Manual Colored
40
ILLUSTRATION ALBUM VAZ - 21213, VAZ - 21214 TOGLIATTI • RUSSIA • AO AVTOVAZ 2001 CONTENTS VEHICLE PACKAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ENGINE (sectional view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ENGINE (cross-sectional view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Components of crank mechanism and timing gear. . . . . . . . . . . . . . . . . . . . . . . . . . 5 ENGINE LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 CARBURETTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 CARBURETTOR OPERATION DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 AIR CLEANER. SILENCERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 CLUTCH OPERATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 GEARBOX OPERATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 TORQUE CONVERTER AND ITS DRIVE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . 17 TORQUE CONVERTER OPERATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . 18 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 BRAKE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 BRAKE OPERATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 WIRING DIAGRAM FOR ELECTRICAL EQUIPMENT OF VAZ 21213 VEHICLE. . 27 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ALTERNATOR 94.3701 (FOR INJECTION VEHICLES) . . . . . . . . . . . . . . . . . . . . . 29 STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 WINDSCREEN WIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 BODY FITTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 HEATING AND VENTILATION. WIPER/WASHER. . . . . . . . . . . . . . . . . . . . . . . . . 35 INJECTION SYSTEM (GM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 INJECTION SYSTEM DIAGRAM (GM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 WIRING DIAGRAM FOR INJECTION SYSTEM (GM) . . . . . . . . . . . . . . . . . . . . . . 38 WIRING DIAGRAM FOR INJECTION SYSTEMEURO2. . . . . . . . . . . . . . . . . . . . . 39 WIRING DIAGRAM FOR INJECTION SYSTEM EURO3 . . . . . . . . . . . . . . . . . . . . 40
Transcript of Manual Colored
ILLUSTRATION ALBUMVAZ - 21213, VAZ - 21214
TOGLIATTI • RUSSIA • AO AVTOVAZ2001
CONTENTS
VEHICLE PACKAGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2ENGINE (sectional view). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3ENGINE (cross-sectional view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Components of crank mechanism and timing gear. . . . . . . . . . . . . . . . . . . . . . . . . . 5ENGINE LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8CARBURETTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9CARBURETTOR OPERATION DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10AIR CLEANER. SILENCERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12CLUTCH OPERATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14GEARBOX OPERATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16TORQUE CONVERTER AND ITS DRIVE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . 17TORQUE CONVERTER OPERATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . 18REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24BRAKE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25BRAKE OPERATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26WIRING DIAGRAM FOR ELECTRICAL EQUIPMENT OF VAZ 21213 VEHICLE. . 27ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28ALTERNATOR 94.3701 (FOR INJECTION VEHICLES) . . . . . . . . . . . . . . . . . . . . . 29STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31WINDSCREEN WIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33BODY FITTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34HEATING AND VENTILATION. WIPER/WASHER. . . . . . . . . . . . . . . . . . . . . . . . . 35INJECTION SYSTEM (GM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36INJECTION SYSTEM DIAGRAM (GM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37WIRING DIAGRAM FOR INJECTION SYSTEM (GM) . . . . . . . . . . . . . . . . . . . . . . 38WIRING DIAGRAM FOR INJECTION SYSTEMEURO2. . . . . . . . . . . . . . . . . . . . . 39WIRING DIAGRAM FOR INJECTION SYSTEM EURO3 . . . . . . . . . . . . . . . . . . . . 40
