VAZ 21213a.pdf

VAZ VEHICLES

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

REPAIR MANUAL

Contents

Alternator .......................................................................140

Starter motor .................................................................146

Ignition system ..............................................................149

Lighting and signalling...................................................156

Windscreen wiper/washer .............................................159

Instruments....................................................................163

Section 1. General data ..........................................................4

Section 2. Engine ..................................................................7

Engine - removal and reﬁtting..........................................12

Cylinder block ..................................................................19

Inspection and repair..................................................19

Pistons and connecting rods ...........................................21

Selecting piston to cylinder ........................................23

Dismantling and reassembly ......................................23

Crankshaft and ﬂywheel ..................................................24

Design description......................................................24

Inspection and overhaul .............................................24

Cylinder head and valve gear..........................................26

General description ....................................................26

Valve clearance adjustment .......................................27

Cylinder head - removal and reﬁtting .........................28

Cylinder head - dismantling and reassembly ............28

Camshaft and timing gear ...............................................32

Cooling system ...............................................................34

Lubrication system ...........................................................38

Fuel system .....................................................................42

Carburettor.......................................................................46

Exhaust gas recirculation system ....................................55

Exhaust system ...............................................................46

Chapter 8. Bodywork .........................................................167

Bodywork - repair .........................................................169

Paintwork.......................................................................172

Door...............................................................................176

Bonnet, bumpers ...........................................................179

Bodywork glazing and windscreen washers .................180

Instrument panel, seats .................................................181

Heater unit.....................................................................183

Chapter 9. VAZ-21213 vehicle modifications, alternative and addi-

tional equipment ...............................................................185

VAZ-21214 vehicle ........................................................185

Engine repair - description ............................................185

Central Injection Unit .....................................................186

VAZ-21214-20 vehicle ...................................................189

Engine 21214-10 ...........................................................190

VAZ-21215-10 vehicle ...................................................197

Cooling system..............................................................200

Lubrication system ........................................................202

Fuel system ...................................................................202

Exhaust emission system..............................................203

Electrical system ...........................................................203

Steering with BREED «SRS-40»

driver’s airbag in the steering wheel ............................209

Chapter 3. Power train .........................................................57

Clutch ..............................................................................57

Gearbox...........................................................................64

Transfer box ....................................................................73

Drive line .........................................................................80

Rear axle .........................................................................84

Front axle ........................................................................96

Chapter 4. Wheel suspensions ...........................................100

Front suspension...........................................................102

Rear suspension............................................................110

Attachments .....................................................................212

Chapter 5. Steering ...........................................................115

Steering - inspection, check and adjustment ................116

Steering mechanism......................................................118

Chapter 6 Braking system ..................................................121

Front brakes ..................................................................128

Rear brakes...................................................................130

Handbrake .....................................................................134

hapter 7. Electrical system ...............................................135

Wiring and fuses ...........................................................135

Battery ...........................................................................136

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çä. Ü 0021311

About this manual

This Manual provides information on routine maintenance and servicing and is intended for engineers

and mechanics of service outlets, garages and workshops.

The Manual covers the following models:

VAZ-21213 model - an off-road vehicle, three-door body of all-steel unitary construction,

with 1.7 litre carburettor engine;

VAZ-21214 model - with 1.7 litre Central Fuel Injection Engine;

VAZ-21214-20 model - with 1.7 litre Sequential Fuel Injection Engine;

VAZ-21215 model - with Turbo Diesel Engine.

The chapters of the manual give full descriptions of VAZ-21213 vehicle units. For general description,

service and repair procedures applicable to other models, refer to Section 9 where you can also find the

information on additional and alternative equipment fitted to the vehicles.

The Manual provides a detailed description of service operations on the base of OEM parts, with help-

ful information on fault diagnosis, along with clear indications on removal and refitting, dismantling and

reassembly, adjustment and repair of various vehicle units.

We recommend to use special tools and working facilities as listed in Attachment No 2. Tighten the

thread connections to torques specified in Attachment No 1. Basic adjustments and inspection checks are

outlined in Attachment No 3. Refer to Attachment 4 for recommended lubricants and fuels.

Due to the on-going process of vehicle improvement aimed to enhance the VAZ vehicle reliability and

performance, the manufacturer can make alterations and design changes which may fail to enter this pub-

lication. Such changes and alterations will be incorporated into our manuals at the earliest opportunity.

The Manual describes the vehicle design as of October 1999.

Section 1. General Data

Table 1-1

TECHNICAL SPECIFICATION

Features

VAZ-21213

VAZ-21214

VAZ-21214-20

VAZ-21215

General

Number of seats

Kerb weight, kg

1210

1240

Payload, kg

400

Overall dimensions

Fig.1-1

Maximum braking distance at GVW and 80 km/h

on horizontal dry flat asphalt road, not greater, meters:

¥ with service braking system applied

¥ with emergency system applied (either of two service braking circuits) 90

Maximum speed* in top gear, km/h:

¥ with driver and passenger

137

130

¥ at full load

135

128

Acceleration time*, 0 to 100 km/h through gear shifting, seconds:

¥ with driver and passenger

¥ at full load

Engine

Model

21213

21214

21214-10

DHW (XUD-9SD)

Type

Four-stroke,

petrol, carburettor

petrol, CFI

petrol, sequential injection

turbo diesel

No of cylinders

four in-line

Bore x stroke, mm

82õ80

83õ88

Capacity, litre

1.69

1.905

Compression ratio

9.3:1

21.5:1

Maximum power:

as per GOST 14846 (net), at least, êW (h.p.)

58 (78.9)

58.5 (79.6)

55 (74.8)

as per ISO 1585, êW

58.5

Maximum crankshaft speed at maximum power, rpm

5200

5400

5000

4600

Firing order

1-3-4-2

____________________________________

* Measured using a special procedure

Features

VAZ-21213

VAZ-21214

VAZ-21214-20

VAZ-21215

Power train

Clutch

single dry plate, diaphragm spring

Clutch release mechanism

hydraulic, servo spring

Transmission

5-speed, synchro units on all forward gears

Gear ratio:

¥ first gear

3.67

¥ second gear

2.10

¥ third gear

1.36

¥ fourth gear

1.00

¥ fifth gear

0.82

¥ reverse gear

3.53

Transfer case

two-gear, lockup differential

Gear ratio:

¥ top gear

1.2

¥ bottom gear

2.135

Transfer case differential

bevel gears, two pinion gears

Drive line:

¥ from transmission to transfer case

flexible coupling and CV joints

¥ from transfer case to front and rear axles

two universal joints on needle bearings with grease nipples and yokes

¥ from front axle to wheels

open, with CV joints

Final drive ratio, front and rear axles

bevel, hypoid

¥ gear ratio

3.9

¥ differential

bevel, two pinion gears

Suspension and wheels

Front suspension

independent, lower track control arms (wishbones), coil springs,

hydraulic telescopic shock-absorbers, anti-roll bar

Rear suspension

rigid axle beam with Panhard rod and four trailing arms,

coil springs/hydraulic telescopic shock-absorbers

Wheels

pressed-steel disc

¥ wheel rim

127J x 406 (5J x 16)

Tyres

tubed, cross-ply or radial ply

size:

¥ cross-ply tyres

175 x 406 (6.95 x16),

¥ radial-ply tyres

175/80R16

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