Vaz 21213 Repair Manual Download Page 1

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VAZ VEHICLES

VAZ-21213, VAZ-21214, VAZ-21214-20, VAZ-21215

REPAIR MANUAL

Summary of Contents for 21213

Page 1: ...VAZ VEHICLES VAZ 21213 VAZ 21214 VAZ 21214 20 VAZ 21215 REPAIR MANUAL ...

Page 2: ...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 ...

Page 3: ...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...

Page 4: ... 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...

Page 5: ...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 independe...

Page 6: ...ying 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 ...

Page 7: ...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 ...

Page 8: ...8 Fig 2 2 Front sectional view of the engine ...

Page 9: ...sufficient cylinder compression below 1 åP 10 kgf Òm2 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 connectio...

Page 10: ... 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 rel...

Page 11: ...er matrix 4 Leaking water pump seal 5 Damaged radiator cap or cap seal 6 Defective cylinder head gasket 7 Leaks from fissures in cylinder block or cylinder head 8 Leaks from fissures in water pump housing water jacket return pipe thermostat expansion tank or intake pipe 11 1 Tighten fittings or replace gaskets and oil seals 2 Wash components of crankcase ventilation system 3 Rebore and renew pisto...

Page 12: ...s 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 in...

Page 13: ...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 Ä 60330 R Fig 2 10 and undo the nut using tool Ä 5012 Fig 2 5 Withdraw the valve cover and ...

Page 14: ...he 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 bearing shells thrust washers pistons and oil seals Alw...

Page 15: ...the rear side up and position the dial gauge foot against the crankshaft 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 ÏÏ 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...

Page 16: ...t 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 Tighten the cylinder head bolts in the established procedure Fig 2 18 in four steps to...

Page 17: ... 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 al...

Page 18: ...e 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 provisional cap WARNING Never se...

Page 19: ...oller stand without additional rollers for the front wheels Cylinder block General description The cylinder block basic sizes are shown in 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 ë D Ö The cylinder class is engraved on the cylinder block bottom face Fig 2 26 The cylinders can be rebor...

Page 20: ...inder size class engraved on the cylinder block Fig 2 27 Measuring the cylinder bore with the inside dial gauge 1 inside dial gauge 2 setting to zero against reference gauge Fig 2 25 Basic sizes of the cylinder block ...

Page 21: ...iameter 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 the 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...

Page 22: ... 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 22 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 ...

Page 23: ...ing 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 ...

Page 24: ...s can be reground during the engine overhaul when the diameter is reduced by 0 25 mm 0 5 mm 0 75 mm and 1mm 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 bea...

Page 25: ...e 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 The main and big end bearing running clearance is checked by measuring the components It is convenient to check the clearance wit...

Page 26: ...placement 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 starter ring interference on the flywheel The starter ring should not rotate when applying 590 ç Ï 60 kgf m Check to see there are no scratches or scores on flywheel face 1 mating the crankshaft flange or on surfac...

Page 27: ...n a bigger final clearance The clearance is adjusted as follows turn the crankshaft clockwise to align the indentation in 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 leve...

Page 28: ...ead 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 42 Checking the clearance between the rocker levers and cam lobes 1 feeler blade Ä 95111 2 adjuster bolt 3 lock nut Fig 2 43 Valve comp...

Page 29: ...ocker lever springs Slacken lock nuts 14 undo adjuster bolts 13 and bushes 15 Position tool Ä 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 Ä 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 fr...

Page 30: ...ith tool Ä 94101 to achieve the working cham 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 diame...

Page 31: ... 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 31 Fig 2 50 Limit sizes for valve chamfer regrinding I inlet valve II outlet valve Fig 2 51 ...

Page 32: ...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 c...

Page 33: ...sal of removal observing the recommendations outlined in section Engine assembly 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...

Page 34: ...e 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...

Page 35: ...ap 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 eviden...

