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Vaz -21213 Repair Manual
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Vaz -21213 Repair Manual

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

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Summary of Contents for Vaz VAZ-21213

  • Page 1 VAZ VEHICLES VAZ-21213, VAZ-21214, VAZ-21214-20, VAZ-21215 REPAIR MANUAL...

  • Page 2: Table Of Contents

    Valve clearance adjustment ........27 Cylinder head - removal and refitting ......28 Heater unit..............183 Cylinder head - dismantling and reassembly....28 Camshaft and timing gear ..........32 Chapter 9. VAZ-21213 vehicle modifications, alternative and addi- Cooling system ...............34 tional equipment...............185 Lubrication system............38 VAZ-21214 vehicle ............185 Fuel system ..............42...
  • Page 3 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.

  • Page 4: Section 1. General Data

    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 1210 1210 1240 Payload, kg Overall dimensions Fig.1-1 Maximum braking distance at GVW and 80 km/h on horizontal dry flat asphalt road, not greater, meters: •...
  • Page 5 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...

  • Page 6: Braking System

    Voltage, volts Battery 6ëí-55Ä, 55 ampere-hour Alternator AC, integral diode plate and electronic voltage regulator Starter motor pre-engaged, solenoid switch and overrun clutch Body Type all-steel unitary construction, monocoque, three-door, double-space Fig.1-1. Basic overall dimensions of VAZ-21213 vehicle...

  • Page 7: Section 2. Engine

    Section 2. Engine Refer to Fig.2-1 and Fig.2-2 for front and side sectional views of the engine. Fig.2-1. Side sectional view of the engine...
  • Page 8 Fig.2-2. Front sectional view of the engine...

  • Page 9: Fault Diagnosis

    Fault diagnosis Symptom/fault Remedy Engine fails to start 1. Carry out the following operations: 1. No fuel to carburettor: - blow fuel pipes, clean fuel tank, renew fuel filter; - blocked fuel pipes or fuel filter; - clean filters; - clogged carburettor or fuel pump filters; - check pump operation and renew any damaged components - faulty fuel pump 2.
  • Page 10 Main bearing knocking Typical knocking or thumping noticeable at sudden throttle opening at idle which intensifies with higher crankshaft rate. Excessive endfloat of crankshaft causes sharper irregular knocking, especially noticeable during smooth increase or decrease in crankshaft speed. 1. Early ignition 1.
  • Page 11 Excessive oil consumption 1. Oil leaking through engine gaskets 1. Tighten fittings or replace gaskets and oil seals 2. Restricted crankcase ventilation system 2. Wash components of crankcase ventilation system 3. Worn piston rings 3. Rebore and renew pistons and rings 4.

  • Page 12: Engine - Removal And Refitting

    Engine - removal and refitting Undo the nuts holding the downpipe to exhaust manifold. Detach the downpipe from the bracket on the transmission and Put the vehicle on a lift or over an inspection pit and apply the lower it down. handbrake.
  • Page 13 Fig.2-4. Removing the oil filter using tool Ä.60312 Fig.2-5. Releasing the crankshaft nut using tool Ä.50121 Remove the starter motor heat shield, followed by the starter motor, hot air intake complete with the supply hose. Remove from the cylinder head two side brackets together with the front engine mounting rubbers.
  • Page 14 Fig.2-7. Removing the camshaft thrust flange: 1 - thrust flange; 2 - camshaft; 3 - bearing housing; 4 - thrust flange securing Fig.2-8. Removing the oil pump shaft: stud 1 - thrust flange; 2 - flange securing bolt; 3 - oil pump shaft; 4 - wrench Remove thrust flange 1 (Fig.2-8) of the oil pump drive shaft and take the shaft out of the cylinder block.
  • Page 15 Fig.2-11. Pressing out the bearing from the crankshaft using tool A.40006 Fig. 2-12. Refitting the thrust washers to the rear mounting Fit the centre main bearing shells without an oilway into the bearing recesses. Fit into other cylinder bores the bearing shells with an oilway, while into the relevant main bearing caps - the bearing shells without an oilway.
  • Page 16 Fig.2-15. Crankshaft rear oil seal housing. Fig.2-16. Clutch dowels (arrowed black) and clutch housing centering pins (arrowed white) The lugs (arrowed) for centering the housing against the crankshaft flange Locate the flywheel in position so that the marking (a cut-out) near the rim is against the No 4 cylinder crankpin axis.
  • Page 17 Turn the flywheel so that the mark on the crankshaft sprock- et is against the cylinder block mark (Fig.2-19). Check to see the camshaft bearing housing centering pins are in position (Fig.2-20). Refit the sprocket to the camshaft com- plete with the bearing housing and turn the camshaft so that the timing mark in the sprocket is aligned against the mark on the bearing housing (Fig.2-21).
  • Page 18 Fig.2-23. Timing cover Fig.2-22. Camshaft bearing housing nuts tightening sequence Projections (arrowed) for cover centering against crankshaft pulley hub Adjust the clearance between the camshaft lobes and valve Fit the valve cover complete with the gasket and fuel piping levers. bracket.