VEHICLE PACKAGING
SpecificationPayload, kg . . . . . . . . . . . . . . . . . . . . . . . 400Kerbweight , kg . . . . . . . . . . . . . . . . . . . 1210Max. speed, km/h . . . . . . . . . . . . . . . . . . 137Acceleration time from 0 to 100 km/h, with gearchange, on GVW vehicle, sec . . 21
Overall dimensions, mm: length . . . . . . . . . . . . . . . . . . . . . . . . 3740width . . . . . . . . . . . . . . . . . . . . . . . . 1680unladen height . . . . . . . . . . . . . . . . . 1640
Wheelbase, mm . . . . . . . . . . . . . . . . . . . 2200Track:
front, mm . . . . . . . . . . . . . . . . . . . . . 1430rear, mm . . . . . . . . . . . . . . . . . . . . . . 1400
1. Headlight2. Front lamp3. Jack4. Radiator4. Windscreen / headlight washer fluid reservoir6. Engine7. Air cleaner8. Cooling system expansion tank9. Battery10. Differential lock lever in transfer box
11. Gear change lever12. Gear change lever in transfer box13. Steering wheel 14. Front seat15. Rear seat16. Tailgate washer fluid reservoir17. Main silencer18. Rear bumper19. Rear brakes20. Rear suspension coil spring
21. Rear shock - absorber22. Rear suspension transverse torque rod23. Rear suspension longitudinal torque rod24. Fuel tank25. Rear axle26. Intermediate silencer27. Rear propeller shaft28. Reservoir for brake hydraulic fluid29. Reservoir for clutch hydraulic fluid30. Torque converter
31. Clutch pedal32. Brake pedal 33. Front brake34. Front suspension coil spring35. Front axle36. Direction indicator side repeater light37. Front bumper
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ENGINE(sectional longitudinal view)
Specification
Engine model . . . . . . . . . . . . . . . VAZ - 21213Cylinder bore and piston stroke, mm . 80 x 80Displacement, l . . . . . . . . . . . . . . . . . . . . 1.69Compression ratio . . . . . . . . . . . . . . . . . . . 9.3Rated power as per GOST 14846-89 (net)and ISO 1585-82 at crankshaft rate5,200 rpm, kW (HP) . . . . . . . . . . . . . . 59 (80.2)
1. Crankshaft2. Main bearing shell3. Crankshaft sprocket4. Crankshaft front oil seal5. Crankshaft pulley6. Ratchet7. Timing cover 8. Coolant pump / alternator drivebelt9. Alternator pulley
10. Oil pump / ignition distributor / fuel tank /drive sprocket
11. Oil pump / ignition distributor / fuel tankdrive shaft
12. Engine cooling system fan13. Cylinder block14. Cylinder head15. Timing chain16. Camshaft sprocket
17. Exhaust valve18. Inlet valve19. Camshaft bearing housing20. Camshaft21. Valve operating lever22. Valve cover23. Coolant temperature gauge sender24. Spark plug25. Piston
26. Gudgeon pin27. Crankshaft rear oil seal retainer28. Crankshaft thrust half-ring29. Flywheel30. Upper compression ring31. Lower compression ring32. Oil ring33. Clutch bellhousing cover plate34. Oil sump
35. Power unit front mounting36. Connecting rod 37. Front mounting bracket38. Power unit39. Power unit rear mounting
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ENGINE(cross-sectional view)
1. Big end cap2. Shell bearing3. Connecting rod4. Starter motor5. Starter motor heat shield6. Exhaust manifold7. Inlet pipe drain tube8. Inlet pipe
9. Oil deflector cap10.Valve collet11. Valve spring cap12. Valve operating lever spring13. Valve operating lever14. Valve adjuster bolt15. Ignition distributor16. Adjuster bolt bush17. Valve guide18. Valve seat
19. Oil pump / ignition distributor / fuel pump drive shaft
20. Fuel pump21. Oil pump / ignition distributor drive gear22. Oil filter23. Oil pump drive shaft24. Oil pump body25. Oil pump driven gear shaft26. Oil pump drive gear27. Oil pump cover 28. Reducing valve spring
29. Reducing valve30. Oil pump driven gear31. Oil pump inlet pipe32. Camshaft sprocket33. Chain damper34. Oil pump / ignition distributor / fuel pump
drive sprocket35. Valve chain36. Crankshaft sprocket37. Chain stop pin38. Chain tensioner shoe
39. Chain tensioner