Page 36: ...nsion Fig 2 63 Removing the impeller 1 puller 2 impeller Fig 2 62 Sectional view of the coolant pump 1 pulley hub 2 shaft 3 cover 4 impeller 5 housing 6 thrust ring 7 oil seal 8 bearing stop screw 9 pulley 10 blower fan 11 cover plate 12 fan hub ...

Page 37: ...e 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 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...

Page 38: ...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 ...

Page 39: ... 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 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 gal...

Page 40: ...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 per...

Page 41: ...e bushes For removal and refitting use tool Ä 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 concentric ity of the shaft bushes use the finishing reamer Ä 90353 for con ...

Page 42: ...r man ifold to draw crankcase emission on the throttle body to the side of the air cleaner 42 Fig 2 73 Removal and refitting of the oil pump distributor shaft bush 1 tool Ä 60333 1 2 Fig 2 74 Pressing out the oil pump distributor inner gear bush 1 tool Ä 60326 R Fig 2 75 Crankcase ventilation diagram 1 filter element air cleaner 2 exhaust manifold 3 flame arrester 4 hose to draw crankcase emission...

Page 43: ...urs 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 ma...

Page 44: ...ver 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 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 distance gasket ...

Page 45: ...ce 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 Ç with the gasket Ä When the size d is over 1 3 mm replace the gas ket Ç with the gasket ë Recheck the size d and secur...

Page 46: ...zer 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 46 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 va...

Page 47: ...et marking 40 spring compression 9 5 mm length N 14 5 15 Accelerator pump atomizer marking 45 delivery 10 full strokes cc 14 cam marking 4 Starting clearances choke valve clearance Ç mm 3 0 throttle valve clearance ë mm 1 1 Diameters mm crankcase vent drilling 1 2 vacuum advance unit orifice 1 2 needle valve bore 1 8 fuel return orifice to petrol tank 0 70 _________________________________________...

Page 48: ...ve 7 float 8 secondary throttle valve 9 main fuel jets 10 primary throttle valve 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 adjustme...

Page 49: ...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 en...

Page 50: ... 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 cutoff solenoid 4 is disactivated to shut off fuel supply When the idle switch is not grounded the solenoid will not be disabled 5...

Page 51: ...e 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...

Page 52: ... throttle stop 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 filter Wash the...

Page 53: ...ning 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...

Page 54: ...itting 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 pi...

Page 55: ... 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 ë the thermo vacuum switch triggers t...

Page 56: ...aust 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 Fig 2 93 ...

Page 57: ...7 clutch bellhousing 8 bellhousing to flywheel bolt 9 gearbox input shaft 10 clutch release bearing assembly 11 clutch release fork 12 release fork ball 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 21 locknut 22 protective cap ...

Page 58: ...drive adjustment 58 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 ãëñ 15 or îËÓÎ 1 îËÓÎ 2 In case of badly worn splines causing seizure renew input shaft or clutch disc 6 Renew clutch cover pressure plate assembly 7 Bleed system 8 Tighten connections renew damaged components bleed sy...

Page 59: ... check the tightness of connections find out if there are cracks on tubes or leaks in places of connections Air inleak is possible through 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 liqu...

Page 60: ...disc hub and the gearbox input shaft clean the splines and grease with a thin layer of greasing ãëñ 15 or îàéã 1 îàéã 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 gearbox input shaft splined end fig 3 4 60 Fig 3 3 Slave cylinder and clutch release fork 1 release bearing 2 ball pivot 3 clutch ...

Page 61: ...ed 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 the clutch disc or the damper springs 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...

Page 62: ...etaining washer 7 cap 8 circlip 9 pushrod piston 10 sealing ring 11 master cylinder piston 12 spring Fig 3 7 Straightening the clutch disc Fig 3 9 Slave cylinder components 1 body 2 bleeder 3 cap 4 pushrod 5 sealing ring 6 piston 7 sealing ring 8 sleeve 9 spring 10 disc 11 lock ring ...

Page 63: ...king 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 reser...

Page 64: ...er 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 flang...