  • Page 19: Cylinder Block

    Engine run-in after overhaul WARNING. Never check the engine or vehicle on the roller stand without additional rollers for the front wheels. After overhaul the engine is bench tested (run-in) at no loads under the following cycle: Cylinder block 750-800 rpm 2 minutes 1000 rpm 3 minutes...
  • Page 20 Fig.2-25. Basic sizes of the cylinder block Fig.2-27. Measuring the cylinder bore with the inside dial gauge: Fig.2-26. Cylinder size class engraved on the cylinder block 1 - inside dial gauge; 2 - setting to zero against reference gauge...

  • Page 21: Pistons And Connecting Rods

    There is practically no wear in the land 1 area of the cylin- There are five classes (Ä, Ç, ë, D, Ö) of the piston according ders. Compare the values measured on the first and other cylin- to their major diameter, in steps of 0.01 mm. The piston has a complex outside shape: tapered in height and oval in the cross- der lands to see the amount of the cylinder wear.
  • Page 22 The connecting rod small-end features a pressed-in steel- rod. The engine must always be fitted with the connecting rods of the same weight class. The connecting rod weight can be adjust- bronze bush. As to the diameter of the bush, the connecting rods ed by removing excess metal from the bosses on the small-end are divided into three classes in steps of 0.004 mm (similar to the or big-end up to the minimum size of 16.5 mm or 35.5 mm (Fig.2-...

  • Page 23: Selecting Piston To Cylinder

    Dismantling and reassembly Table 2-1 Connecting rod classification as to Dismantling. Prise out the gudgeon pin circlips from the pis- small-end and big-end weights ton, press out the gudgeon pin and detach the connecting rod from the piston. Remove the piston rings. Connecting rod weight, g Class Paint mark...

  • Page 24: Crankshaft And Flywheel

    0.02-0.05 mm for the oil control ring. When worn, the tolerance must not exceed the specified maximum of 0.15 mm. The piston ring gap should be checked with a feeler gauge via inserting the rings into the gauge (Fig.2-35), with the bore equal to the piston ring nominal diameter ±0.003 mm.
  • Page 25 Fig.2-36. Basic crankshaft dimensions crankpins. Regrind when the wear is in excess of 0.03 mm, oval- ity is over 0.03 mm, or when scoring and scuffing is obvious. Regrind the journals and crankpins through reducing the diameter to the nearest undersize (Fig.2-36). When regrinding, observe the sizes for the crankshaft fillet as shown in Fig.2-36 for the standard-size crankshaft.

  • Page 26: Cylinder Head And Valve Gear

    Fig.2-38. Measuring the big-end bearing running clearance: Fig.2-39. Flywheel: 1 - crushed Plastigage; 2 - bearing shell; 3 - big end cap; 4 - scale for clear- 1 - surface mating the crankshaft flange; 2 - surface for clutch securing; 3 - ance measurement clutching surface The nominal design clearance is 0.02-0.07 mm for the...

  • Page 27: Valve Clearance Adjustment

    Fig.2-40. Basic dimensions of the valves, valve guides and valve seats The outer diameter of the replacement guides is 0.2 mm big- ger. Bearing housing 5 with camshaft 6 is fitted to the cylinder head. Valve train. Valves 2 are operated by the cams through levers 4.

  • Page 28: Cylinder Head - Removal And Refitting

    Fig.2-42. Checking the clearance between the rocker levers and cam lobes: 1 - feeler blade Ä.95111; 2 - adjuster bolt; 3 - lock nut lock nut tightening, until the blade is a firm sliding fit when the lock nut is tightened (Fig.2-42); - after the clearance is adjusted at the cylinder No4 exhaust valve and cylinder No3 intake valve, turn the crankshaft progres- Fig.2-43.

  • Page 29: Cylinder Head - Dismantling And Reassembly

    Disconnect the leads from the spark plugs and coolant tem- Slacken lock nuts 14, undo adjuster bolts 13 and bushes 15. perature sender, from carburettor idle switch and fuel cutoff sole- Position tool Ä.60311/R, as shown in Fig.2-44, compress the noid.
  • Page 30 Fig. 2-46. Intake valve seat profile: Fig. 2-47. Exhaust valve seat profile: I - new seat; II - reconditioned seat I - new seat; II - reconditioned seat Put spring A.94069/5 on tool Ä.94059, fit tapered wheel A.94078 on spindle Ä.94069 for the exhaust valve seats or wheel Ä.94100 for the inlet valve seats, secure the spindle in a grinder and recut the valve seat (Fig.2-48).
  • Page 31 Fig.2-50. Limit sizes for valve chamfer regrinding: Fig.2-53. Valve spring checking diagram: I - inlet valve; II - outlet valve Ä - dimension in free state; Ç - dimension under load When a new valve fails to take up clearance between the valve guide and the valve rim, renew the valve guides using tool Ä.60153/R (Fig.2-51).