A. Mounting lug on camshaft bearing housingB. Camshaft sprocket timing markC. Cylinder block timing markD. Timing mark on crankshaft sprocketE. TDC pointer on crankshaft pulleyF. 00 timing markG. 50 timing markH. 100 timing mark
I. Firing ordera. Inductionb. Compressionc. Powerd. Exhaust
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ëOMPONENTS OF CRANK MECHANISM AND TIMING GEAR
1. Tensioner housing 2. Cap nut 3. Tensioner rod 4. Circlip 5. Clamping block 6. Plunger 7. Spring, tensioner 8. Washer
9. Spring, plunger 10. Camshaft sprocket 11. Thrust flange 12. Camshaft bearing housing 13. Camshaft 14. Big-end bearing shells 15. Big end cap 16. Connecting rod 17. Bush, conrod small end 18. Circlip 19. Piston
20. Top compression ring 21. Bottom compression ring 22. Oil ring 23. Gudgeon pin 24. Thermoregulator plate 25. Bolt, conrod 26. Starter ring gear 27. Flywheel 28. Thrust half-ring, rear 29. Front bearing, gearbox input shaft 30. Thrust half-ring, front
31. Centre main bearing (No 3) shells 32. Crankshaft oil gallery plug á 33. 1st, 2nd, 4th and 5th crankshaft bearing shells 34. Crankshaft 35. Crankshaft sprocket 36. Alternator drive / coolant pump pulley 37. Nut 38. Inlet valve 39. Inlet valve guide 40. Exhaust valve guide 41. Exhaust valve
42. Seat, outer spring 43. Seat, inner spring 44. Inner valve spring 45. Outer valve spring 46. Spring seat 47. Valve collet 48. Outer cap 49. Circlip 50. Washer, adjusting bolt 51. Locknut 52. Spring
53. Push rod 54. Stop plate, push rod spring 55. Adjusting bolt, valve
a, b, c – TDC marks, 1st and 4th cylinder pistons
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ENGINE LUBRICATION SYSTEM
1. Sprocket hole for chain lubrication2. Camshaft main oil gallery 3. Cam lobe oilway4. Camshaft centre bearing journal oil recess5. Oil filler neck6. Camshaft journal oilway7. Inclined oilway in cylinder head
8. Oilway to timing gear9. Cylinder block main oil gallery10. Oil pressure warning light sender11. Oilway to main bearing12. Oilway to big end bearing 13. Oil sump14. Oil filter15. By-pass valve16. Paper filter element
17. Check valve18. Oil pump 19. Oil pump - to - oil filter gallery20. Oilway from oil filter to main oil gallery21. Oilway to oil pump drive gear bush22. Front crankshaft grease seal23. Oilway to main bearing and to oil pump drive gear
shaft24. Oil pump / ignition distributor drive shaft
25. Inlet pipe26. Throttle valve, carburettor secondary barrel27. Throttle valve, carburettor primary barrel28. Air cleaner unit29. Discharge ventilation manifold30. Flame arrester31. Hose to draw crankcase gases behind carburettor
throttle valve32. Discharge hose
33. Oil level dipstick34. Oil separator cover35. Oil separator36. Drain pipe
I. Engine crankcase ventilation diagram
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COOLING SYSTEM
1. Temperature sensor for fuel injection system2. Radiator top hose3. Expansion tank filler cap4. Expansion tank5. Radiator cap6. Fluid return hose to expansion tank 7. Cooling water jacket8. Filler neck
9. Inlet valve10. Exhaust (steam) valve11. LH fluid cooler12. Radiator matrix13. RH fluid cooler14. Fan impeller15. Swirler16. Radiator mounting rubber17. Fan cowl18. Fan belt
19. Radiator outlet hose 20. Coolant pump21. Coolant pump supply hose22. Thermostat23. Thermostat by-pass hose24. Coolant return hose from heater radiator25. Coolant return pipe from part throttle
channel heater 26. Coolant supply hose to part throttle channel
heater
27. Coolant return hose from heater radiator28. Coolant supply hose to heater radiator29. Rubber insert30. Inlet elbow (from radiator) 31. Main valve32. Thermostat housing33. By-pass valve34. By-pass hose pipe35. Coolant pump supply pipe36. Thermostat cover
37. Piston38. Water pump cover39. Oil seal thrust sealing ring40. Oil seal collar41. Water pump shaft bearing outer ring 42. Fan pulley hub43. Stop screw44. Water pump shaft45. Water pump housing46. Water pump impeller
47. Inlet pipe
I. Thermostat operation diagramA. Coolant temperature below 800CB. Coolant temperature within 80 to 940CC. Coolant temperature over 940C.