Page 65: ...d 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 idle...

Page 66: ...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 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 15 Clutch bellhousing view from inside The black a...

Page 67: ...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 a...

Page 68: ...haft 6 1st 2nd selector rod 7 3rd 4th selector rod Fig 3 22 Removing the 5th speed reverse selector rod 1 5th reverse selector rod 2 5th reverse fork 3 distance sleeve 4 gear unit Fig 3 21 Removing the 5th gear bush 1 bush 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 ...

Page 69: ... 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 69 Fig 3 25 Withdrawing the intermediate shaft from transmission casing Fig 3 2...

Page 70: ...t fig 3 31 from the rear end of the shaft remove the 1st synchro gear 11 with 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 ...

Page 71: ... 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 ãàíéã 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 th...

Page 72: ...ase 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 72 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...

Page 73: ... 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 ...

Page 74: ...ge 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 w...

Page 75: ...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 75 Fig 3 35 Transfer box 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 oi...

Page 76: ...l locking fork rod 7 front axle case cover 8 lock washer 9 lever shaft bush 10 lever shaft 11 differential locking lever 12 gear shift fork rod 13 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 ...

Page 77: ...t 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 77 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 37 Transfer box mountin...

Page 78: ...r 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 78 Fig 3 41 Drive shaft and layshaft components 1 flange 2 oil seal 3 bearing thrust ring ...

Page 79: ...gear moment of resistance to rotation should not exceed 14 7 N m 1 5 kgf m 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 w...

Page 80: ...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 loa...

Page 81: ...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 pliers Press out the bearing housing from the U joint yoke Proceed as follows place the propeller sh...

Page 82: ...he 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 158 or îàéã 2ì 0 8 1 2 gr on each bearing Do not grease the spider thorns to avoid an air plug dur...

Page 83: ... 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 cm3 of Longtern 00 from Dow corning Shaft balance The front and rear propeller sha...

Page 84: ...oving 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 g...

Page 85: ... axle shaft 1 axle shaft 2 knockout tool 67 7823 9516 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 suspension spring cup 13 rear axle beam 14 rear suspension bar mounting bracket 15 axle shaft guide 16 differential ...

Page 86: ...icator or a feeler gauge with a try square 4 The maximum pressing force during straightening should not exceed 98 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 flang...

Page 87: ...d 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 s...

Page 88: ... 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 reductio...

Page 89: ...le 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 ...

Page 90: ... 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...

Page 91: ...inimum reading of a1 fig 3 72 and record Repeat this operation on the landing surface of the second bearing and record the reading of a2 Define thickness S of the driving gear adjusting ring which is an algebraic difference between a and b S a b Where a average arithmetic distance from the tool 1 face fig 3 64 to the differential bearing journals a a1 a2 2 b deviation of the driving gear from the ...

Page 92: ...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 N cm 20 kgf cm and 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 les...

Page 93: ...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 ge...

Page 94: ...d 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 conside...

Page 95: ...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 braking plate to the axle beam and using a pusher remove the axle shafts from the differ ential box disconnect the pro...

Page 96: ... 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 the 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 o...

Page 97: ...nt 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 ...

Page 98: ...el 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 wheel hub bearing nuts adjust the bearing cleara...

Page 99: ...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 òêìë 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 bal...

Page 100: ...t work 4 Loose fastening nuts on balljoint pins 5 Misalignment of front wheels 6 Worn arm shaft silent blocks 7 Wheels are significantly out of balance 8 Worn arm balljoints Often stiffness in suspension 1 Suspension springs set down 2 Shock absorbers do not work 3 Deformed front suspension arms Excessive gap in balljoints 1 Worn balljoint rubbing surfaces as a result of fouling due to leaks in sh...

Page 101: ... valve leak 2 Insufficient amount of liquid due to leak 3 Worn guide bush and rod 4 Impurities in liquid 5 Worn or damaged compression valve discs Shock absorber knock and squeak 1 Worn rubber bushes in eyes 2 Impact deformation of boot 3 Insufficient amount of liquid due to leak 4 Loose tank and piston fastening nuts 5 Jammed rod due to deformation of cylinder tank or rod 6 Loose shock absorber f...

