Braking system disc type floating caliper automatic disc to pad clearance adjustment drum type self applying shoes and automatic shoe to drum clearance adjustment foot type hydraulic dual circuit split diagonally vacuum servo unit and pressure regulator cable operated on rear wheels Electrical system single wire negative earth type 6CT 55A 55 ampere hour AC integral diode plate and electronic voltage regulator pre engaged solenoid switch and overrun clutch Body all steel unitary construction monocoque three door double space 5 LAX 4 Fig 1 1 Basic overall dimensions of VAZ 21213 vehicle 6 Section 2 Engine Refer to Fig 2 1 and Fig 2 2 for front and side sectional views of the engine oe NA ut e id HD WM SSY ex d NN SS SS ec Sa Sm 7 qo ie 7A ED ra em IL 1 BENE E m pl SSX NN d 5 y PA N UE SS SSS SSS SSSA pel fut WIES P em p ur cH NULL E Es ia LSS ETS S i MESSE TN Sf 7 as cy L qu Lil T z ESS h X CERRO EL NS H og i DEAN T NE Pm WY Lp Z fp ZU Q D
338. ry is non charged 1 Alternator drivebelt slipping 2 Voltage regulator damaged 3 Damaged diodes 4 Field winding diodes damaged 5 Stator winding broken shorted or earthed 1 Adjust belt tension 2 Renew voltage regulator 3 Renew diode plate 4 Renew diodes or diode plate 5 Replace alternator stator Warning light is on with engine running Battery is overcharged Voltage regulator damaged short Renew voltage regulator circuit between terminal LU and earth Alternator is noisy 1 Loose alternator pulley nut 2 Alternator bearings damaged 1 Tighten nut 2 Renew rear bearing or front cover with bearing 3 Stator winding shorted internally 3 Renew stator or to housing alternator howl 4 Short circuit in diode plate 5 Brush squeak 4 Renew diode plate 5 Clean brushes and slip rings with cotton cloth moistened in petrol WARNING Always earth the battery negative post to the bodyshell and connect the positive post to the alternator clip 30 If battery connections are erroneously reversed the alternator diodes will be damaged by resulting high voltage Never operate the alternator with the battery disconnect ed since this causes overvoltage peaks at the alternator ter minal 30 and can damage the voltage regulator or other elec tronic devices of the vehicle electrical system Never test the alternator for spark by earthing the alternator terminal 30 even for a short time The diodes
339. ry diodes can be detected with an oscilloscope through distortions in the voltage waveform across terminal 61 and also by low voltage below 14 volts across terminal 61 at a medium rate of the alternator rotor Voltage regulator testing The function of the voltage regulator is to continuously adjust the field current flow to the alternator so that the alternator volt age is maintained within the preset range at various speed load conditions of the alternator operation In vehicle test For this test you need a DC voltmeter with 15 30 volt scale and accuracy of at least 1 0 class Run the engine for 15 minutes at medium speeds with the headlights on measure the voltage between the alternator termi nal 30 and alternator earth The reading should be within 13 6 14 6 volts When battery undercharge or overcharge becomes repeti tive while the adjustable voltage falls outside the specification the voltage regulator must be renewed Off vehicle test For testing the voltage regulator removed from the alternator make the connections as shown in Fig 7 10 The pre 1996 voltage regulator should be tested complete with the brush holder Fig 7 10 b since at the same time you can detect a broken brush connection or a poor contact between the voltage regulator terminals and brush holder Connect a test lamp of 1 3 watt 12 volts across the brush ter minals The terminals B b when available and earth ter minal should be con
340. s and separators to sat urate well in electrolyte Then check the battery voltage without loads The battery is ready for use when its voltage reading is at least 12 5 volts At values below 12 5 volts but over 10 5 volts the battery should be recharged to the output voltage which is spec ified by the manufacturer The battery is rejected when the volt age is equal or below 10 5 volts The saturation of internal plates and separators normally results in a lower electrolyte level Therefore top up the battery with electrolyte of the original specific gravity before refitting it to the vehicle Always re charge the battery after it is filled with electrolyte in the event the battery will be initially operated in heavy duty conditions in cold weather at frequent engine starts etc the battery has been stored for over 12 months from the date of manufacture Electrolyte level checking Electrolyte level in all battery cells must be maintained between the MIN MAX marks on the translucent battery case Never try to use the battery with the electrolyte level below the MIN mark In the course of vehicle operation the electrolyte level gradu ally decreases due to water evaporation Only distilled water should be used to top up the battery If spillage is suspected to be the cause for low electrolyte level always add electrolyte of the same specific gravity as that remaining in the battery cell When overfilled
341. s 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 flywheel securing bolts 4 Excessive main bearing running clearance 5 Excessive thrust washers to crankshaft clearance 1 Adjust ignition timing 2 Refer to subsection Insufficient oil pressure at idle 3 Tighten bolts to torque specified 4 Grind journals and renew bearing shells 5 Fit new thrust washers check clearance Big end bearing knocking Big end bearing knocking is sharper than that of main bearings It is noticeable during engine idle at sudden throttle opening The origin of knocking can be easily identified through switching off spark plugs one at a time 1 Insufficient oil pressure 2 Excessive big end bearing running clearance 1 Refer to Insufficient oil pressure at idle 2 Fit new bearing shells and regrind journals Piston slap Thumping noise caused by piston runout in cylinder Most noticeable at low crankshaft speed and under load 1 Excessive piston to cylinder bore clearance 2 Excessive gudgeon pin to piston groove clearance 1 Renew pistons rebore and hone cylinders 2 Fit new rings or new pistons with rings Knocking of intake or exhaust valves Excessive valve clearances cause typical regular noise its frequency is lower than the frequency
342. sembly from the joint housing 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 fig 3 83 The high quality of dismantling reassem bly works is provided with observance of below instructions Mark with paint the mutual arrangement of the race cage and the joint housing Fix the outer joint in vice as shown on fig 3 84 Incline the race and cage so that one ball will go out from the groove in the case of the joint as far as possible Using a screw driver made of soft metal push the ball out from the cage Then turn all components so that the next ball will occupy the same position and take it out from the cage Using the above proce dure take out other balls The sequence of removing the balls from the cage can be different every other ball Slight tapping on the cage or race with a tool made of soft material is allowed No excessive effort when turning the cage is admissible as the balls may be blocked what will complicate the further dismantle Place the cage race unit so that the elongated apertures of the cage are situated against the ledges of the joint case see fig 3 85 and take out the cage in assembly with the race
343. sher 14 front brake drive piston 127 Fig 6 11 Checking the leak proofness of the master cylinder 1 test bench bleeding valve 2 manometer 3 reservoir 4 master cylinder 5 flywheel 6 pushrod shift indicator 7 vent 8 vessel 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 subsequent drying by com pressed air The cylinder mirror and working surfaces of pistons should be completely clean without rust marks and other defects No excessive gap between the cylinder and pistons is allowed Every time when dismantling the cylinder renew the seal ings even if they are in good condition Check the piston spring tension the length of which should be 41 7 mm under load of 42 18 3 92 N 4 3 0 4 kgf 21 mm under load of 90 64 8 83 N 9 24 0 9 kgf in free state 59 7 mm Master cylinder leak proofness check Place the master cylinder on a test bench and connect it to the bench elements as shown on fig 6 11 Open the bench bleeding valves 1 and by moving the mas ter cylinder piston several times by its full stroke bleed the sys tem Then close valves 1 Rotate flywheel 5 slowly move the ma
344. ssembly turn the inner gear by hand to check the gears are running smoothly without jerks or Seizures Inspection After dismantling wash all components in kero sine or petrol blow dry with compressed air then check the pump 40 housing and cover for cracks renew when applicable Using feeler blades check the backlash in the gears and the radial play Fig 2 70 to be respectfully 0 15 mm maximum per missible value is 0 25 mm and 0 11 0 18 mm maximum permis sible value is 0 25 mm If the tolerances are exceeded then the gears or pump housing should be renewed Using a feeler gauge and a straight edge Fig 2 71 check the axial clearance to be 0 066 0 161 mm maximum permissible value is 0 20 mm When the clearance is over 0 20 mm renew the gears or pump housing whichever is worn out Having taken the measurements determine the clearance between the outer gear and its axle to be 0 017 0 057 mm maxi mum permissible value is 0 10 mm and the clearance between the oil pump shaft and the housing bore to be 0 016 0 055 mm maxi mum permissible value is 0 10 mm Renew any worn parts when the tolerances exceed the values specified Checking the pressure relief valve Always inspect the pressure relief valve during the oil pump repair Draw special attention to the valve surfaces and bores in the intake manifold assembly since possible contamination or sediments on the mat ing surfaces can result in the valve seizures