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FUEL SYSTEM
1. Rocker arm shaft2. Rocker arm 3. Pushrod4. Bottom cover5. Delivery valve6. Delivery union
7. Suction valve8. Fuel filter9. Suction union10. Fuel pump eccentric on shaft 19 (See p.4)11. Thermal insulating spacer12. Gasket13. Fuel tank shim14. Priming lever15. Rocker
16. Eccentric17. Fuel tank cover18. Diaphragm plate19. Inner spacer 20. Upper diaphragms21. Lower diaphragm22. Outer spacer23. Return spring24. Pullrod
25. Top cover26. Carburettor27. Fuel pump28. Fine filter29. Check valve30. Return flow line31. Supply line from fuel tank32. Intake pipe filter33. Fuel gauge sender
34. Fuel tank35. Fuel vapour separator36. Separator connecting hoses37. Air hose38. Fuel filler neck39. Filler cap40. Vent hose
I. Fuel pump operation diagramII. Fuel pump mounting diagram
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CARBURETTOR
1. Part throttle channel heater2. Primary throttle3. Crankcase emission suction union4. Accelerator pump operating lever5. Accelerator pump rocker arm6. Accelerator pump diaphragm7. Fuel jet, part throttle enrichment 8. Ball valve, part throttle enrichment 9. Diaphragm, part throttle enrichment
10. Electromagnetic shut-off valve11. Idling fuel jet12. Return pipe to fuel tank13. Carburettor cover14. Supply union15. Primary barrel main air jet16. Choke valve plate17. Accelerator pump atomizers18. Pull-down diaphragm 19. Adjustment screw20. Throttle stop screw
21.22. Vacuum discharge to EGR system23. Vacuum discharge to ignition distributor vacuum control24. Idle mixture adjusting screw25. Primary throttle adjustment screw (pull-down unit)26. Choke operating lever27. Choke drive lever28. Secondary barrel main air jet29. Emulsion tube30 Secondary barrel main fuel atomizer31. Fuel filter32. Float chamber needle valve
33. Carburettor body34. Secondary throttle 35. Secondary throttle lever36. Secondary barrel main fuel jet37. Secondary throttle operating lever38. Float39. Throttle valves operating lever40. Secondary barrel lock lever
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CARBURETTOR OPERATION DIAGRAM
1. Adjustment screw (choke pull-down unit)2. Pull-down diaphragm3. Pushrod4. Electromagnetic shut-off valve5. Idling fuel jet6. Main air jet, primary barrel 7. Idling air jet8. Main fuel atomizer, primary barrel9. Choke valve plate10. Accelerator pump nozzle11. Main fuel atomizer, secondary barrel
12. Injection pipe, full throttle enrichment13. Secondary main air jet14. Air correction jet, secondary barrel15. Carburettor top cover 16. Needle valve17. Return line to fuel tank18. Fuel-to-tank return jet19. Fuel filter20. Fuel supply to carburettor21. Diaphragm, part throttle enrichment 22. Ball valve, part throttle enrichment 23. Fuel jet, part throttle enrichment 24. Float
25. Fuel jet and tube, full throttle enrichment26. Secondary barrel fuel correction jet with tube27. Secondary barrel emulsion tube28. Secondary barrel main fuel jet29. Secondary throttle30. Primary throttle31. Part throttle channel heater32. Idle mixture adjustment screw33. Crankcase emission discharge pipe34. Vacuum discharge to ignition distributor vacuum
control35. Vacuum discharge to EGR valve (second pipe is not
shown)
36. Primary main fuel jet37. Primary emulsion tube38. Accelerator pump non-return ball valve39. Accelerator pump diaphragm40. Accelerator pump operating lever 41. Choke drive lever42. Outer rod securing bracket43. Primary throttle adjusting screw (pull-down unit)44. Throttle valve operating lever45. Choke control lever46. Fuel supply ball valve47. Accelerator pump operating cam
a. Air passage, pull-down unitb. Float chamber balance passagec. Air passage, part throttle enrichment d. Fuel passage, part throttle enrichment e. Secondary correction outlet ports f. Idling air passage holeg. Idling transients hole
I. Carburettor operation diagram at full throttleII. Pull-down unit operation diagramIII. Carburettor operation diagram at idle speedIY. Carburettor operation diagram at part throttleV. Acceleration pump operation diagram10
AIR CLEANER. SILENCERS.