Page 102: ... 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 e...

Page 103: ...ower 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 2...

Page 104: ...ness of 0 75 mm Plus adding a washer minus removing a washer To adjust the caster angle undo the fastening nuts of 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 nut...

Page 105: ...ion 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 und...

Page 106: ...he rim with special springs 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...

Page 107: ...ngles and toe in Suspension units dismantle and reassembly Dismantle If 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 ou...

Page 108: ...e 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 Ä 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 sid...

Page 109: ...r 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 out joint 3 from the aperture To press out the second joint turn over the...

Page 110: ...draulic 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 c...

Page 111: ...oils 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 i...

Page 112: ...valve cap 12 recoil valve discs 13 piston ring 14 recoil valve nut washer 15 recoil valve throttling disc 16 by pass valve cap 17 by pass valve spring 18 restricting plate 19 tank 20 rod 21 cylinder 22 housing 23 rod guide sleeve 24 tank sealing ring 25 oil seal retainer 26 rod oil seal 27 gasket 28 rod guard ring 29 tank nut 30 shock absorber eye upper 31 front suspension shock absorber securing ...

Page 113: ... 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...

Page 114: ...e tie rod ballpin nuts 6 Loose fastening bolts on stee ring box or slave arm shaft brack et 7 Wrong roller to worm gap Vehicle wandering 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 Vehicle unstable 1 Wrong front wheel alignment ang...

Page 115: ...m bear ing cover lower 21 roller shaft 22 ball bearing 23 worm shaft oil seal B C marks 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 mounti...

Page 116: ...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...

Page 117: ...fit 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 ...

Page 118: ...rizon 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 Drai...

Page 119: ...ten 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 N cm 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 rotat...

Page 120: ...t 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 screwed in to an angle smaller than 60 to provide for subse quent splinting After refitting adjust the front wheel toe in Check and r...

Page 121: ...of drums 3 Excessive oil on friction linings 4 Worn linings or trapped detri mental inclusions 5 Excessive disc runout or non uniform wear 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...

Page 122: ...linder tank 13 pressure regulator 14 pressure regulator control arm 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 val...

Page 123: ...lightly 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 ...

Page 124: ...n layer of Ñí 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 upward...

Page 125: ...ector 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...

Page 126: ...and refit the springs use tool A 70017 Reassembly of the master cylinder is carried out in reverse order When reassembling grease with ãàíéã 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 126 Fig 6 8 Clutch brake pedal bracket exploded view 1 bracket 2 nut 3 spring washer 4 brake pedal inner...

Page 127: ...he 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 t...

Page 128: ...2 Before repairing the brakes carefully wash them in warm water with washing liquids and immediately dry with a jet of com pressed air 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 R...

Page 129: ... 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...

Page 130: ...ake 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 o...

Page 131: ...st 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 Inspec...

Page 132: ... 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 cm2 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 cm2 during 5 minutes is permissible ...

Page 133: ...g 3 When reassembling which is carried out in reverse sequence 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...

Page 134: ...e Handbrake adjustment When refitting grease with ãàíéã 24 or ãëñ 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 th...

Page 135: ...135 ...

Page 136: ...136 ...

Page 137: ...g light Oil pressure warning light Coolant temperature gauge Low fuel gauge and fuel reserve warning light Tachometer 3 8Ä Left hand headlight main beam Main beam warning light 4 8 Ä Right hand headlight main beam 5 8 Ä Left hand headlight dipped beam 6 8 Ä Right hand headlight main beam 7 8 Ä Left hand front lamp side marker light Right hand front lamp side marker light Number plate light Side ma...

Page 138: ...n 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 hea...

Page 139: ...witch 51 switch windscreen washer 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 ...

Page 140: ...s 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 Alwa...