  • Page 32: Camshaft And Timing Gear

    In the cylinder bottom there is stop pin 6 to prevent the chain When replacing the bolts take care not to fit similar bolts from dropping into the crankcase when camshaft sprocket 1 is other VAZ engines of the same type (2101, 21011, 2103, 2107, removed. 2121), but made of different steel.
  • Page 33 Fig.2-56. Sectional view of the chain tensioner: 1 - cap nut; 2 - tensioner housing; 3 - core; 4 - spring; 5 - washer; 6 - plunger; 7 - spring; 8 - collet; 9 - spring ring; Ä - plunger surface; Ç - centre-punch points on housing face Before refitting, smear the chain with engine oil.

  • Page 34: Cooling System

    Check collet 8, core 3 and plunger 6 for scores, check the When necessary, use an areometer to check the coolant mating surfaces of the tensioner shoe and plunger for deep density to be 1.078-1.085 g/cu.cm for TOSOL A-40 which is used scores. Always renew any damaged components. in VAZ vehicles.
  • Page 35 When the level in the expansion tank is below the value spec- - disconnect the heater hose (top) from the union on the vehi- cle body; ified, while its density is in excess of that required, top up distilled water. - pour coolant (10.7 litre) to the radiator (up to the upper filler edge) until it starts flowing from the hose and heater union;...
  • Page 36 Fig.2-63. Removing the impeller: Fig.2-61. Checking the water pump belt tension 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: Coolant Pump

    Water pump drivebelt tension adjustment The belt tension is checked by exerting a hand pressure on the chain between the alternator pulley and pump pulley or between the pump pulley and crankshaft pulley. With proper ten- sion, slack A in the belt (Fig.2-61) at 98 N (10 kgf) must be 10-15 ÏÏ, while at the same pressure the deflection Ç...

  • Page 38: Lubrication System

    - disconnect the hoses from the radiator; - separate the fan cowl halves and withdraw the fan cowl; - undo two bolts holding the radiator to the body, release the upper catch of the radiator cowling upwards, move the radiator top towards the engine and withdraw the radiator from the engine compartment;...
  • Page 39 Fig.2-67. Lubrication system: 1 - oil passage to main bearing; 2 - main bearing-to-big-end bearing oil passage; 3 - oil filter relief valve; 4 - paper element; 5 - check valve; 6 - oil pump; 7 - oil pump-to- oil filter oil passage; 8 - oil passage from oil filter to main oil gallery; 9 - oil passage to oil pump gear and ignition distributor; 10 - oilway to oil pump shaft and ignition dis- tributor;...
  • Page 40 Fig.2-68. Basic dimensions of the oil pump components and associated parts Removal and refitting. When only the oil pump requires recon- housing and cover for cracks, renew when applicable. ditioning, remove it from the vehicle (Refer to section «Engine - Using feeler blades, check the backlash in the gears and the removal and refitting»), place it on the turning stand, drain the oil radial play (Fig.2-70) to be respectfully 0.15 mm (maximum per-...
  • Page 41 Fig.2-69. Dismantling the oil pump: Fig. 2-70. Checking the oil pump radial play 1 - relief valve; 2 - valve spring; 3 - cover; 4 - housing; 5 - shaft Oil pump shaft and drive gears Check to see there is no denting or scuffing of the shaft bear- ing journals or eccentric cam surfaces.
  • Page 42 Fig.2-73. Removal and refitting of the oil pump / distributor shaft bush: 1 - tool Ä.60333/1/2 Fig.2-75. Crankcase ventilation diagram: 1 - filter element, air cleaner; 2 - exhaust manifold; 3 - flame arrester; 4 - hose to draw crankcase emission on throttle body; 5 - discharge hose; 6 - oil sepa- rator cover;...

  • Page 43: Fuel System

    Fig.2-76. Air cleaner and temperature regulator: 1 - gasket; 2 - corrugated hose; 3 - air temperature control flap handle; 4 - cold air intake; 5 - temperature regulator; 6 - clamp bolt; 7 - air cleaner cover secur- ing nut; 8 - air cleaner cover; 9 - air cleaner cover gasket; 10 - filter element; 11 - filter cover mounting bracket;...
  • Page 44 Fig.2-78. Fuel tank and fuel pipeline associated components 1 - fuel tank; 2 - hoses, fuel vapour separator and fuel tank; 3 - fuel vapour separator; 4 - filler pipe; 5 - cap; 6 - hose, fuel tank and filler pipe; 7 - hose, fuel vapour sepa- rator and fuel tank cover;...
  • Page 45 Check and renew any worn components. Always fit new pump gaskets, remember to lubricate the gaskets with a thin layer of grease before refitting them to the pump. Refitting pump to engine. For correct fitting, use two out of three gaskets as stated below: «Ä»...