1. EGR valve thermo-vacuum switch2. Exhaust manifold3. EGR valve4. EGR tube5. Intake manifold6. Carburettor7. Cold air intake
8. Temperature flap9. Warm air intake manifold10. Pinch bolt11. Air cleaner housing12. Pointer for air filter cover alignment13. Gauze14. Filter element perforated plates15. Paper filter element16. Air cleaner cover mounting bracket
17. Securing nut18. Discharge pipe19. Air cleaner cover20. Front exhaust pipe21. Front exhaust pipe bracket22. Clips23. Intermediate silencer24. Suspension rings25. Main silencer
26. Tail pipe27. Intermediate silencer rear perforated tube28. Intermediate silencer rear baffle plate29. Front baffle plate30. Front perforated tube31. Intermediate silencer housing32. Main silencer front perforated tube33. Main silencer inlet pipe34. Main silencer outlet pipe
35. Main silencer housing36. Rear baffle plate37. Centre baffle plate38. Rear perforated tube39. Front baffle plate
I. Recirculation diagramII. Air cleaner unitIII. Intermediate silencerIY. Main silencer
11
CLUTCH
1. Diaphragm spring2. Clutch friction discs3. Diaphragm spring rivet4. Clutch disc5. Rivet - damper tip6. Disc adaptor
7. Retainer plate8. Clutch disc hub9. Damper spring10. Pressure plate11. Flywheel12. Clutch cover13. Clutch bellhousing14. Gearbox input shaft
15. Pressure plate - to - clutch cover strap16. Diaphragm spring clip17. Diaphragm spring fulcrum ring18. Thrust flange / clutch cover strap19. Thrust flange friction washer20. Strap rivet21. Diaphragm spring thrust flange22. Release bearing
23.Clutch release fork / bearing spring24. Clutch release bearing25. Damper friction washer26. Spring washer bearing disc27. Damper spring washer28. Release fork ball pivot29. Release fork spring30. Release fork pushrod
31. Clutch release fork32. Slave cylinder33. Release fork return spring
I. Damper operation diagram
12
CLUTCH OPERATION SYSTEM
1. Clutch master cylinder2. Vacuum servo unit3. Brake master cylinder 4. Servo boot 5. Vacuum servo bracket6. Pedal cluster mounting bracket7. Over-centre spring hook
8. Pedal spacer sleeve9. Pedal outer bushes10.Brake / clutch pedal shaft 11. Pedal inner bush12. Brake pedal return spring13. Booster spring14. Master cylinder fluid reservoir15. Filler cap16. Baffle
17. Clutch cover18. Clutch disc19. Pressure plate20. Diaphragm spring21. Clutch release bearing22. Gearbox input shaft23. Bleed nipple24. Sealing ring25. Slave cylinder housing
26. Protective cap27. Release fork pushrod28. Piston29. Piston bearing plate30. Spring disc31. Circlip32. Plug33. Clutch release fork ball pivot34. Clutch release fork
35. Adjustment nut36. Locknut 37. Clutch pedal return spring38. Brake pedal39. Clutch pedal screw40. Clutch pedal41. Union 42. Retaining washer43. Gasket
44. Circlip 45. Pushrod piston46. Master cylinder piston47. Return spring48. Master cylinder body
I. Clutch hydraulic system operation diagram
13
GEARBOX
1. Input shaft2. Gearbox front cover with clutch release
bearing guide sleeve 3. Input shaft oil seal4. Spring washer5. Bearing thrust ring6. Gearbox housing7. Breather8. Output shaft needle bearing9. Synchro sleeve thrust washer10. 4th speed synchro unit crown11. 3rd / 4th synchro unit sleeve12. 3rd / 4th synchro unit hub
13. Circlip14. Synchro - ring15. Spring16. 3rd speed synchro gear 17. 2nd speed synchro gear18. Output shaft19. 1st speed synchro gear20. 1st gear bush21. Output shaft idler bearing22. Lock plate23. Flange24. Bellows25. Spring26. Gear change lever27. Lever rod
