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RR213 R1-2 Engl
VAZ VEHICLES
VAZ-21213, VAZ-21214, VAZ-21214-20, VAZ-21215
REPAIR MANUAL
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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
Äâòîìîáèëè Ä-21213, Ä-21214, Ä-21214-20, Ä-21215
óêîâîäñòâî ïî ðåìîíòó àâòîìîáèëåé
© Ä ÄÄ Ä Ä/ ÄÄ
© Äâòîðû-ðàçðàáîò÷èêè: îëãèí . ., îçëîâ . ., îñàðåâ . .
© åðåâîä . Äíèñîâîé, . òàíêîâîé
© àêåò-îðèãèíàë èçãîòîâëåí Ä Ä ÄÄ. îìïüþòåðíàß âÞðñòêà è îôîðìëåíèå - . Äëàåâ, . âêîâ, . èòðîôàíîâ. òåë. (8482) 22-54-19.
çä. Ü 0021311
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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.
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Section 1. General Data
Table 1-1
TECHNICAL SPECIFICATION
Features
VAZ-21213
VAZ-21214
VAZ-21214-20
VAZ-21215
General
Number of seats
5
5
5
5
Kerb weight, kg
1210
1210
1210
1240
Payload, kg
400
400
400
400
Overall dimensions
Fig.1-1
Maximum braking distance at GVW and 80 km/h
on horizontal dry flat asphalt road, not greater, meters:
¥ with service braking system applied
40
40
40
40
¥ with emergency system applied (either of two service braking circuits) 90
90
90
90
Maximum speed* in top gear, km/h:
¥ with driver and passenger
137
137
137
130
¥ at full load
135
135
135
128
Acceleration time*, 0 to 100 km/h through gear shifting, seconds:
¥ with driver and passenger
19
19
19
22
¥ at full load
21
21
21
24
Engine
Model
21213
21214
21214-10
DHW (XUD-9SD)
Type
Four-stroke,
Four-stroke,
Four-stroke,
Four-stroke,
petrol, carburettor
petrol, CFI
petrol, sequential injection
turbo diesel
No of cylinders
four in-line
four in-line
four in-line
four in-line
Bore x stroke, mm
82õ80
82õ80
82õ80
83õ88
Capacity, litre
1.69
1.69
1.69
1.905
Compression ratio
9.3:1
9.3:1
9.3:1
21.5:1
Maximum power:
as per GOST 14846 (net), at least, êW (h.p.)
58 (78.9)
58 (78.9)
58.5 (79.6)
55 (74.8)
as per ISO 1585, êW
58
58
58.5
55
Maximum crankshaft speed at maximum power, rpm
5200
5400
5000
4600
Firing order
1-3-4-2
1-3-4-2
1-3-4-2
1-3-4-2
____________________________________
* Measured using a special procedure
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Features
VAZ-21213
VAZ-21214
VAZ-21214-20
VAZ-21215
Power train
Clutch
single dry plate, diaphragm spring
Clutch release mechanism
hydraulic, servo spring
Transmission
5-speed, synchro units on all forward gears
Gear ratio:
¥ first gear
3.67
3.67
3.67
3.67
¥ second gear
2.10
2.10
2.10
2.10
¥ third gear
1.36
1.36
1.36
1.36
¥ fourth gear
1.00
1.00
1.00
1.00
¥ fifth gear
0.82
0.82
0.82
0.82
¥ reverse gear
3.53
3.53
3.53
3.53
Transfer case
two-gear, lockup differential
Gear ratio:
¥ top gear
1.2
1.2
1.2
1.2
¥ bottom gear
2.135
2.135
2.135
2.135
Transfer case differential
bevel gears, two pinion gears
Drive line:
¥ from transmission to transfer case
flexible coupling and CV joints
¥ from transfer case to front and rear axles
two universal joints on needle bearings with grease nipples and yokes
¥ from front axle to wheels
open, with CV joints
Final drive ratio, front and rear axles
bevel, hypoid
¥ gear ratio
3.9
3.9
3.9
3.9
¥ differential
bevel, two pinion gears
Suspension and wheels
Front suspension
independent, lower track control arms (wishbones), coil springs,
hydraulic telescopic shock-absorbers, anti-roll bar
Rear suspension
rigid axle beam with Panhard rod and four trailing arms,
coil springs/hydraulic telescopic shock-absorbers
Wheels
pressed-steel disc
¥ wheel rim
127J x 406 (5J x 16)
Tyres
tubed, cross-ply or radial ply
size:
¥ cross-ply tyres
175 x 406 (6.95 x16),
¥ radial-ply tyres
175/80R16
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