345. ssembly in the casing previously hav ing fit the sealings on the pins Tighten the fastening nuts of the joint bearing covers Front wheel drive Torque from the front axle is transferred to the front wheels through the right and left drives each consisting of shaft 4 fig 3 82 and two CV joints The joints are mounted on the ends of shaft 4 The outer joint is connected with the front wheel hub it is of a rigid type with angular degree of freedom The inner joint is of universal type with an angular and axial degree of freedom It is connected with the front axle shaft gear The outer joint consists of case 13 race 11 cage 8 with balls 10 lock ring 12 and thrust ring 7 Race 11 is connected with case 13 through balls which come into race grooves made on the radius and in the case grooves The race is fixed on shaft 4 splines against ring 7 and is secured by circlip 12 In compressed 97 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 grooves differs the design of the inner joint from the outer one The axial movement of components in the case is limited by circlip 2 The components of the inner joint and separate sets of the ou
346. ssure of 0 05 MPA 0 5 kgf cm as read by the pressure gauge 4 Ensure that pressure holds steady for 5 minutes Repeat sim ilar test at liquid pressure of 0 1 0 2 0 3 0 4 0 5 MPA 1 2 3 4 5 kgf cm 132 Reduce pressure and connect a high pressure manometer 5 Ensure that pressure holds steady for 5 minutes repeat similar test at liquid pressure of 5 10 15 MPA 50 100 150 kgf cm There should be no pressure decrease due to liquid leak through sealing elements pipeline connections bleeding con nectors or through casting pores An insignificant reduction of pressure no more than 0 5 MPA 5 kgf cm during 5 minutes is permissible especially at high pressure due to shrinkage of sealings Rear brake pressure regulator Removal and refitting Disconnect arm 12 fig 6 22 from tie rod 7 and holder 18 from bracket 14 and shackle that is fas tening the pipelines going to the pressure regulator Disconnect the components of muffler mounting from the body and move the pipeline with the mufflers aside Undo the bolts fastening the regulator on the bracket and the bracket on the car body remove the regulator bracket and then having lowered the regulator downward disconnect the pipelines Fig 6 21 Checking the rear brake wheel cylinders 1 piston rests 2 cylinder under check 3 cylinder bracket 4 low pressure manometer 5 high pressure manometer 6 cylinder for building up
347. ster cylinder pistons until pressure monitored by manometer 2 will reach 12 5 MPA 125 kgf cm In this position block the mas ter cylinder push rod Specified pressure should remain constant for no less than 5 seconds In case of liquid leaks or drop of established pressure during 5 seconds renew the cylinder piston sealings Front brakes The design of the front brake is shown on fig 6 12 Before repairing the brakes carefully wash them in warm water with washing liquids and immediately dry with a jet of com pressed air 128 Fig 6 12 Front wheel brake system 1 cylinder block 2 brake pads 3 caliper clamping lever 4 splash guard 5 clamping lever shaft 6 carrier 7 caliper 8 brake disc 9 bleeders 10 brake hoses ATTENTION Do not use petrol diesel fuel trichloroeth ylene or any other mineral solvents to clean the brakes as these materials damage the cylinder sealings Removal and refitting Removal Lift the front part of the vehicle place it on supports and remove the wheel Remove the hose guide brackets Undo the bypass bolts dis connect from the cylinder block hoses 10 see fig 6 12 avoid penetration of dirt into the cylinder cavities Plug the openings of the cylinder block and hoses Unbend the edges of the front brake splash guard undo the bolt fastening the brake to the steering knuckle fig 6 13 and remove the brake assembly The refitting of the front brak
348. supporting the gearbox from below Place a jack or other suitable support under the transmission cas ing Using a socket spanner A 55035 undo the fastening bolts and remove the gearbox together with the clutch bellhousing by moving it to the rear part of the vehicle so that to take out the gearbox input shaft from the front bearing and from the clutch disc hub ATTENTION So that not to deform the clutch straps do not rest the end of the input shaft on the clutch diaphragm spring flange when removing or refitting the gearbox Refitting the gearbox is a reversal of removal Before refit ting apply a thin layer of greasing JICU 15 JIMTOJT 24 on the spline end of the input shaft and centralize the clutch disc using tool A 70081 see fig 3 4 5 o Ge ah ox Ne z A A P SNE 57 56 55 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 circlip 14 baulk ring 15 synchro unit spring 16 3rd speed synchro unit crown and gear 17 2nd speed synchro unit crown and gear 18 output shaft 19 1st speed synchro unit crown and gear 20 1st gear bush 21 output shaft idler bearing 22 idler bearing lock plat
349. sure regulator and electric fuel pump for satisfactory operation Relief the pressure in the fuel line as described earlier for removal of the central injection unit Reconnect the wiring plug to the fuel pump Disconnect the fuel pipe from the fuel supply pipe union of the central injection unit then using a T piece connect a pressure gauge between the pipe union and fuel pipe Turn the ignition key to the position Ignition Check the pressure gauge is functional check its connection shows no leaks The pressure should be within 190 210 kPa When there is no pressure listen to hear the fuel pump cuts in when the ignition key is turned to the position Ignition the pump operation and its relay clicks can be distinctly heard in the passenger compartment Should the fuel pump fails to operate check the pump circuit After two seconds of operation the fuel pump shuts off as no 187 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 and instead goes down operate the fuel pump and immediately after its stop pinch the hose that supplies fuel to the central injection unit If no pressure drop is evident check the fuel line for l
350. sured as a difference between the maximum measured diameter of plunger 5 and min imum measured diameter of housing 1 The tensioner housing and plunger make a unit where no replacement of either part is allowed once the clearance has been selected Plunger 5 should easily stroke within housing 1 up to 16 mm Fig 9 9 Removing the fuel system components 1 intake manifold 2 injector 3 bolt 4 fuel fail 5 fuel pressure regulator 6 vacuum hose 7 gasket 8 receiver unit 192 Wy SSIES NG CALLE A LW SS 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 qud f 42 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 shaft sprocket 8 crankshaft sprocket 193 SS SS SS 3 FIM CT SSS 4 m Pc DLE j SS E m JG e a Vd 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 B working cavity C locating slot 1 hole E reserve cavity Fig 9 13 Cooling system 1 radiator pad 2 radiator return
351. system as described in the procedure for removing the central injection unit Disconnect the fuel pipes from the fuel pump and undo the nuts holding it to the fuel tank Withdraw the fuel pump unit from the fuel tank Refitting is a reversal of the removal procedure The electric pump cannot be dismantled or repaired In case of failure always replace it with a new one 188 Evaporative emission control system Examine the hoses and charcoal canister If the housing is found cracked or damaged renew the charcoal canister If leakage is evident check the hose connections for tight ness Renew a leaking canister Electrical equipment Refer to Fig 9 5 for electric wiring diagram that is comple mented with the injection wiring harness routed between the injection electronic control unit ECU and various sensors and injection system actuators Through a separate connector three wires of the injection wiring harness are linked to the low tension LT input of the tachometer in the instrument cluster to the CHECK ENGINE lamp and terminal 15 of the ignition switch There are five fuses in the injection wiring harness Fuse 16 50 amperes is housed separately It protects the intake manifold preheater The remaining four fuses 15 amperes each are located in a separate fusebox 17 on the left hand side under the facia console Refer to Table 9 1 for detailed information on the circuits fused Table 9 1 I
352. t ambient air of 20 30 C full load and 80 km h not greater C isssisssssssssssss I tenet ee eeenaes 95 Minimum dle TpiT 2 sache tie staan Mestad Ahad ee Lue AINE eee debates Ba ees Bobet Les A 750 800 Oil pressure in engine lubrication system oil temperature of 85 C and crankshaft speed of 5400 rpm MPa kgf cm 0 0 0c ccc cece e 0 35 0 45 3 5 4 5 Coolant level in expansion tank cold engine n u nan eee eH 3 4 cm above MIN mark Alternator drivebelt deflection at 98 N 10 kgf mm ssssssssssseem m 10 15 Electrode gap mm carburettor erigirig canes i poe preda hea Sheed red bee bade Pad ede pu eeu elg ud DOREM e RR Yd 0 7 0 8 INJECTIONS ONGINGS 3 3 nib rotos ut ss ils eR NER QUI St ttd Secus toos DOE DS 1 00 1 13 Initial ignition timing BTDC degrees OT TRON TUL S cire eal Auer uM LE MEUM tai aduM io dece im cou 1H 939 RON 95 RON TUel es sae tie totos om a nan td tated eens mee Cau I pale UN A na det Aunt LE 3 1 Clutch pedal fr amp e play miii o creo dep odes Chee ah al Nera wde Sue a ON IM oe ent a 25 35 Brake pedal free play engine stalled MM 6 ect teen dette teen ene eees 3 5 Steering wheel play vehicle in straight ahead position not greater degrees MM 00 cece eee eee eed 5 18 20 Front wheel toe in run in vehicle at 3140 N 320 kgf MM teeta 2 4 Front wheel camber run in wheel at 3140 N 320 kgf degrees MM 0 eee cece eee teed 0 30 20 1 5 Castor r
353. t holes then move the engine forward in order to release the input shaft from the bear ing in the crankshaft flange Fig 2 3 Engine mounting unit 1 right hand support bracket with rubber 2 left hand support bracket 3 mounting rubber 4 cross piece rear mounting 5 bracket with rear mounting 12 Fig 2 4 Removing the oil filter using tool A 60312 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 connection the input shaft must precisely engage the clutch disc splines Furthermore for perfect engine transfer box centering the centering washers of the front engine mounting rubbers must be in the respective side brackets holes Engine dismantling Flush the engine mount it on a stand for dismantling and drain the oil sump Remove the carburettor for that disconnect the hoses and throttle operating rod Remove the fuel pump and ignition distributor Use spanner 67 7812 9514 to unscrew the spark plugs and coolant tempera ture sensor Remove the alternator and water pump drivebelt Remove the alternator and its retaining bracket On the pump and exhaust manifold disconnect the coola
