Vaz 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 VAZ-21213

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

Page 2: ...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 hapter 7 Electrical system 135 Wiring an...

Page 3: ...quipment 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 r...

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...

Page 5: ...rive 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...

Page 6: ...lying 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...

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 P 10 kgf m2 broken or sticking piston rings poor valve to seat fitting excessively worn cylinders or piston rings 9 1 Carry out the following operations blow fu...

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 c...

Page 11: ...ater 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 h...

Page 12: ...uts 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...

Page 13: ...o 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 separ...

Page 14: ...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...

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...

Page 16: ...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...

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...

Page 18: ...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...

Page 19: ...roller 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 Th...

Page 20: ...nder 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...

Page 21: ...er 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 wi...

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...

Page 23: ...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 t...

Page 24: ...an 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 bo...

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 i...

Page 26: ...splacement 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...

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 t...

Page 28: ...head carry out the following operations Apply the handbrake remove the spare wheel and discon nect the battery negative lead Remove the air cleaner and protect the carburettor with the provisional plu...

Page 29: ...Remove the rocker lever springs Slacken lock nuts 14 undo adjuster bolts 13 and bushes 15 Position tool 60311 R as shown in Fig 2 44 compress the valve springs and release the collets A stationary too...

Page 30: ...ool 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 va...

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...

Page 32: ...er 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...

Page 33: ...rsal 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...

Page 34: ...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...

Page 35: ...p 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...

Page 36: ...sion 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 pu...

Page 37: ...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...

Page 38: ...mmerse 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 alum...

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...

Page 40: ...pplicable 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...

Page 41: ...the bushes For removal and refitting use tool 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 cylin...

Page 42: ...or 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 60333 1 2 Fig 2 74 Pressing...

Page 43: ...ours 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 fu...

Page 44: ...er 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 p...

Page 45: ...place the gasket B on the face mating the pump Using tool 67 7834 9506 measure the distance d minimum rod protru sion to be set through slow crankshaft rotation When the size d is within 0 8 1 3 mm se...

Page 46: ...er 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 dat...

Page 47: ...jet 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 mm 3 0 throttle va...

Page 48: ...e 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 tub...

Page 49: ...s 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 decreas...

Page 50: ...g 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...

Page 51: ...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 th...

Page 52: ...hrottle 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...

Page 53: ...ing 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 pet...

Page 54: ...ting 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 clearan...

Page 55: ...e 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...

Page 56: ...ust 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 se...

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Vaz VAZ-21213, Repair Manual

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