  • Page 46: Carburettor

    Carburettor The carburettor has two main fuel jet systems for the primary and secondary barrels, a primary barrel idling system with air cor- rection, a secondary barrel air correction system, part throttle General description enrichment (economizer), full throttle enrichment (econostat), The engine is fitted with the 21073-1107010 carburettor diaphragm-type accelerator pump, semi-automatic choke control (Fig.2-81) of emulsion, twin progressive throttle type.
  • Page 47 Table 2-2 21073-1107010 CARBURETTOR Parameters Primary barrel Secondary barrel Barrel diameter, mm Venturi diameter,mm Main jet system: • fuel jet marking* 107.5 117.5 • air jet marking Emulsion tube, type Idling and air correction systems, primary barrel: – • fuel jet marking –...
  • Page 48 Fig.2-82. Main metering system: 1 - main air jets and emulsion tubes; 2 - atomizers, primary and secondary barrels; 3 - balance orifice; 4 - fuel filter; 5 - return pipe with calibrated orifice to petrol tank; 6 - needle valve; 7 - float; 8 - secondary throttle valve; 9 - main fuel jets; 10 - primary throttle valve Fig.2-83.
  • Page 49 Fig.2-84. Part throttle and full throttle enrichment systems: 1 - secondary throttle valve; 2 - main fuel jet, secondary barrel; 3 - fuel jet and tube, full throttle enrichment; 4 - main fuel jet, primary barrel; 5 - primary throttle valve; 6 - vacuum port;...
  • Page 50 engine speed. Inner profiles 4.1 and 4.2 operate choke lever 6 allowing choke opening to a certain amount at intermediate posi- tions of lever 4. Rotation of choke lever 4 anticlockwise causes the wider slot to release choke lever 6 stud; the choke is held in a fully closed position by return spring 7.
  • Page 51 When the crankshaft speed goes down as low as 1900 rpm Refitting is a reversal of the removal procedure. Before refit- on the overrun, the control unit re-triggers the fuel cutoff solenoid ting, examine the carburettor heat screen and intake pipe/carbu- to feed fuel through the idle jet, and the engine gradually shifts to rettor mating surfaces.
  • Page 52 Fig.2-88. Carburettor cover components: 1 - float spindle; 2 - needle valve; 3 - float; 4 - gasket; 5 - diaphragm and rod, choke pull down unit; 6 - spring; 7 - adjusting screw; 8 - cover, choke pull down unit; 9 - idling fuel jet;...
  • Page 53 Fig.2-89. Carburettor housing components: 1 - accelerator pump diaphragm; 2 - operating lever, accelerator pump; 3 - cover; 4 - cam, accelerator pump linkage; 5 - cover, part throttle enrichment; 6 - diaphragm, part throttle enrichment; 7 - fuel jet, part throttle enrichment; 8 - valve, part throttle enrichment; 9 - return valve, accelerator pump; 10 - atomizer and fuel feed valve, accel- erator pump;11 - main metering atomizers;...
  • Page 54 Fig. 2-91. Throttle stop screw: 1 - throttle stop screw; 2 - idle mixture adjustment screw; 3 - sealing ring; 4 - adjusting screw cap Check the jet marking and consult Table 2-2 to prevent the jet confusion when refitting. Before refitting pivot pit 19 (Fig.2-88), apply sealant ìÉ-9 on the pivot end and over 1-1.5 end turns of thread.

  • Page 55: Exhaust Gas Recirculation System

    throttle must be fully closed. If not, adjust the pedal and throttle by means of end piece 10 at front rod 1 end. Secure the end of throttle linkage cable 3 so that with knob 5 pulled, the choke is fully closed, while with knob 5 pushed in - fully open.

  • Page 56: Exhaust System

    Fig.2-93. Exhaust system: 1 - sealing gasket; 2 - downpipe; 3 - bracket to secure downpipe to transmission; 4 - connection clasp; 5 - suspension ring, main silencer; 6 - main silencer; 7 - front silencer Exhaust system Exhaust gases escape from the engine through the exhaust manifold, front exhaust pipe (downpipe) 2 (Fig.2-93), centre (front) silencer 7 and main (rear) silencer 6.

This manual is also suitable for:

Vaz-21214-20Vaz-21214Vaz-21215

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