354. t system The vehicle VAZ 21215 10 is fit ted with an antitheft system of relay type ATIC 2P The antitheft system includes control module 1 Fig 9 29 system state indication LED 2 and code key fobs 3 The theft deterrent system represents an electronic control module which allows in case of unauthorized use to inhibit the engine start through disconnecting the relevant electrical circuits Refer to Fig 9 30 for the wiring diagram of theft deterrent sys tem The installation of the antitheft system brought alterations in operation of direction indicators and hazard flashers Fig 9 31 windscreen wipe wash Fig 9 32 rear window wipe wash and heating Fig 9 33 203 Fig 9 26 Wiring diagram for alternator 1 battery 2 alternator 3 instrument cluster 4 digital tachometer 5 resistor 50 Ohm 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 battery 3 alternator 4 ignition relay 5 control module theft deterrent system 6 ignition switch 204 Fig 9 28 Wiring diagram for Engine Management System 1 glow plug control module 2 glow plugs 3 EGR valve 4 fuel pump 5 battery 6 ignition switch 7 breaker 8 thermoswitch 9 relay EGR valve 10 relay thermoswitch 11 glow plug warning light Fig 9
355. t which the sepa rated flanges will be on one level parallel and with minimum clearances between them the transfer box shafts should be par allel with the car body bottom the formed gap between the floor and the support should be filled with a sufficient amount of shims aign the flange centering oolars wihhout tensioning the supports of the transfer box andthe engine and while keeping the transfer box inthis place tighten the earier sackened Support nus 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 and slacken the flange fastening nuts on the input shaft and on the front and rear axle shafts Undo the fastening nuts and remove the front axle casing 1 fig 3 39 in assembly with cover 2 lever fork differential lock coupling and the front axle shaft Remove the speedometer drive unit housing 3 in assembly with the speedometer driven gear After removing lock washer 8 see fig 3 36 take out lever shaft 10 and remove differential locking lever 11 Then remove cover 7 from the front axle drive and take out the detent spring and ball 19 Undo clamping bolt 3 from the differential lock fork take out rod 6 fork 1 and lockin
356. talyst of 3 4 96 of the primer weight The ready mixture with catalyst should be consumed within 7 hours The primer viscosity should be 23 25 cs by the viscosimeter B3 4 Thin the primer with thinner P3 11B or ksylol Allow the bodywork cool down proceed with wet sanding using the abrasive paper of 55C 4 M type flush with water blow with compressed air and allow to dry Any irregularities remained can now be filled carefully applying filler paste dry the body and smooth down the areas with the abra sive paper of 55C 4 M type Wash the body and blow dry with com pressed air Mask off the surrounding areas from overspray with thick paper and masking tape then place the vehicle body into the paint booth Degrease the surfaces to be painted with white spirit Using a spray gun apply two coats of paint MJ1 197 or MJI 1195 type at 7 10 minute interval on inner surfaces of the pas senger compartment door apertures engine bay luggage com partment Apply three colour paint coats on the outside body surfaces at 7 to 10 minute intervals Allow to dry at 90 C within an hour and cool down at ambient environment Before application add 10 catalyst of 1T Y 70 type into the paint For paints of MJT 197 type it is permitted to use 20 male ic anhydride in ethylacetate The paint viscosity should be 20 cs when measured by the viscosimeter B3 4 It is advisable to thin paint with thinner of P 197 type It is recommended to use CM 7 t
357. tap fails to shut off water flow 2 Renew tap Air to interior compartment is not heated Heater tap inoperative due to faulty tap cable drive Faulty heater tap Insufficient air Inoperative air intake cover cable drive cover closed 1 Check cable operation secure outer cable renew cable if applicable 2 Renew tap inflow to interior Check cable operation secure outer cable renew cable when applicable 168 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 sizes for inspection are shown in Fig 8 4 The bodywork damages can vary greatly thus demanding specific remedial actions in each particular case Maximum use of panel ding and dent is recommended Where applicable avoid heat treatment of metal to preserve the factory welding and body work rustproof protection The exposed body panel should be lift ed off only when it is absolutely necessary in order to locate the damaged area to straighten or align the bodywork In the event of major body damage it is advisable to remove all interior trim to facilitate measurement examination or fitting of hydraulic and screw jacks to rectify any crosslays or damages All p
358. tate the crankshaft two turns clockwise Tension checking tighten the retaining bolts and refit the flywheel retainer loosen bolt 4 and nut 2 to spread tension over the belt tighten bolt 4 and nut 2 to 18 Nem refit the crankshaft pulley coat bolt 20 with Loctite 243 fix the flywheel with tool OUT0000049 refit the pulley retaining bolt torque to 40 Nem turn to fur ther 60 refit bottom cover 3 Fig 9 21 tighten bolts 1 to 15 Nem refit cover 5 tighten bolts 4 to 15 Nem tighten right hand cover 6 bolt 7 to 10 Nem Note When you fail to refit any securing bolt or a retainer repeat the complete procedure for the cambelt refitting Alternator removal and refitting Removal Loosen tensioner 2 bolt and bolt 9 Fig 9 23 Tighten bolt 8 until it comes against the limiter Remove the belt CHECK to see pulley 4 rotates easily without seizures Fig 9 23 Removing and refitting the alternator drive belt 1 crankshaft pulley 2 tensioner pulley 3 alternator 4 alternator pulley 5 nut 6 alternator drivebelt 7 vacuum pump pulley 8 tensioner bolt 9 ten sioner fixing bolt 201 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 un
359. tch turn lights headlights and wipers on the column Refit the steering wheel on the shaft so that the spokes are located horizontally The steering wheel should rotate smoothly and easily in both directions then tighten the steering wheel fas 117 Fig 5 5 Steering mechanism exploded view 1 steering box 2 drop arm 3 box cover lower 4 shims 5 worm shaft bearing ring outer 6 race with balls 7 drop arm shaft 8 adjusting screw 9 adjusting plate 10 lockwasher 11 worm shaft 12 top cover 13 gas ket 14 pitman shaft bush 15 worm shaft oil seal 16 pitman shaft oil seal LILLE 7 gt Fig 5 7 Removing the outer ring of the worm upper bearing using tool 67 7853 9541 1 steering box 2 worm upper bearing ring outer 3 tool 67 7853 9541 Fig 5 6 Removing the drop arm 1 remover A 47043 2 drop arm shaft 3 drop arm 4 bracket A 74076 R 118 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 shaft shroud and fasten them with screws Apply a thin layer of greasing on the lower contact ring and refit the horn push pad trim
360. tch contact unit 7 Check leads and connections battery starter cut in relay starter solenoid terminal 50 8 Remove solenoid check arma ture for smooth slide No or slow armature rotation solenoid inoperative 1 Battery defective or fully dis charged 2 Battery posts and lead clamps severely corroded ends loose 3 Loose end of cable from power plant to body or between power plant to battery minus post 4 Solenoid terminal bolts oxidized or terminal bolt wire end retaining nuts loose 5 Commutator burnt brushes Sticking or worn 6 Stator winding or armature bro ken or shorted 7 Positive brush holder earthed 1 Renew or charge battery 2 Clean battery posts and wire ends tighten and apply a coat of petroleum jelly 3 Tighten cable end fasteners 4 Clean terminal bolts tighten lead retaining nuts 5 Clean commutator renew brush es 6 Renew stator or armature 7 Eliminate shock circuit or renew commutator end cover Solenoid repetitive cutting in and out 1 Battery discharged 1 Recharge battery 2 Excessive voltage drop in sole 2 Check leads and connections noid power circuit caused by between battery and solenoid ter badly oxidized lead ends minal 50 3 Solenoid holding winding bro 3 Renew solenoid ken or shorted Starter motor armature rotates flywheel inoperative 1 Overrun clutch slipping 2 Clutch operating lever broken or pivot shaft dropped 3 One
361. ted into direct current in diode plate 2 fitted to hous ing 1 Electronic voltage regulator 12 is integral with the brush holder and is also attached to housing 1 The alternator wiring diagram is shown in Fig 7 4 When the ignition is switched on the voltage for the alternator actuation is applied to the regulator terminal B alternator terminal 61 via warning light 6 in instrument cluster 3 Once the engine is start ed the current to the field winding is supplied from three supple mentary diodes in the alternator diode plate The alternator operation is checked via warning light 6 in the instrument cluster The light comes on when the ignition is Switched on and goes out after the engine has been started when the alternator is good Bright or dim light of the warning lamp indicates faults Before 1995 an electronic voltmeter in the instrument cluster was used to control voltage in the vehicle electrical system With correct voltage the voltmeter LED did not light up In case of over voltage the LED started flashing while in case of undervoltage the LED stayed steadily Starting from 1996 an alternative voltage regulator and brush holder are used Now the voltage regulator is located in the metal housing and is riveted to the brush holder Fig 7 10 a making a unit The new voltage regulator has no terminal b so voltage is supplied only to terminal B Both the earlier and new voltage regulators are similar and are inter