Page 141: ... 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 ë should be as shown in Table 7 4 When recharging the battery frequently check the electrolyte temperature to keep i...

Page 142: ...ing 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 voltag...

Page 143: ...tor 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 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...

Page 144: ...ct the battery lead to the regulator terminal Ç 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...

Page 145: ...t 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 bul...

Page 146: ...r minals The terminals Ç Å when available and earth ter minal should be connected 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 ci...

Page 147: ...upplementary 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 regu...

Page 148: ... starter motor is of pre engaged type 35 3708 model DC with field coils incorporating 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 ...

Page 149: ...ble 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 overhaul damaged components to remedy the situation No load test Disengage the tester...

Page 150: ...ture 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 ...

Page 151: ... 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 r...

Page 152: ...gap 5 Spark plug damaged perished insulation 6 Wrong HT leads connection to distributor cap terminals 7 Wrong ignition timing Engine operates erratically or stalls at idle 1 Ignition timing too advanced 2 Electrode gap excessive Engine running unstable or irregular at high crankshaft speeds Weak weight springs in ignition distributor 150 1 Carry out the following check wiring and connections renew...

Page 153: ...tion 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...

Page 154: ...dule 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 ...

Page 155: ... 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 ...

Page 156: ...lator 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 wi...

Page 157: ...t 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 èÇÇè 8 or 2...

Page 158: ...n 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 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 dir...

Page 159: ... canceling device inoperative 1 Cancelling mechanism seized 2 Combination switch guide ring shoulders worn or broken Steering column levers fail to switch between the positions 1 Lever catch balls jammed 2 Self cancelling device seized Turn signal warning light inoperative 1 Bulb filament blown 2 Indicators flasher relay faulty Direction indicator warning light flashes at higher rate 1 Direction i...

Page 160: ...hts 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 Rear light unit To repla...

Page 161: ...e windscreen wiper con tinuous operation and intermittent operation ensured by a relay of êë 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...

Page 162: ...attery 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 160 Fig 7 35 Windscreen wiper motor components 1 cover 2 panel 3 drive gear 4 steel washer 5 tekstolite washe...

Page 163: ...elay 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 ë The resistance of the electromagnet winding is 66 2 Ohm while the breaker winding resistance is 23 1 éhm When the wiper is activated for an intermittent oper...

Page 164: ...g 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 No5 in the supplementary fuse box and discon nected cigarette lighter To restore the cigarette lighter operation eliminate the cause of its lengthy operation dismantle the cigarette lighter...

Page 165: ... knob in the instrument cluster Reset the trip counter only on a stationary vehicle turning the knob clockwise WARNING To avoid damage to the instrument cluster glass never use solvents for its cleaning Fault diagnosis Cause Remedy Temperature gauge or fuel gauge inoperative 1 Gauge faulty 2 Sender unit faulty 3 Wires damaged or wire ends corroded Fuel gauge at zero with full tank Float stop set i...

Page 166: ...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 ...

Page 167: ... 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 éhm it should stay at the beginning of the re...

Page 168: ...ntrol 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 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 ...

Page 169: ...ft 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 Failure to unlock door with interior handle Insufficient travel of inner control lever due to insufficient operating link travel Failure to unlock bonnet from passenger compartment 1 L...

Page 170: ...tap linkage 2 Heater tap fails to shut off water flow Air to interior compartment is not heated 1 Heater tap inoperative due to faulty tap cable drive 2 Faulty heater tap Insufficient air inflow to interior Inoperative air intake cover cable drive cover closed 168 1 Renew spring 2 Adjust operating link length through loop on lock hook 3 Adjust lock position Renew window lifter 1 Lubricate friction...

Page 171: ...ut 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 ë cherry red...

Page 172: ...e 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 Fi...

Page 173: ...ëÛ 18 2 type or èéëëÛ 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 i...

Page 174: ...ric CO2 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 Strict...

Page 175: ...d 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 ...

