Chapter 9. VAZ-21213 vehicle modifications
Contents
1. A Lo Ze a aos o SA NRA 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 A 1 16 T TL EmN O m o w aN WA 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 A hole E reserve cavity 12 13 Fig 9 13 Cooling system 1 radiator pad 2 radiator return 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 of2. 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 Throttle position sensor Before fitting the TP sensor fully Close the throttle then turning the sensor anticlockwise align the flats of the shaft with the sensor pickup lever Tighten the securing screws WARNING Never clean or wash the TP sensor or idle air control valve with petrol 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 23 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 i
3. 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 lever 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 10 9 8 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 silen
4. 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 Injection system protective fuses Fuse Circuits protected 1 2 Fuel pump on relay contacts Electric fuel pump Fuel injector 3 4 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 Nl 4B Pa 35 PU BY 3 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 tempe
5. on any surfaces position the holes upward never put anything on the gas generator Fig 9 39 Steering wheel 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 wheels 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
6. 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 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 ampers 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 To differential lockup sensor To low oil pressure sensor To brake fluid level sensor LAGA NIVA axa 140 o v2 4 5Q 90 130 Paf ae po 20g Fam 7160 4 A 80 Ne Nae F Poe es 8 Pe Ts 1Ts oo NOOA WO N EE CEE Fig 9 35 Ins
7. 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 fuel remains under pres sure always depressurize the fuel system To do this disconnect the fuel pump wiring plug from the injection wiring harness Start the engine and run it until it 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 r
8. oO 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 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 spee
9. 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 remedial 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 adjustme
10. 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 the flywheel using tool OUTO000049 loosen the crankshaft pulley retaining bolts remove the crankshaft pulley fix the flywheel with tool OUTO000015 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 Re
11. 1 Fig 9 39 WARNING Never apply excessive force to the inflator unit when dismantling If the inflator unit doesnt 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 kgfem 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 coinci
12. 203 B 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 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 94 3 C The relay is housed in the engine bay and is bolted to the top bulk head re
13. 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 operation and diagnostics of fuel injection system removal and refitting 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
14. 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 antitheft system The vehicle VAZ 21215 10 is fit ted with an antitheft system of relay type AMC 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
15. al 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 mounting 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 Coolin
16. 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 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 th
17. ankshaft 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 the 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
18. cer 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 rom 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 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
19. 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 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
20. d 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 250410 Ohm with a half filled tank 66 6 Ohm with a full tank 2042 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 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 redun
21. d 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 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 Fuse Circuits preteeted 2 Eleetrie 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 fusib
22. dant 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 He a S f f 2 7 8 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 a Era S 16 15 14 1 112 A 9 209 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 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 n
23. de 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
24. e 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 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 se
25. e 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 O MCM 1 or MIT 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 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
26. econnected 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 sealing 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 fil
27. ection 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 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 thr
28. ee 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 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
29. fitting 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 rotate 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 Alter
30. g 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 significantly 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
31. inforcement The motors are maintenance free and must always be renewed in case of failure Motor specification Nominal motor shaft speed with impeller load KOM as r EA n wart hier aan ad 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 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 to interior light C to ignition relay terminal 86 D to starter relay terminal 86 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
32. ircuit 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 leaks 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 i
33. itrogen 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 and 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
34. le 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 rpm 2000 2200 Current consumption at speeds and loads as specified amperes not greater ccc eee eee 15 2123 1411020 10 CERTI 55 37 19 Heli 20 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 cr
35. n 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 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
36. nator 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 A A 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 OUTO000016 use bolt 8 to tighten the belt until the tool reads 115 10 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 Nem 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 th
37. nt 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 Withdraw 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 hos
38. o 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 separator 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 manifol
39. rature 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 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 inj
40. rough 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 Q gt 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 measured 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 OD YO Ry Fig 9 9 Removing the fuel system components D AD 1 intake manifold 2 injector 3 bolt 4 fuel fail 5 fuel pressure regulator 6 vacuum hose 7 gasket 8 receiver unit 192 SSS i SS J be A PZI 4 LE SV O 2 A oA N 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 Y
41. s 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 pressure 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 c
42. ter 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 diaphragm 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
43. 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 bay 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 int
44. trument cluster wo 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 To high beam relay To exterior lighting switch To indicators flasher relay 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 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 oeoenNnt nor O N oe a a p
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