362. ter cylinder piston 1 Adjust switch position 2 Adjust bolt position see fig 6 2 3 Replace servo unit 4 Clean aperture and bleed system 5 Carefully wash system with brake liquid renew damaged rub ber parts bleed system 6 Check and replace if necessary master cylinder bleed system Snubbing of one wheel at released brake pedal 1 Loose or damaged return spring of rare brake shoes 2 Jammed piston in wheel cylin der due to corrosion 3 Swollen wheel cylinder sealing due to penetration of fuels and lubricants in liquid 4 No gap between shoes and drum 5 Wrong position of caliper in relation to brake disc due to loose bolts that are fastening carrier to steering knuckle 6 Excessive runout of brake disc more than 0 15 mm 1 Renew spring 2 Dismantle cylinder clean and wash all components renew dam aged parts 3 Renew rings wash system with brake liquid 4 Adjust parking brake 5 Tighten securing bolts renew damaged parts if necessary 6 Grind disc in case thickness is less than 9 mm renew Vehicle wandering or skidding at braking 1 Leak of brake liquid in one of 1 Renew seals and bleed system wheel cylinders 2 Jammed piston in brake wheel 2 Check and rectify piston sticking cylinder 3 Clogged tube due to dent or contamination 4 Different pressure in tyres 5 Wrong wheel alignment angles 6 Dirty or oily discs drums and lin ings 7 Wrong adjustment of p
363. ter joints are sorted according to their sizes into different assembly groups therefore do not replace only part of the joint during repair The joint should be replaced in assembly Only shroud 5 and boot 6 clips 9 clamp 3 and circlip 2 can be replaced separately Fault diagnosis Diagnosis Remedy Noise knock from the front axle at vehicle movement especially at cornering 1 Worn components in outer or 1 Replace damaged or worn joints inner joints 2 Deformed wheel drive shafts 2 Straighten or replace shafts Cil leak 1 Damaged or broken protective 1 Renew greasing in joint and boot cover of inner or outer joint In case of wear or damage replace joint assembly Removal and refitting Removal Place the vehicle on a lift or over an inspection pit set the handbrake and do the following from both sides of the vehicle raise the front part of the vehicle and put it on supports disconnect the shock absorber from the suspension lower arm remove the suspension spring and disconnect the balljoint from the lower arm remove the wheel hub cap and undo the wheel hub bearing nut then unscrew the fastening nut of the inner joint housing bearing cover undo the fastening bolt of the front axle suspension right arm remove the outer and inner joints from the wheel hub and from the front axle The refitting of the front wheel drive is carried out in reverse sequence When tightening the
364. ter mounting bracket 2 clip 3 clutch pedal servo spring 4 clutch pedal return spring 5 clutch pedal limiter bolt 6 clutch pedal 7 pushrod 8 protective cap 9 circlip 10 pushrod piston 11 sealing ring 12 master cylinder piston 13 inlet port 14 sealing ring ring valve 15 piston bypass orifice 16 cylinder cavity 17 piston return spring 18 gasket 19 plug 20 master cylinder body 21 bypass compensation port 22 gasket 23 union 24 washer 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 necessary put a hose on bleeder 9 see fig 3 3 of the slave cylinder and place its lower end into a container with hydrodrive liquid 30 90 gr undo bleeder 9 by 1 2 3 4 turn several times rapidly depress and smoothly release the pedal until there will be no air bubbles coming out from the hose depress the pedal and fully tighten the bleeder Remove the hose and refit the bleeder cap If despite a continuos bleeding there are still air bubbles in the hose check the tightness of connections find out if there are cracks on tubes or leaks in places of connections Air inleak is possible through
365. ter polishing wipe the surface clean with flannel Respraying with acrylic paints Using plenty of water and a putty knife or a brush rub down any loose paint from the affected areas Use abrasive paper 68C 8 M or 55C 4 1 for wet sanding of the surfaces to be painted In case of a thin coating and no evi dence of mechanical damages sand the repair area down to the factory primer layer In the event of severe corrosion or earlier applied nitric paints strip down the areas to the bare metal Wash the body with water blow dry with compressed air Degrease the painted surfaces with white spirit or petrol sol vent BP 1 and apply bodystopper paste like Plastisol 1 4A 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 D 073 or BJ1 023 over the areas rubbed down to the bare metal Allow five minutes The primer viscosity should be 22 24 cs at 20 C when measured with the viscosimeter B3 4 Use ksylol for thinning Using a spray gun apply primer 31 0228 over the surfaces coated with the base coat 073 or BJ1 023 and over the renewed body parts Dry off at 90 C within 60 minutes Prior to spraying to primer 311 0228 add HO 1 type siccative of 6 8 96 or MTT 75 type ca
366. thdraw the bonnet disconnect wiring from the battery and electrical units fitted to the vehicle Remove the battery and underbonnet lamp Drain fluid form the cooling system and heater to do this unplug the expansion tank undo the drain plugs on the radiator underneath left hand side and on the cylinder block left hand side Fig 9 17 Engine general view 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 cleaner cover complete with the gasket extract the filter element Undo four nuts which hold the air cleaner housing to the intake pipe and withdraw the air cleaner housing and gasket Disconnect the fuel delivery and return hoses from the high pressure fuel pump Using a box spanner undo the nuts retaining the front exhaust pipe to the exhaust manifold Using a flat screwdriver release the ball end and disconnect the fuel delivery operating cable from the high pressure pump Undo the retaining screw and release the end piece then dis connect the cable from the timing advance lever Remove the transmission working as described in section Gearbox in the Repair Manual Hoist the cross piece TCO 3 379 and lock
367. the principle of measuring the voltage pulse frequency in the alter nator field winding The tachometer is checked on a test bench simulating the vehicle ignition system Connect the tachometer as applicable apply 14 volts to the primary circuit and set the spark gap at 7 mm Turn the ignition distributor shaft at such a speed to bring the tachometer needle to one of main scale divisions At this moment the ignition distributor shaft speed should be within the permissible limits Refer to Table 9 5 Table 9 5 Tachometer specification Tachometer Ignition distributor reading rpm shaft speed rpm 1000 900 1100 2000 1900 2250 3000 2950 3300 4000 3950 4300 Fuel level sender checking With an empty tank the sen sor resistance should be 250110 Ohm with a half filled tank 66 6 Ohm with a full tank 20 2 Ohm Fig 9 37 Steering components 1 steering mechanism 2 seal 3 middle shaft 4 upper steering column shroud 5 steering wheel 6 bracket 7 lower steering column shroud 8 clamp bolt universal joint 9 securing bolts steering mechanism 10 chas sis arm 11 drop arm 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
368. the bearing on the differential housing 1 tool 67 7853 9558 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 remove brackets assembly The reassembly of the transfer box is carried out in reverse sequence Pay attention to the following reassemble the interaxial differential having matched the marks on its cases so that not to disturb the balance of this unit the spring washer on the differential pinion shaft should be placed from the blind hole side on the shaft end face the axial gap of each axle drive gear should be 0 0 10 mm and the gear moment of resistance to rotation should not exceed 14 7 Nem 1 5 kgfem If the gap is greater renew the support washers with those having bigger thickness if this will not help to obtain the specified gap renew the gears because of their exces Sive wear drive and layshafts are installed in the transfer box casing simultaneously see fig 3 44 bearings are press fitted on the differential casing with tool 67 7853 9558 see fig 3 45 the working surfaces of oil seals are greased with JINTOJI 24 before their refitting in the covers and casings threaded connections
369. the engine on the right hand side at the clamp fitted to the front exhaust manifold securing stud while on the left hand side at the hole for clutch housing fastening Slightly tighten the hoist chain undo the nuts securing engine mounting rubbers 2 Fig 9 19 to the front sus pension cross member and lift the engine out Remove the heat shield of the starter motor and withdraw the starter motor Undo the clutch retaining bolts and withdraw the clutch Refitting the engine is carried out as follows refit the cooling hoses connectors and clamps check the radiator for deposits leaks damages check the radiator cooling fan operation check the radiator cap seal and valve fit a new air cleaner and fuel filter elements refill the engine with oil adjust the controls eliminate air pockets and refill the cooling system start and warm up the engine adjust idle speed check the lubricating and cooling systems for leaks Draw special attention to the engine transmission connec tion the input shaft must fully engage the splines of the clutch disc Fig 9 18 Air cleaner 7 1 mounting rubber 2 bracket 3 air cleaner 4 clasp 5 air duct 6 cold air intake 7 crankcase emission hose 199 Fig 9 19 Engine support 1 left hand bracket retaining pin 2 engine mounting rubber 3 right hand bracket rubber assembly 4 bracket with rear engine support mounti