28. Thrust ring29. Rubber ring30. Spacer31. Retaining sleeve32. Collar33. Cap34. Ball socket35. Gear change lever housing36. Guide plate37. Propeller shaft coupling flange38. Nut39. Centering ring seal40. Centering ring41. Output shaft rear bearing oil seal42. Output shaft rear bearing
43. Spacer sleeve44. Oil deflector washer45. Gear unit bearing46. 5th speed / reverse gear unit47. Reverse idler gear shaft48. Reverse idler gear49. Intermediate shaft rear bearing50. Intermediate shaft 1st speed gear51. 1st/2nd synchro sleeve52. Intermediate shaft 2nd speed gear53. Intermediate shaft 3rd speed gear54. Filler and check orifice cap55. Intermediate shaft56. Intermediate shaft constant mesh gear57. Intermediate shaft front bearing
58. Intermediate shaft bearing clamping washer59. Clamping washer bolt60. Input shaft constant mesh gear61. Input shaft rear bearing62. Circlip63. Reverse lock clip64. Guide plate washers65. Guide bar66. Detents cover67. Spring68. Detent69. 5th / reverse shift fork70. Thrust washer71. Circlip72. 3rd / 4th selector fork
73. 1st / 2nd selector rod74. 3rd / 4th selector rod75. 1st / 2nd selector fork76. 5th / reverse selector rod77. Locking collets
14
GEARBOX OPERATION DIAGRAM
1. Input shaft2. Output shaft3. Input shaft constant mesh gear4. 4th speed synchro crown5. 4th gear synchro baulk ring6. 3rd and 4th synchro sleeve7. 3rd and 4th gear selector fork8. Synchro circlip
9. 3rd synchro baulk ring10. Synchro spring11. Synchro spring thrust washer12. 3rd synchro gear and crown13. 2nd synchro gear and crown14. 1st and 2nd synchro sleeve15. 1st and 2nd gear selector fork16. 1st synchro gear and crown17. Reverse gear18. 5th synchro sleeve hub
19. 5th synchro sleeve20. 5th and reverse gear selector fork21. Gear change lever22. 5th synchro gear and crown23. Oil deflector washer24. 5th gear bush25. Distance sleeve26. Flexible sleeve flange27. 5th gear and reverse selector rod28. 3rd and 4th selector rod
29. 1st and 2nd selector fork rod30. Reverse light switch31. Gear unit reverse gear32. Reverse idler gear33. End plug34. 5th and reverse gear unit35. Reverse idler gear shaft36. Layshaft 1st speed gear37.1st synchro baulk ring38. 1st and 2nd synchro sleeve hub
39. 2nd synchro baulk ring40. Layshaft 2nd speed gear41. Layshaft 3rd speed gear42. 3rd and 4th synchro sleeve hub43. Layshaft constant mesh gear44. Circlip45. Poppet spring
I. Neutral positionII. Beginning of 3rd gear engagementIII. Complete engagement of 3rd gear
15
PROPELLER SHAFT
1. LH wheel drive2. Front axle3. RH wheel drive4. Forward propeller shaft5. Gearbox6. Engine7. Layshaft flexible coupling
8. Layshaft constant velocity joint9. Torque converter10. Rear propeller shaft11. Rear axle12. Sliding yoke13. Oiler14. Retainer15. Grease seal16. Propeller shaft end
17. Propeller shaft tube18. Balance plate19. Propeller shaft joint fork20. Propeller shaft trunnion21. Needle bearing circlip22. Needle roller housing23. Flange - propeller shaft yoke24. Washer25. Needle roller
26. Needle bearing oil seal27. Trunnion oil seal28. Constant velocity joint shell29. Ball30. Boot31. Protective shroud32. Cage33. Coupling flange securing bolt34. Coupling flange
35. Coupling liner36. Balance washer37. Rubber sleeve38. Centering bush39. Clips40. Plug41. Oil seal splash guard ring42. Outer joint shell43. Circlip
44. Outer joint race45. Thrust ring46. Outer joint boot47. Protective sleeve48. Road wheel drive shaft49. Inner joint boot50. Detent51. Inner joint race52. Inner joint shell
I. Drive line viewII. Front wheel drive
16
