LADA NIVA Service Repair Manual

VAZ VEHICLES VAZ-21213, VAZ-21214, VAZ-21214-20, VAZ-21215 REPAIR MANUAL

2 Contents Section 1. General data ..........................................................4 Section 2. Engine ..................................................................7 Engine - removal and refitting..........................................12 Cylinder block ..................................................................19 Inspection and repair ..................................................19 Pistons and connecting rods ...........................................21 Selecting piston to cylinder ........................................23 Dismantling and reassembly ......................................23 Crankshaft and flywheel ..................................................24 Design description ......................................................24 Inspection and overhaul .............................................24 Cylinder head and valve gear ..........................................26 General description ....................................................26 Valve clearance adjustment .......................................27 Cylinder head - removal and refitting .........................28 Cylinder head - dismantling and reassembly ............28 Camshaft and timing gear ...............................................32 Cooling system ...............................................................34 Lubrication system ...........................................................38 Fuel system .....................................................................42 Carburettor .......................................................................46 Exhaust gas recirculation system ....................................55 Exhaust system ...............................................................46 Chapter 3. Power train .........................................................57 Clutch ..............................................................................57 Gearbox...........................................................................64 Transfer box ....................................................................73 Drive line .........................................................................80 Rear axle .........................................................................84 Front axle ........................................................................96 Chapter 4. Wheel suspensions ...........................................100 Front suspension ...........................................................102 Rear suspension............................................................110 Chapter 5. Steering ...........................................................115 Steering - inspection, check and adjustment ................116 Steering mechanism......................................................118 Chapter 6 Braking system..................................................121 Front brakes ..................................................................128 Rear brakes ...................................................................130 Handbrake .....................................................................134 ëhapter 7. Electrical system...............................................135 Wiring and fuses ...........................................................135 Battery ...........................................................................136 Alternator .......................................................................140 Starter motor .................................................................146 Ignition system ..............................................................149 Lighting and signalling...................................................156 Windscreen wiper/washer .............................................159 Instruments....................................................................163 Chapter 8. Bodywork .........................................................167 Bodywork - repair .........................................................169 Paintwork.......................................................................172 Door ...............................................................................176 Bonnet, bumpers ...........................................................179 Bodywork glazing and windscreen washers .................180 Instrument panel, seats .................................................181 Heater unit .....................................................................183 Chapter 9. VAZ-21213 vehicle modifications, alternative and additional equipment ...............................................................185 VAZ-21214 vehicle ........................................................185 Engine repair - description ............................................185 Central Injection Unit .....................................................186 VAZ-21214-20 vehicle ...................................................189 Engine 21214-10 ...........................................................190 VAZ-21215-10 vehicle ...................................................197 Cooling system..............................................................200 Lubrication system ........................................................202 Fuel system ...................................................................202 Exhaust emission system..............................................203 Electrical system ...........................................................203 Steering with BREED «SRS-40» driver’s airbag in the steering wheel ............................209 Attachments.....................................................................212 Ä‚ÚÓÏÓ·ËÎË ÇÄá-21213, ÇÄá-21214, ÇÄá-21214-20, ÇÄá-21215 êÛÍÓ‚Ó‰ÒÚ‚Ó ÔÓ ÂÏÓÌÚÛ ‡‚ÚÓÏÓ·ËÎÂÈ © ÉÖçÖêÄãúçõâ ÑÖèÄêíÄåÖçí êÄáÇàíàü Ä/é ÄÇíéÇÄá © Ä‚ÚÓ˚-‡Á‡·ÓÚ˜ËÍË: ÇÓÎ„ËÌ ë. ç., äÓÁÎÓ‚ è. ã., äÓÒ‡Â‚ ë. ç. © èÂÂ‚Ó‰ á. ÄÌËÒÓ‚ÓÈ, à. ëÚ‡ÌÍÓ‚ÓÈ © å‡ÍÂÚ-ÓË„ËÌ‡Î ËÁ„ÓÚÓ‚ÎÂÌ Åäå ìèÄÇê Äé ÄÇíéÇÄá. äÓÏÔ¸˛ÚÂÌ‡ﬂ ‚ﬁÒÚÍ‡ Ë ÓÙÓÏÎÂÌËÂ - Ç. ÄÎ‡Â‚, Ç. à‚ÍÓ‚, Ç. åËÚÓÙ‡ÌÓ‚. ÚÂÎ. (8482) 22-54-19. àÁ‰. ‹ 0021311

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 of 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. 3

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 braking 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 petrol, CFI petrol, sequential injection turbo diesel No of cylinders four in-line four in-line four in-line four in-line Bore x stroke, mm 82ı80 82ı80 82ı80 83ı88 Capacity, litre 1.69 1.69 1.69 1.905 Compression ratio 9.3:1 9.3:1 9.3:1 21.5:1 Maximum power: as per GOST 14846 (net), at least, ÍW (h.p.) 58 (78.9) 58 (78.9) 58.5 (79.6) 55 (74.8) as per ISO 1585, ÍW 58 58 58.5 55 Maximum crankshaft speed at maximum power, rpm 5200 5400 5000 4600 Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 ____________________________________ * Measured using a special procedure 4