370. the front suspension upper arm shaft and replace the washers from one bolt to the other one until a normal reading of the angle will be obtained The caster angle increases at rearrangement of washers from the rear bolt to the front one and decreases at reverse swapping tighten the nuts with a torque wrench and check the caster angle 104 Fig 4 2 Inspection of the front suspension arm silent block 1 rubber bush 2 outer bush 3 shaft securing nut 4 suspension arm shaft 5 thrust washer 6 inner bush Fig 4 3 On vehicle check of the clearance in the suspension upper balljoint 1 upper control arm 2 indicator 3 upper balljoint housing 4 indicator fas tening bracket 5 control arm 6 dynamometer 7 block Front wheel camber If the camber angle differs from nor mal it should be adjusted by changing the amount of washers 50 see fig 4 1 between the upper arm shaft and crossmember bracket To reduce the camber angle remove the same amount of washers from both bolts and to increase add Front wheel toe in If the toe in differs from normal value it is necessary to slacken the fastening clamps on the side tie rods and using tool 67 7813 9504 identically turn both adjuster pins in opposite directions thus the pins are turned on or off and change the length of side tie rods After adjustment refit the fastening clamps with the slot fac ing back with allowable deviation d
371. the frontal impact and at 30 impact leftward and rightward to the vehicle centre line The sys tem is not activated during impacts at more than 30 to the vehicle centre line side impacts rear impacts rollover minor frontal impacts The SRS 40 system consists of the following main compo nents gas generator inflator with a built in impact sensor airbag module special steering wheel with fixtures The system is activated by inertial impact force via triggering a mechanical sensor opposite to electrical pulse which oper ates the gas generator thus making redundant wiring and power supply Since the system is mechanical there is no need in the warning light or diagnostic unit The system is always ready to operate it is maintenance free though after seven years in field the gas generator is subject to mandatory replacement Fig 9 38 Steering components 1 steering mechanism 2 seal 3 middle shaft 4 upper shaft 5 bracket 6 upper shroud 7 ball bearing 8 race 9 cap 10 steering wheel 11 nut 12 infla tor unit with integral impact sensor 13 airbag module 14 lower shroud 15 16 fixtures steering shaft bracket A fixing pin B D shaped outlet ignitor unit 209 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
372. the outer surface and should not get in contact with mineral oils and greasings that dis solve rubber heavily depress the brake pedal and inspect the hoses for bulges that will indicate malfunctions all brake lines should be reliably fastened loose fastening will result in vibration causing damage liquid leak through pipeline connections is not allowed if necessary fully tighten the connections without deforming the pipelines 121 11 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 13 pressure regulator 14 pressure regulator control arm 10 ROR PKK a BAAR Fig 6 2 Brake servo unit 1 rod 2 master cylinder flange sealing ring 3 servo housing cup 4 adjuster bolt 5 rod sealing 6 diaphragm return spring 7 pin 8 sealing boot 9 servo unit housing 10 diaphragm 11 servo unit housing cover 12 piston 13 valve body boot 14 air cleaner 15 push rod 16 push rod return spring 17 valve spring 18 valve 19 valve body bush 20 reaction disc 21 valve body A vacuum chamber B atmospheric chamber C D ports 122 Fig 6 3 Brake pe
373. tial box 3 roller bearings with the help of a universal puller A 40005 1 6 and rest A 45028 undo the driven gear fastening bolts and punch out the dif ferential pinion shafts from the differential box 89 Fig 3 66 Undoing the drive gear nut 1 tool to fix the drive gear flange 2 box wrench 3 drive gear flange 4 bracket 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 on the final drive gear teeth and for prop er location of the bearing pattern between the teeth In case of inadmissible wear renew the parts find the reason for wrong teeth mesh Note As spare parts the driving and driven gears are deliv ered in a complete set matched by noise and mesh therefore both should be replaced in case of damage Inspect the differential pinion apertures and the shafts insignificant surface damages smooth with fine sandpaper and renew in case of serious damages Inspect the surfaces of the axle shaft gear journals and their bores in the differential box check the condition of box apertures for differential pinion shafts The revealed damages should be eliminated as described above if necessary replace
374. tighten the securing nuts and bolts to the specified torque Tighten the connecting rod bolts to 51 Hem 5 2 kgfm while the main bearing cap bolts to 80 4 Hem 8 2 kgfem remove the bearing cap and check the running clearance by comparing the width of the crushed Plastigage on each journal with the scale printed on the card gauge to obtain the bearing running clearance Fig 2 38 25 HE i y os j Fig 2 38 Measuring the big end bearing running clearance 1 crushed Plastigage 2 bearing shell 3 big end cap 4 scale for clear ance measurement f Fig 2 39 Flywheel 1 surface mating the crankshaft flange 2 surface for clutch securing 3 clutching surface 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 replace the respective bearing shells with new ones Where the crankshaft journals are worn and are reground to their undersize change the bearing shells to those oversize Thrust washers Similar to the bearing shells no adjust ments are possible on the thrust washers Always renew the thrust washers when there is scoring scuffing or flaking The thrust washers must be renewed when
375. til the tool reads 115310 SEEM remove the tool tighten the tensioner bolt and bolt 9 turn the crankshaft clockwise four turns locate tool OUT0000016 check the tension and adjust it as applicable remove the tool tighten bolts to 22 N m Lubrication system Design description The lubrication system is of mixed type The crankshaft and camshaft bearings oil pump shaft and inner gear are pressure lubricated while pistons piston rings gudgeon pins and cylinder walls are fling lubricated Oil change Change oil on a warm engine only Allow at least 10 minutes after opening the drain plug to completely drain oil Oil change should be accompanied by the oil filter renewal use tool A 60312 to undo the filter When refitting the filter into position tighten the filter by hand only do not use any tools Renew oil in the following sequence stop the engine and drain oil without removing the oil filter pour in cleaning oil to the MIN mark of the oil dipstick Use cleaning oils of BHAMHN O4 MCM 1 or MINT 2M type start the engine and run it at low rpm for 10 minutes fully drain the cleaning oil and discard the old oil filter fit a new filter and pour oil of required season grade Fuel system Design description Fuel system consists of a fuel tank a fuel filter a high pres sure fuel pump injectors an air cleaner an intake pipe and high low pressure fuel pipes High pressure fuel pump
376. tmeter A to vehicle wiring harness Start testing the control unit with checking its correct wiring Check the control unit operation using a voltmeter ranged 0 15 volts in the following sequence disconnect the green wire from the idle switch and earth the wire end connect the voltmeter to the control unit using special con nector 2 Fig 7 42 Start the engine and let it running gradually increase the speed while observing the voltmeter readings after start up the voltmeter should read at least 10 volts with an instantaneous drop as low as 0 5 volts at the moment the solenoid shuts off once the solenoid is shut off gradually decrease the engine speed until the solenoid cuts in again there should be an instant surge in voltage to 10 volts at least run the engine at 2200 2300 rpm disconnect the carburet tor idle switch earth lead and then reconnect it The solenoid should cut in when the earth wire is disconnected and cut off when the wire is reconnected to earth Note The control unit can be checked without a voltmeter by audible clicks the solenoid produces at cut in or cut off Fig 7 41 Fuel cutoff solenoid control system wiring diagram 1 ignition switch 2 ignition solenoid 3 ignition coil 4 control unit 5 fuel cutoff solenoid 6 idle switch amp 166 Chapter 8 Bodywork Fault diagnosis Cause Remedy Dark spots 1 Hot water was used for w
377. to drain Oil renewal should be accompanied by the oil filter removal use tool A 60312 Fig 2 4 to undo the filter When refitting screw the filter into position on the engine and tighten the filter by hand only do not use any tools Change oil in the following order stop the engine drain the oil and without removing the oil fil ter pour cleaner oil to the MIN mark of the oil dipstick 2 9 litre Use oil equivalent to grades BHMMHTT O71 MCTI 1 or MITT 2M start the engine and run it for 10 minutes at low rpm completely drain the cleaner oil and discard the old oil filter fit a new oil filter and pour oil of respective season grade Oil pump The basic dimensions of the pump components and its link age are shown in Fig 2 68 d ua zu N AAG 1 KT ar a we ww a N N v AA N HO Me A AN E A LO te ME S LO NVA ANS BV 3 N EN rSv S es Pw N W RSEN ae CXA a i VA PO 14 v 13 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 oilway to oil pump shaft and ignition dis tributor 11 oil pump and ignition distributor shaft 12 oilway
378. to flanges of front rear axles reduction gear and transfer case M8 FRONT AXLE Front axle to engine retaining bolt M12x1 25 Front axle to engine retaining nut M12 Front axle to engine retaining bolt M10x1 25 Inner joint housing bearing cover retaining nut M8x1 25 Differential bearing cover retaining nut M12x1 25 Retaining bolt lockplate to spring washer M6x1 Driven gear securing bolt M10x1 25 REAR AXLE Bolt holding reduction gear casing to rear axle beam M8 Differential bearing cover bolt M10x1 25 Driven gear bolt M10x1 25 Flange to drive gear nut M16x1 5 Retaining nut axleshaft bearing and rear brake M10x1 25 FRONT SUSPENSION Nut lower bolts holding cross member to chassis arms M12x1 25 Nut upper bolts holding cross member to chassis arms M12x1 25 28 4 45 1 2 9 4 6 53 9 87 2 5 5 8 9 31 8 51 4 3 25 5 25 15 7 25 5 1 6 2 6 15 7 25 5 1 6 2 6 15 7 25 5 1 6 2 6 66 6 82 3 6 8 8 4 79 4 98 8 1 10 0 11 7 18 6 1 2 1 9 26 5 32 3 2 7 3 3 15 0 18 6 1 53 1 9 14 7 24 5 1 5 2 5 28 4 45 2 9 4 6 11 8 18 6 1 2 1 9 11 7 18 6 1 2 1 9 66 6 82 3 6 8 8 4 96 117 6 9 8 12 0 96 117 6 9 8 12 0 57 8 71 5 5 9 7 3 27 4 34 3 2 8 3 5 74 5 92 7 6 9 4 60 8 75 6 2 7 66 42 1 52 4 3 5 3 19 6 24 5 2 0 2 5 62 7 75 4 6 3 7 7 3 8 6 2 0 39 0 63 83 3 102 9 8 5 10 5 35 43 2 3 57 4 41 43 3 53 5 4 42 5 46 83 3 102 9 8 5 10 5 Refer to section Rear axle 41 6 51 4 4 25 5 25 66 6 82