TORQUE CONVERTER AND ITS DRIVE SYSTEM
1. Driven gear2. Differential bearings3. Spring washer4. Circlip5. Differential locking coupling6. Differential carrier crown7. Front axle drive shaft crown8. Front axle drive shaft bearing9. Oil slinger
10. Splash guard11. Front axle drive shaft12. Flange13. Oil seal14. Oil drain plug15. Speedometer driven gear16. Speedometer drive gear17. Plug, oil level inspection / top-up orifice18. Torque converter front cover19. Layshaft roller bearing20. Bracket, torque converter mount 21. Input shaft bearing cover
22. Bearing thrust ring23. Input shaft bearings24. Top gear25. Gear shift clutch hub26. Gear shift clutch27. Torque converter casing28. Low gear29. Low gear bush30. Input shaft31. Rear cover32. Layshaft ball bearing33. Layshaft
34. Differential housing 35. Rear axle differential gear thrust washer36. Rear axle drive shaft bearing37. Rear axle differential gear38. Pinion39. Pinion thrust washer40. Circlip41. Pinion shaft42. Spring washer43. Front axle differential gear44. Suspension mounting bracket rubber 45. Shaft, torque converter mount
46. Differential locking clutch yoke47. Yoke stop bolt48. Locked differential warning light switch49. Boot50. Spring51. Differential locking fork rod52. Front axle case cover53. Lock washer54. Lever shaft bush55. Lever shaft56. Differential locking lever57. Gear shift fork rod
58. Gear lever bracket59. Gear lever60. Gear lever knob61. Gear shift clutch fork62. Spacer sleeve63. Detent ball64. Detent spring bush65. Detent spring
I. Torque converter operating system
17
TORQUE CONVERTER OPERATIONDIAGRAM
1. Grease seal2. Thrust ring, input shaft front bearing3. Front bearing cover4. Input shaft front bearing5. Torque converter front cover6. Top gear7. Gear engagement clutch hub8. Gear engagement clutch
9. Low gear10.Torque converter case11. Input shaft rear bearing12. Input shaft13. Torque converter rear cover14. Layshaft15. Layshaft rear bearing16. Differential rear bearing17. Rear axle drive shaft retaining ring18. Rear axle drive shaft bearing19. Oil slinger20. Rear axle drive shaft flange
21. Rear axle drive shaft22. Bearing thrust ring23. Differential housing24. Rear axle drive gear25. Pinion26. Differential pinion shaft27. Differential pinion shaft circlip28. Spring washer29. Driven gear30. Differential front bearing circlip31. Differential lock coupling32. Front axle drive shaft
33. Front axle casing34. Circlip, front axle drive shaft bearing35. Differential front bearing spring washer36. Differential front bearing37. Speedometer driven gear38. Speedometer drive unit housing39. Layshaft front bearing40. Gearbox41. Coupling42. CV joint43.Torque converter44. Shims
45. Bracket, torque converter mounting 46. Bracket, engine rear mounting
I. Top gear engagedII. Low gear engagedIII. Low gear engaged, differential locked up
18
VAZ - 21213
REAR AXLE
1. Road wheel cap2. Brake drum - to - wheel securing bolt3. Oil deflector4. Brake drum5. Brake drum iron ring6. Wheel cylinder7. Brake bleed nipple8. Half-shaft bearing
9. Bearing locking collar10. Rear axle beam flange11. Half-shaft oil seal12. Coil spring cup13. Rear axle beam14. Suspension bar securing bracket15. Half-shaft guide16. Differential bearing nut17. Differential bearing18. Differential bearing cover
19. Breather20. Pinion21. Crown wheel22. LH halfshaft23. Halfshaft gear24. Rear axle reduction gear casing25. Drive gear shim26. Bearing spacer sleeve27. Bearing, pinion28. Oil seal, pinion