Page 176: ... encouraging rust For the purposes of noise reduction corrosion protection and wear resistance the underbody and chassis arms are factory treated with PVC plasticate Plastisol Ñ 11Ä of 1 1 5 mm thick ness over epoxy ùî 083 primer 174 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...

Page 177: ...ort bulk head between the bulkhead and front cover plate between the rear floor rear floor extensions and rear wheel arches bodysides and rear end cross member 175 Fig 8 8 Underneath view of the body Inner cavities of 1 front chassis arms 2 front chassis arms Òonnections 3 middle chassis arms 4 middle chassis arms connectors 5 rear floor cross member 6 rear chassis arms 7 rear end cross member Tab...

Page 178: ...iew 1 front chassis arm connection with bottom radiator support 2 front chassis arm to bulkhead joints 3 battery tray to bulkhead connection from passen ger compartment side 4 bulkhead to front cover abutting joints from engine compartment side Fig 8 11 Locations for 51 É 7 type sealant application rear body view 1 rear floor to rear wheel arch joints 2 slots in angular joints of rear floor extens...

Page 179: ...m 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 13 177 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 ...

Page 180: ...ter 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 c...

Page 181: ...finally tighten the 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 u...

Page 182: ...e 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 w...

Page 183: ... 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 t...

Page 184: ...etainer 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 1 slide 2 seat sliding mechanism handle 3 bottom seat back rake adjuster lever 4 seat sliding spring 5 locking catch 6 shaft 7 stop 8 catch 9 roller 10 tracks Fig 8 32 Front seat back reclining and tipping mechanisms 1 hook 2 spring 3 botto...

Page 185: ...ts mechanically Lower down handle 2 and Ë 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 relevan...

Page 186: ...connections for leaks 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 c...

Page 187: ...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...

Page 188: ...g 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 ...

Page 189: ... 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 conne...

Page 190: ...he 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 pr...

Page 191: ...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 pr...

Page 192: ...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 Disc...

Page 193: ...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...

Page 194: ...nsor 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 va...

Page 195: ...rail hydraulic valve lifter 5 camshaft 6 hydraulic valve lifter 7 nut Fig 9 11 Exploded view of chain tensioner 1 chain 2 tensioner shoe 3 oil delivery pipe to tensioner 4 chain tensioner 5 camshaft sprocket 6 chain damper 7 oil pump shaft sprocket 8 crankshaft sprocket ...

Page 196: ...ooling 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 cow...

Page 197: ...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 eleme...

Page 198: ...ate fusebox 26 underneath the left hand end trim cover Refer to Table 9 2 for details Table 9 2 Injection system fuses Fuse Circuits protected 1 2 Electric fuel pump relay contacts 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...

Page 199: ...r 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...

Page 200: ... 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 3 Engine does not start emitting white smoke cold engine Check the following items ...

Page 201: ...iece íëé 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...

Page 202: ...e 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...

Page 203: ...aft pulley coat bolt 20 with Loctite 243 fix the flywheel with tool OUT0000049 refit the pulley retaining bolt torque to 40 N m turn to fur ther 60 refit bottom cover 3 Fig 9 21 tighten bolts 1 to 15 N m refit cover 5 tighten bolts 4 to 15 N m tighten right hand cover 6 bolt 7 to 10 N m Note When you fail to refit any securing bolt or a retainer repeat the complete procedure for the cambelt refitt...

Page 204: ...aks 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 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 ...

Page 205: ...When the ignition is switched on the alternator Ç 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 F...

Page 206: ...chometer 5 resistor 50 éhm 5 W 6 low battery warning light 7 fusebox 8 ignition relay 9 control mod ule theft deterrent system 10 ignition switch Fig 9 27 Wiring diagram for starter motor 1 starter motor 2 battery 3 alternator 4 ignition relay 5 control module theft deterrent system 6 ignition switch ...

Page 207: ... renewed in case of failure Motor specification Nominal motor shaft speed with impeller load rpm 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 T...

Page 208: ...ontrol 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 t...