379. toff solenoid 4 is disactivated to shut off fuel supply When the idle switch is not grounded the solenoid will not be disabled Fig 2 86 Choke pull down unit 1 diaphragm 2 adjusting screw 3 diaphragm rod 4 choke control lever 4 1 lever 4 bottom profile to restrict maximum choke opening 4 2 top profile to ensure choke mechanical opening 4 3 lever 4 edge to ensure primary throttle starting clearance 5 choke valve 6 choke lever 7 choke return spring 8 choke cable 9 adjuster screw stop 10 primary throttle opening adjuster screw 11 throttle lever 12 primary throttle B choke starting clearance C throttle starting clearance 50 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 secondary barrel lock lever In this case during throttle opening the lock lever operates lever 13 through lever 14 to open the secondary throttle When the choke is closing lever 5 outer edge operates lock lever pin 2 to disengage lever 14 and lock lever Now the sec ondary throttle is locked out and cannot be opened Carburettor removal and refitting Carburettor removal and refitting is done on the cold
380. tool A 95688 R for adjusting front axle pinion FRONT SUSPENSION Tool for pressing out silent blocks of suspension upper arms Wrench shock absorber cartridge nut A 57070 A 74177 1 02 8701 9502 67 7820 9514 67 7820 9520 67 7820 9521 67 7823 9514 67 7823 9515 67 7823 9517 67 7823 9526 67 7823 9527 67 7824 9513 67 7834 9507 67 7853 9519 67 7853 9528 67 7853 9534 67 7853 9535 67 7853 9536 67 7853 9540 67 8732 9501 67 7820 9517 A 47035 A 47043 A 74076 1 A 74076 R A 74105 A 74186 A 90336 67 7813 9504 67 7824 9516 67 7853 9541 67 8720 9501 A 56124 67 7820 9519 67 7823 9519 02 7823 9504 A 78034 Spanner front shock absorber removal and installation Tool for fitting silent blocks to front suspension upper control arm to be used with tool 67 7853 9519 Tool for checking front suspension balljoints Cross member for engine lifting Mandrel nut reduction Lever for moving front wheel hub to check clearance in bearings Removal tool wheel hub cap Removal tool lower control arm shaft Tool for pressing out in lower control arm silent blocks Tool for pressing in out lower control arm silent blocks on press Tool for pressing out upper control arm silent block Repair tool kit shock absorber Tool for measuring clearance in front wheel hub bearing Tool for pressing in upper control arm silent block to be used with tool A 74177 1 Tool for fitting wheel hub cap Washer for pressing out front wheel hub inner bear
381. tor has a thermal bimetal fuse for overload protection The washer motor integral with the pump is secured on the bracket to the left hand bodyside panel The wiring diagram for rear window wipe wash is shown in Fig 7 37 The wiper is activated by push button 2 located at the left hand side of the instrument panel At the push button middle position only the wiper is activated while at a fully depressed push button the rear window washer is operated too The motor design allows its dismantling to eliminate minor faults commutator cleaning etc Dismantling and reassembly methods are similar to those described earlier for the windscreen wiper motor The rear window wiper should operate at 50 5 rpm double sweeps at a load of 0 49 Nem 0 05 kgf m supply voltage of 14 volts ambient temperature of 25 10 C and maximum consump tion current of 2 amperes The rear window heating is activated by switch 8 through supplementary relay 6 113 3747 10 model fitted at the left hand side of the instrument panel Refer to Lighting and sig nalling for details The cigarette lighter 11 3725 model is provided with protec tion against extended operation over 30 seconds of the heating element by means of a fusible washer secured on the insulator at the rear of the cigarette lighter When overheated the washer melts and closes the central lighter contact to earth This results in a blown fuse Nod in the supplementary fuse box and disco
382. tor man Fig 2 74 Pressing out the oil pump distributor inner gear bush ifold to draw crankcase emission on the throttle body to the side as DOR QU RED of the air cleaner 42 Fig 2 76 Air cleaner and temperature regulator 1 gasket 2 corrugated hose 3 air temperature control flap handle 4 cold air intake 5 temperature regulator 6 clamp bolt 7 air cleaner cover secur ing nut 8 air cleaner cover 9 air cleaner cover gasket 10 filter element 11 filter cover mounting bracket 12 emission discharge pipe 13 air filter housing 14 spring retainer 15 warm air intake from exhaust manifold Fig 2 77 Refitting the air cleaner cover 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 temperature regulator 5 Loosen clamp bolt 6 and remove temperature regulator 5 complete with cold air intake 4 When refitting the air cleaner position the arrow on the filter cover as shown in Fig 2 77 in order to reduce intake air noise Fuel tank Removal and refitting Before removing fuel tank 1 Fig 2 78 disconnect the battery earth lead Undo cap 5 of filler pipe 4 and remove as m
383. ts 4 Wash all parts renew liquid 5 Renew damaged components Shock absorber knock and squeak Worn rubber bushes in eyes Impact deformation of boot Insufficient amount of liquid due to leak Loose tank and piston fastening nuts Jammed rod due to deformation of cylinder tank or rod Loose shock absorber fastening nuts Damaged components of shock absorbers NO of WP 1 Renew bushes 2 Renew or repair boot 3 Renew damaged components and top up liquid 4 Tighten nuts 5 Renew damaged components or repair 6 Tighten nuts 7 Renew damaged components 101 Diagnosis Remedy 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 1 Choose speed according to road conditions 2 Avoid sharp acceleration 3 Use brakes correctly 4 Adjust wheel alignment angles 5 Adjust clearance 6 Avoid vehicle overload 7 Rearrange wheels on vehicle according to service manual Tyres squeal at cornering 1 Abnormal tyre pressure 2 Wrong wheel alignment angle 3 Deformed suspension arms crossmember or body front elements Front suspension The design of the front suspension is shown on fig 4 1 Suspension components inspection At each maintenance and repair it is necess
384. tter pin and withdraw the lever and armature actuator assembly next disconnect the operating lever 147 IPC ASSIS EALLA AEAEE 27777241 f wy Yee f e _ 21 16 17 18 0 20 1g 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 17 housing 18 stator pole 19 arma ture 20 intermediate ring 21 stop collar Fig 7 14 Starter wiring connections 1 starter motor 2 battery 3 alternator 4 starter cut in relay 5 ignition switch 148 Fig 7 15 Wiring connections for starter motor testing 1 voltmeter with scale limit at least 15 v 2 starter motor 3 rheostat 800 amps 4 amperemeter shunted to 1000 amps 5 switch 6 battery 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 Once the starter motor has been dismantled blow its parts with compressed air and wipe
385. turn hoses from the engine Undo two bolts retaining the radiator to the body release the top catch of the fan cowl move the top radiator toward the engine and withdraw the radiator from the engine bay complete with the thermostat and associated hoses Remove the fan cowl Undo the nuts holding the downpipe to exhaust manifold Detach the downpipe from the bracket on the transmission and lower it down Slacken the clips disconnect the hoses from the fuel pump and secure the pump in the position that excludes any fuel leakage Detach the fuel return hose from the carburettor Release the clips and disconnect the hoses from the heater manifolds detach the brake servo hose from the intake pipe Use socket spanner 02 7812 9500 to unbolt the starter motor from the clutch housing Undo the bolts holding the clutch hous ing cover to the lower clutch Using A 55035 undo the clutch bell housing to the cylinder block Hoist the beam TCO 3 379 and secure the engine right side to the lifting yoke at the front exhaust manifold stud while the left side shall be secured through the clutch housing mounting hole Slightly tension the hoist undo the nuts that retain front engine mounting rubbers 3 Fig 2 3 to the side brackets undo the nut and bolt holding the front axle housing to the engine brackets Disconnect the engine negative lead Lift out the engine first raise its top in order to take the bolts of the mounting rubber out of the bracke
386. uch petrol as pos sible Remove the rear seat undo screws holding the right hand and left hand wheel arch liner remove the liners Unbolt and remove the cover in the floor to expose the fuel tank Disconnect hoses 9 and wiring from fuel level sender 8 fol lowed by hoses 2 from the fuel vapour separator Undo the retaining bolts and withdraw the petrol tank The fuel tank refitting is a reversal of removal Cleaning and inspection Remove the fuel level sender Clean the tank with petrol to remove any contaminants or sedi ments Wash the tank with a jet of hot water and steam out any petrol residuals Thoroughly examine the fuel tank welding seam for leaks If leakage is evident solder the fuel tank WARNING Before soldering check to see the fuel tank is thoroughly cleaned and steam treated and there are no fuel vapours which can ignite and explode during soldering Fuel pump Refer to Fig 2 79 Fuel pump inspection Insufficient fuel flow to the carburet tor can be caused by a faulty fuel pump clogged or damaged fuel lines or fuel filter To find the cause of failure disconnect the hose from supply manifold 1 and using fuel priming lever 8 check fuel delivery If there is no fuel disconnect the hose from intake manifold 4 and check the manifold for vacuum In case of vacuum the fuel lines are damaged if not the fuel pump is faulty The fuel pump can be tested on a stand By rotating the drive shaft at 2000