Features VAZ-21213 VAZ-21214 VAZ-21214-20 VAZ-21215 Power train Clutch single dry plate, diaphragm spring Clutch release mechanism hydraulic, servo spring Transmission 5-speed, synchro units on all forward gears Gear ratio: • first gear 3.67 3.67 3.67 3.67 • second gear 2.10 2.10 2.10 2.10 • third gear 1.36 1.36 1.36 1.36 • fourth gear 1.00 1.00 1.00 1.00 • 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 1.2 1.2 1.2 1.2 • bottom gear 2.135 2.135 2.135 2.135 Transfer case differential bevel gears, two pinion gears Drive line: • from transmission to transfer case flexible coupling and CV joints • from transfer case to front and rear axles two universal joints on needle bearings with grease nipples and yokes • from front axle to wheels open, with CV joints Final drive ratio, front and rear axles bevel, hypoid • gear ratio 3.9 3.9 3.9 3.9 • differential bevel, two pinion gears Suspension and wheels Front suspension independent, lower track control arms (wishbones), coil springs, hydraulic telescopic shock-absorbers, anti-roll bar Rear suspension rigid axle beam with Panhard rod and four trailing arms, coil springs/hydraulic telescopic shock-absorbers Wheels pressed-steel disc • wheel rim 127J x 406 (5J x 16) Tyres tubed, cross-ply or radial ply size: • cross-ply tyres 175 x 406 (6.95 x16), • radial-ply tyres 175/80R16 5

Features VAZ-21213 VAZ-21214 VAZ-21214-20 VAZ-21215 Steering Steering mechanism globoidal worm, double-crest roller, steering ratio 16.4 Steering linkage three links, relay rod and two steering rods, drop arm, idler arm and swing arms Braking system Service braking system: • front brakes disc-type, floating caliper, automatic disc-to-pad clearance adjustment • rear brakes drum-type, self-applying shoes and automatic shoe-to-drum clearance adjustment • brake operation line foot-type, hydraulic, dual circuit, split diagonally, vacuum servo unit and pressure regulator Handbrake cable-operated on rear wheels Electrical system Wiring diagram single-wire, negative earth type Voltage, volts 12 Battery 6ëí-55Ä, 55 ampere-hour Alternator AC, integral diode plate and electronic voltage regulator Starter motor pre-engaged, solenoid switch and overrun clutch Body Type all-steel unitary construction, monocoque, three-door, double-space 6 Fig.1-1. Basic overall dimensions of VAZ-21213 vehicle

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

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

Fault diagnosis Symptom/fault Remedy Engine fails to start 1. No fuel to carburettor: - blocked fuel pipes or fuel filter; - clogged carburettor or fuel pump filters; - faulty fuel pump 2. Ignition system fault 3. Carburettor fuel cutoff solenoid fails to open at ignition switch-on: - disconnected, loose or broken wiring to solenoid or solenoid control unit; - faulty solenoid control unit; - defective fuel cutoff solenoid 4. Carburettor choke not opening at first flashes in cylinders 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 carburettor/cylinder head 7. Leaking distributor vacuum pipe 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 åP‡ (10 kgf/Òm 2 ): - broken or sticking piston rings; - poor valve-to-seat fitting; - excessively worn cylinders or piston rings 9 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 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 carburettor flange deformation or fit new carburettor 7. Fit new pipe in place of damaged one 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 components; - 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 intensifies with higher crankshaft rate. Excessive endfloat of crankshaft causes sharper irregular knocking, especially noticeable during smooth increase or decrease in crankshaft speed. 1. Early ignition 2. Insufficient pressure oil 3. Loose flywheel securing bolts 4. Excessive main bearing running clearance 5. Excessive thrust washers-to-crankshaft 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 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 Knocking of intake or exhaust valves Excessive valve clearances cause typical regular noise; its frequency is lower than the frequency 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 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 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 Excessive oil pressure on warm engine 1. Seized oil pressure relief valve 2. Excessively tough spring of oil pressure relief valve 10 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 1. Renew valve 2. Renew spring 1. Refer to «Insufficient oil pressure at idle» 2. Fit new bearing shells and regrind journals 1. Adjust clearances 2. Renew spring 3. Replace worn parts 4. Renew camshaft and levers 5. Adjust clearance between lever and cam, tighten locknut 1. Renew pistons, rebore and hone cylinders 2. Fit new rings or new pistons with rings 1. Tighten chain 2. Renew tensioner shoe or damper 3. Eliminate seizure 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

LADA NIVA Service Repair Manual

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