Page 209: ...erential lockup sensor 12 To low oil pressure sensor 13 To brake fluid level sensor 207 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 Fig 9 34 Wiring diagram f...

Page 210: ...33 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 Tu...

Page 211: ...ring 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 37 Steering components ...

Page 212: ... 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 instru...

Page 213: ...nual 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 Ä 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 re...

Page 214: ... 25 30 67 39 3 13 3 99 Coolant pump retaining bolt å8 21 66 26 75 2 21 2 73 Nut water jacket exhaust manifold å8 15 97 22 64 1 63 2 31 Crankshaft ratchet å20ı1 5 101 3 125 64 10 34 12 8 Alternator bracket bolt å10ı1 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 reta...

Page 215: ...earing å18ı1 5 96 117 6 9 8 12 0 Nut holding propeller shaft flange to driving shaft and to front rear axle driveshafts å16ı1 5 96 117 6 9 8 12 0 DRIVE LINE Nut bolts holding flexible coupling to gearbox and transfer box flanges å12ı1 25 57 8 71 5 5 9 7 3 Nut bolt holding propeller shaft flange to flanges of front rear axles reduction gear and transfer case å8 27 4 34 3 2 8 3 5 FRONT AXLE Front ax...

Page 216: ...er arm shaft nut å14ı1 5 63 7 102 9 6 5 10 5 Nut swing arm retaining bolt å12ı1 25 66 6 82 3 6 8 8 4 REAR SUSPENSION Shock absorber retaining nut å12ı1 25 38 2 61 7 3 9 6 3 Nut Panhard rod and trailing arms retaining bolts å12ı1 25 66 6 82 3 6 8 8 4 STEERING Nut steering box retaining bolt å10ı1 25 33 3 41 2 3 4 4 2 Nut idler arm bracket retaining bolt å10ı1 25 33 3 41 2 3 4 4 2 Nut steering rod b...

Page 217: ...ndle valve seat machining Ä 94059 Set of guides valve seat machining Ä 94069 Grinding wheel spindle valve seat machining Ä 94078 Grinding wheel exhaust valve seat machining Ä 94092 Core drill exhaust valve seat machining Ä 94100 Grinding wheel inlet valve seat machining Ä 94101 Core drill 20 inlet exhaust valve seat machining Ä 95111 Blade for checking camshaft valve lever cam lobe clearance 02 78...

Page 218: ...aring nuts Ä 70152 Tool for pressing rear bearing inner race to driving pinion Ä 70157 Installation tool axleshaft oil seal Ä 70171 Tool for pressing in driving pinion rear bearing outer race Ä 70172 Pair of flanges to be fitted to rear axle beam ends during its inspection truing Ä 70184 Tool to determine shim thickness to adjust clearance in final drive gear meshing Ä 70185 Tool for pressing in d...

Page 219: ... 9536 Tool for pressing in front wheel hub bearing outer race 67 7853 9540 Washer for pressing out wheel hub bearing inner race oil seal 67 8732 9501 Tool for checking geometry of front suspension cross member REAR SUSPENSION 67 7820 9517 Tool kit replacement of rear suspension rod silent blocks STEERING Ä 47035 Separator tool for pressing out steering joints from drop arm and idler arm Ä 47043 Re...

Page 220: ...rake pedal free play engine stalled mm 3 5 Steering wheel play vehicle in straight ahead position not greater degrees mm 5 18 20 Front wheel toe in run in vehicle at 3140 N 320 kgf mm 2 4 Front wheel camber run in wheel at 3140 N 320 kgf degrees mm 0 30 20 1 5 Castor run in vehicle at 3140 N 320 kgf degrees 3 30 30 Tyre pressure åPa kgf cm2 front wheels 0 21 2 1 rear wheels 0 19 1 9 Backlash front...

Page 221: ...to 30 ë 10W 40 20 to 40 ë 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 ë Steering box 0 18 80W 90 26 to 35 ë Transfer case 0 75 85W 90 12 to 45 ë 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 alcoho...

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