387. uel 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 cuts off Operate the starter motor for three seconds to equalize pressure in the pipework Reconnect the fuel pump wiring plug to the injection wiring harness Disconnect the battery negative lead Remove the air cleaner and disconnect the throttle cable from the central injection unit Detach the fuel pipes from the central injection unit and plug the pipe ends to prevent fuel leakage Disconnect the wiring plug Fig 9 3 of throttle position sensor 4 injector 2 and idle air control valve 9 On the central injection unit detach the vacuum hoses to the canister and MAP sender along with the crankcase vent hose Make certain everything is reconnected properly Fig 9 2 Removing the central injection unit and intake pipe 1 intake manifold preheater 2 intake manifold 3 central injection unit 186 Undo the retaining pins and remove the central injection unit from the intake pipe complete with the gasket Plug the intake pipe end to prevent entry of extraneous matter Refitting is the reverse order of removing Pay attention to the condition of the seals and gaskets renew if applicable On completion check the fuel pressure as described below WARNING Never re use the gasket mounted under the central injection unit and sealin
388. ug into the seat on the tester and tighten it to a torque of 31 4 39 2 Nem 3 2 4 kgf m Build up the pressure of 2 MPa 20 kgf cm in the tester chamber Take an oil cup and place a few drops of oil or kerosine on the spark plug the broken tightness is evident through the air bubbles between the insulator nose and metal plug body Electrical test Insert the spark plug to the seat on the tester and tighten to the torque specified above Adjust the gap between the spark box electrodes to 12 mm which corresponds to 18 kvolts afterwards using a pump build the pressure up to 0 6 MPa 6 kgf cm Fit the end of the HT cable to the plug and apply HT pulses The spark plug is sound when a good spark is observed through the tester sight window When sparking takes place between the spark box electrodes decrease the pressure in the tester Next recheck the pressure value when the spark jumps between the spark plug electrodes When sparking occurs at the pressure below 0 3 MPa 3 kgf cm 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 Ignition switch Check the ignition switch contacts are closing properly at dif ferent key positions Table 7 5 and theft deterrent device is func tional The batter
389. uge vent 4 and open pressure gauge vent 3 By moving the pushrod provide constant pressure of 10 MPA 100 kgf cm With a fixed pushrod and no liquid leaks pressure should remain constant for no less than 2 minutes Otherwise replace the front sealing ring Fig 3 11 Checking the leak proofness of the front sealing ring 1 bleeding screw 2 vent 3 manometer with 0 2 MPa 2 kgf cm scale 4 manometer with 0 005 MPa 0 05 kgf cm scale 5 reservoir 6 pushrod 7 master cylinder 63 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 1 Renew damaged bearings 2 Replace worn parts 3 Top up oil Rectify cause of oil leak 4 Renew bearings or securing components Difficulty in engaging gears 1 Incomplete clutch release 2 Jammed gearshift lever ball joint 3 Deformed gearshift lever 4 Hard movement of fork rods burrs dirty rod sockets detent seizure 5 Hard movement of sleeve on hub when splines get dirty 6 Deformed gearshift forks 1 See subsec Clutch 2 Clean ball contact surfaces 3 Rectify deformation or renew lever 4 Repair or renew worn compo nents 5 Clean components 6 Straighten forks or renew Jumps out of gear or incomplete cl
390. ulkhead to front bodyside pillar panel compartment side corner 176 Fig 8 12 Removing the front door 1 hinge screw 2 impact screwdriver 3 hinge 4 check strap Arrowed is the direction to hit the impact screwdriver Fig 8 13 Front door inner view 1 top armrest screw clip 2 bottom armrest securing screws Arrowed is the location for door trim securing clips 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 tighten screws 1 adequately line up the door with the aperture in the body Front door dismantling and reassembly Dismantle the door when you have to repair the door or renew its units and mechanisms Remove upper screw plastic clip 1 Fig 8 13 undo the screws that secure the armrest door pull and remove the armrest door pull Prise out surround 20 Fig 8 14 trim 1 and remove window lifter handle 2 Using a screwdriver remove the trim of the inner door lock handle Remove the door trim overcoming the resistance of the spring type plastic retaining clips arrowed in Fig 8 13 137 Fig 8 14 Sliding glass actuation brake drive link 19 housing cove
391. un in vehicle at 3140 N 320 kgf degrees 3 30 30 Tyre pressure MPa kgf cm front wheels iere Y E RR RE Rech a pp Ro dane ene a qn Y TY V PAPA e ER Sd 0 21 2 1 rear wheels 5 2 bib te ie Vie Wet es tae i MEX Rea mu S NT Oe oo SL o 0 19 1 9 Backlash front wheel hub bearings MM iiiiiiiusssssssssssssssee e n 0 02 0 07 Tleld adjuStmehl oes Ce 4 Cer RO RATE RNC AR TATEM Rete GLK bat ua Ea eue tne du ed 0 02 0 15 Minimum permissible lining thickness front pads and rear shoes rm 1 5 Fluid level brake clutch fluid reservoirs lille RRRRRRRRRRRRRRRRRRRRIRRRRRIRRRII up to lower filler neck edge Maximum gradient on dry hard ground where laden vehicle is retained unlimited time With Handbrake applied 9o 445 2 rote ree rOR CHI eae hs anaes ae Me DU ea ee 25 Handbrake lever travel notch on the ratchet adjustment sc cS ev ge TRY RR VITE E ends ea RO bees DUO E Wd RN TX ETER EDERE 4 5 2 4 operalion Ier yg REIS V ca i ee ed bv OEE RE Pega qu gu dax DUNTITPUR UT ET 4 7 2 8 For vehicles with double tooth pawl 218 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 21213 VAZ
392. uring clamp 3 choke cable 4 grommets 5 choke knob 6 shaft 7 throttle pedal 8 return spring lever 9 shaft support bracket 10 longitudinal rod end piece 11 intermediate lever 12 bracket intermediate lever 13 return valve bracket 14 return spring 15 transverse rod 16 carburettor 51 Fig 2 88 Carburettor cover components 1 float spindle 2 needle valve 3 float 4 gasket 5 diaphragm and rod choke pull down unit 6 spring 7 adjusting screw 8 cover choke pull down unit 9 idling fuel jet 10 fuel cut off solenoid 11 fuel supply pipe 12 carburettor cover 13 fuel filter 14 choke valve 15 cap 16 spindle choke valve and lever 17 choke control lever securing ball 18 choke control lever 19 lever spindle 20 bush for securing choke cable 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 carburettor housing Fig 2 89 as described below Remove accelerator pump cover 3 complete with lever 2 and diaphragm 1 Using a screwdriver remove accelerator pump atomizer 10 followed by atomizers 11 of the primary and secondary barrels Grip the housing wh
393. urpose lithium grease NLGI class 2 c M0S2 Automotive multipurpose lithium grease NLGI class 1 KB 521 Fiat Lubrificanti grease VN 2461C Molikot grease Longtern 00 Dow Corning grease Hydrocarbon grease NLGI class 1 or 2 Castrol S 058 grease 219 Astomo6unu BA3 21213 BA3 21214 BA3 21214 20 BA3 21215 PykoBogcTBo no peMoHTy aBroMo6uneii FEHEPANbHbIN JENAPTAMEHT PA3BMTIR A O ABTOBA3 Aptopbi paspa6oTuukn Bonrut C H Koanos M JI Kocapea C H Nepesog 3 AHncoso V CTaHkoBoi Maket opurmvan waroroBneH BKM YTIABP AO ABTOBAS Kownbtorepuas B pcrka n ocopunenve B Anaes B Wlekob B Mwrpodpauos Ten 8482 22 54 19 Mag Ne 0021311 220
394. ut joint 3 from the aperture To press out the second joint turn over the arm and repeat the procedure The press fitting of upper arm joints is done with tool 67 7853 9519 fig 4 11 fixed in vice Fix the arm with shaft 1 in fixture 2 place the joint on the shaft and press fit in the arm bezel with tool 3 A 74177 1 Then repeat the above described opera tions to press fit the second joint on the other side of the arm Fig 4 12 Pressing out the lower control arm balljoint 1 tool 67 78223 9517 2 balljoint Fig 4 13 Press fitting the lower control arm balljoint 1 tool 2 balljoint 3 cap 109 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 bezel and fit tool 67 7823 9517 fig 4 13 complete with cap 3 By tightening the fixture screw press fit the joint in the arm bezel Rear suspension The design of the rear suspension is shown on fig 4 14 Suspension removal and refitting Removal Lift the rear part of the vehicle and place it on sup ports Take off the rear wheels Disconnect the propeller shaft from the final drive gear flange Disconnect the hose of the brake hydraulic system from the
395. utch engagement 1 Worn rod balls and sockets weak detent spring 2 Worn synchro unit baulk rings 3 Broken synchro unit spring 4 Worn teeth on synchro unit sleeve or synchro unit crown 5 Crushed hub short teeth 1 Renew damaged components 2 Renew baulk ring 3 Renew spring 4 Renew sleeve or gear 5 Renew synchro hub Oil leak 1 Worn oil seals on input and output shafts 2 Loose fitting of gearbox cov ers damaged sealings 3 Loose fitting of clutch housing to transmission casing Removal and refitting 1 Replace oil seals 2 Tighten nuts see torque in Appendix or renew seals 3 Tighten nuts Removal Place the vehicle over an inspection pit or on a lift put blocks under front wheels and raise the rear axle from one or two sides Let off the handbrake and place the gearshift lever in neutral Disconnect the wires from the battery Take out the front floor mat and the gaiters from the transfer and gearbox levers Remove the aperture covers and sealings Unscrew the handles from the transfer box levers 64 Push downward lever rod 27 see fig 3 12 and with the help of a screwdriver or any other pointed tool take out the retaining sleeve 31 from the groove on the lever rod remove the rod Disconnect the brackets that are fixing pipes and mufflers in the rear part of the vehicle and then the muffler pipe from the front exhaust pipe Disconnect the exhaust pipe clip and remove the pipe downward
396. valve throttling disc 16 by pass valve cap recoil valve nut 9 8 7 compression valve cap 14 15 recoil valve nut washer 22 housing 23 rod guide sleeve 24 tank sealing ring 25 oil seal retainer front suspension shock absorber securing nut for top end upper 31 37 silent block 112 I S NN ae II Fig 4 19 Shock absorber operating curve force at recoil stroke II force at compression stroke speed of 60 min 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 compression strokes is defined by the peaks of the appropriate diagrams The highest point of the recoil stroke curve with the scale of 1 mm 47 N 4 8 kgf should be on the A distance from the zero line and equal to 25 32 mm for front shock absorbers 23 5 30 5 mm for the rear ones The highest point of the compression stroke curve with the same scale should be on the B distance from the zero line and equal to 3 5 6 5 mm for front shock absorbers 4 5 7 5 for the rear ones The ordinate control points on the diagrams of front and rear shock absorbers are given for cold shock absorbers at shock absorber liquid tempe
397. way clutch guide ring or buffer spring broken 1 Bench test starter motor renew overrun clutch 2 Renew lever or refit pivot shaft 3 Renew clutch Starter motor noisy 1 Starter motor retaining nuts loose or drive end housing broken 2 Starter wrongly mounted 3 Bearing shells or armature shaft journals excessively worn 4 Stator pole loose armature touches pole 5 Pinion or ring gear teeth dam aged 6 Pinion fails to disengage ring gear operating lever seized overrun clutch jams in mesh with armature shaft splines clutch or solenoid springs loose or broken clutch hub circlip lost solenoid armature sticking ignition switch contact part faulty pins 30 and 50 fail to open 1 Tighten retaining nuts or over haul starter motor 2 Check starter fitting 3 Renew starter motor 4 Tighten pole retaining screw 5 Renew drive or flywheel 6 Carry out the following renew operating lever clean and lubricate splines with motor oil renew clutch or solenoid renew damaged components renew solenoid or eliminate stick ing check correct contact closing at different key positions renew faulty contact unit Starter motor bench testing If the starter motor fails to operate effectively check it using a tester The wiring connections for the test are shown in Fig 7 15 The cross sectional area of leads to power source ammeter and starter solenoid terminal bolt shou
398. wear itis recommended to renew the sealing at repair Replace all damaged components and start to reassemble the shock absorber 113 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 needle or on ball bearing In the text the figures for both vari ants are given thus the sign refers to the first embodiment pit man arm roller is established on a needle bearing Fault diagnosis Diagnosis Remedy Excessive free play in the steering wheel 1 Loose steering box fastening 1 Tighten nuts bolt 2 Loose tie rod ballpin nuts 3 Excessive gap in rod balljoints 4 Excessive clearance in front wheel hub bearings 5 Excessive clearance in roller to worm mesh 6 Too large clearance between slave arm shaft and bushes 7 Excessive clearance in worm bearings 8 Loose bolts fastening interme diate shaft to worm shaft or to upper shaft 2 Check and tighten nuts 3 Renew ball joints or tie rods 4 Adjust clearance 5 Adjust clearance 6 Replace bushes or bracket assembly 7 Adjust clearance 8 Tighten bolts Stiff steering wheel 1 Deformation of steering drive components 2 Wrong wheel a
399. windscreen wiper 2 Detach blades from glass taking care not to damage rubber 3 Check and remove foreign object if any 4 Renew motor or motor armature Wiper motor fails to operate intermittently 1 Wiper switch faulty 2 Wiper relay damaged break in relay winding shorted wires in contact part clearance between relay breaker contacts 1 Renew 3 stalk switch 2 Carry out the following renew relay remedy short circuit eliminate clearance renew relay when applicable 159 Continuous operation of wiper blades in intermittent mode 1 Wiper relay breaker winding 1 Renew wiper relay blown 2 Motor gear cam does not oper 2 Bend switch plate so cam can ate limit switch spring plate operate plate 3 Foul motor limit switch contacts 3 Clean limit switch contacts 4 Foul wiper relay breaker con 4 Clean breaker contacts or renew tacts relay Wiper stops in intermittent mode Blades do not stop at park position Motor limit switch contacts cor Clean switch contacts or bend limit roded or close incompletely switch plate Blades inoperative with motor running 1 Motor gear teeth broken 1 Renew gear 2 Loose crank fitting to motor 2 Check tighten crank retaining nut gear shaft in its end position Windscreen wiper removal and refitting The repair of the wiper is basically restricted to straightening the deformed arms and rods or their renewal A failed motor must be renewed The
400. worn or damaged parts Examine the surfaces of the differential side gear support washers even insignificant damages should be eliminated When replacing match the new washers by thickness Examine the roller bearings on the drive gear and the differ ential boxes they should have smooth working surfaces and no wear Replace bearings in slightest doubt in their serviceability as bad condition of bearings can cause noise and teeth jamming Check for deformations or cracks on the casing and on the differential box renew if necessary Reduction gear reassembly The reliable operation of the reduction gear is provided by strict observance of following guidelines on reassembly and adjustment The reduction gear components are shown on fig 3 69 Differential reassembly Grease the differential side gears with support washers and the differential pinions with transmis sion oil and establish them through the openings in the differen tial box Turn differential pinions and differential side gears so that to align the rotation axis with the opening axis in the box then insert the differential pinion shaft Check the axial gap in each differential side gear it should be 0 0 10 mm and the moment of resistance to rotation of the dif ferential gears should not exceed 14 7 N m 1 5 kgf m In case of an excessive gap resulting from wear of differen tial parts replace the support washers of the differential side gears by others of
401. y and alternator voltage is supplied to terminals 30 and 30 1 The vacant terminal INT is intended for radio cas sette player connection The steering lock pin moves out when the key is turned to position IIl parking and is then removed from the switch The lock pin moves in after the ignition key is turned from position III parking to position 0 ignition off The key can only be removed from position Ill When inserting the contact part into the ignition switch hous ing locate it so that terminals 15 and 30 are on the lock pin side Fig 7 27 ensure the wider end of the contact part is well within the wider slot of the ignition switch housing Suppression components testing The following is used for interference suppression 1 kOhm resistor in the distributor rotor arm resistive HT cables of 2000 200 Ohm m for red leads FIBBI1 8 or 2550 270 Ohm m for blue leads TIBTIT1B 40 4 10 kOhm resistors in the spark plugs 2 2 microfarad capacitor in the alternator The leads and resistors are checked with an ohmmeter Refer to subsection Alternator for the capacitor checking procedure Lighting and signalling Fig 7 27 Ignition switch contact unit 1 lock pin 2 wider part of contact unit Table 7 5 Circuits activated at different ignition switch positions Position Live contacts Circuits activated 0 Off 30 and 30 1 E I Ignition 30 INT 30 1 15 Alternator field windi
402. y on three rubber mountings 11 Fig 9 8 Fresh air through air intake 5 and pipe 4 is drawn into air cleaner housing 10 The air then flows through paper filter ele ment 9 MAF sensor 7 hose 6 and throttle housing 2 From the throttle housing the warm air is directed to receiver unit 12 and intake pipe and further to the cylinder head and cylinders Filter element renewal 1 Undo four retaining bolts remove air cleaner cover 8 com plete with MAF sensor 7 and intake pipe hose 6 2 Renew filter element 9 so that its corrugation is parallel to the vehicle axial line 3 Refit and secure the air cleaner cover Crankcase ventilation system Draught ventilation is provided to expel crankcase gases and fuel vapours into the engine intake pipe Crankcase gases are drawn through hose 1 Fig 9 14 into the intake pipe hose and further via the throttle housing and receiver unit into the intake pipe At low rpm and closed throttle most of crankcase gases are drawn along hose 2 to the throttle housing Flushing To flush the system disconnect vent hoses 1 and 2 from the intake pipe hose and throttle housing 3 Remove oil separator 8 cover 5 and wash both units with petrol or kerosine Flush and blow with compressed air all hoses and connectors Fig 9 14 Crankcase ventilation system 1 discharge hose 2 vent hose 3 throttle housing 4 oil dipstick 5 oil separator cover 6 oil pressure gauge 7 gasket 8 oil s
403. ype paint remover For old multilayer paint apply it with brush two or three times depending on the paint thickness Usually 30 40 minutes are required to soften the old paint which is then removed with a wire brush or putty knife Use white spirit to wipe off the remainder of the paint rinse with water allow to dry Respraying separate parts Paint any separately replaced parts wings doors bonnets etc all over outer surfaces The same recommendations are applied to the parts restored after ding and dent Before respraying the parts remember to sand and apply primer on the reassembled parts When performing the job follow the methods adopted for body respraying Bodywork corrosion protection Corrosion mostly attacks inner cavities of the body floorpan lower parts and struts along with anchorages and spot welding areas Hard to reach cavities and underbody parts are most sus ceptible to corrosion caused by moisture mud salts and acids All this necessitates further protection for body inner sur faces and box sections through application of specific rust inhibit ing paints or sealants for joints The products used to resist rust formation are shown in Table 8 1 It is advisable to use corrosion inhibitors MoBWIb or Mo BWIIb 2 for box sections Box sections should be treated every 1 to 1 5 years The corrosion inhibitor is also applicable for the sur faces earlier treated with nygrol or other oils as

Lada Niva 2121 Service Manual

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