29. Oil seal splash guard30. Propeller shaft securing flange31. Nut32. Oil baffle33. Pinion, final drive 34. Differential pinion shaft35. Half-shaft gear thrust wsher36. Differential case37. RH halfshaft38. Bracket to secure suspension components
39. Thrust plate, half-shaft bearing40. Rear brake backplate41. Rear brake shoe42. Friction disc43. Half-shaft flange44. Bearing nut lockplate45. Bearing cover securing bolt
19
FRONT AXLE
1. Differential case2. Differential pinion3. Differential pinion shaft4. Half-shaft gear5. Crown wheel6. Bearing cover retaining stud7. Front axle casing
8. Drain plug9. Casing lower cover10. Casing cover11. Bracket, engine front mounting12. Front axle securing stud13. Front axle securing bracket, LH14. Pinion bearings15. Pinion, final drive 16. Spacer sleeve17. Pinion oil seal
18. Oil seal splash guard19. Pinion flange20. Flange securing nut21. Road wheel drive inner joint 22. Inner joint bearing23. Bearing locating ring24. Spring washer25. Circlip26. Differential bearing adjuster nut27. Differential bearing
28. Inner joint shell, RH halfshaft29. Breather30. RH bracket, front axle31. Drive gear shim32. Bearing oil deflector33. Half-shaft gear thrust washer34. Filler plug35. LH half-shaft, inner joint shell36. Inner joint shell bearing cover37. Splash guard, joint shell oil seal
38. Oil seal39. Differential bearing cover40. Adjuster nut lockplate
20
FRONT SUSPENSION
1. Lower control arm2. Crossmember bracket3. Coil spring lower seat4. Coil spring5. Compression buffer6. Compression buffer mount strut7. Compression restrictor8. Shock absorber mounting bracket9. Shock absorber10. Anti-roll bar securing clamp11. Anti-roll bar mounting rubber
12. Anti-roll bar13. Lower balljoint14. Wheel brake splash guard15. Brake disc16. Wheel hub17. Wheel - to - brake disc securing bolt18. Taper bush19. Wheel cap20. Outer CV joint shank21. Oil seal bush22. Oil seal23. Splash guard ring24. Wheel hub bearing
25. Stub axle26. Ballpin27. Boot28. Bearing29. Ballpin liner race30. Ballpin bearing housing31. Body chassis arm32. Anti-roll bar securing plate33. Tie-rod34. Body-to-tie-rod mounting bracket35. Washers36. Upper balljoint37. Shock absorber rod mounting bushes
38. Shock absorber rod39. Securing washer40. Upper securing bracket, shock absorber41. Upper control arm42. Recoil buffer bracket43. Recoil buffer44. Suspension upper arm shaft45. Upper arm shaft securing bolts46. Shims47. Upper spring mounting48. Upper spring seat49. Spring insulator gasket50. Crossmember-to-tie-rod securing bracket
51. Front suspension crossmember52. Lower control arm shaft bush53. Lower control arm washes54. Lower arm silent block55. Lower control arm shaft56. Lower control arm shaft thrust washer57. Balljoint rubber bush58. Balljoint sleeve, inner59. Balljoint sleeve, outer60. Balljoint thrust washer
I. Camber ( α = 0°30’±20’ ) and inclination ( β = 11030’)angles D - C = 1 ... 5 mm
II. Toe-in A - B = 2 ... 4 mm
III. Castor angle ( γ = 3030’±30”)
All wheel adjustment parameters are given forthe vehicle loaded with 3136 N (320 kgf) beingequal to 4 people weight and 392 N (40kgf) bootluggage.
21
REAR SUSPENSION
1. Lower transverse arm2. Spring insulating gasket, lower3. Spring seat, lower4. Compression buffer5. Upper longitudinal arm securing bolt6. Upper longitudinal mounting bracket7. Coil spring
8. Compression buffer mount9. Spring insulator collar, upper10. Spring insulator, upper11. Spring seat, upper12. Rear brake pressure regulator operating rod link13. Rubber bush14. Shock absorber securing pin washer15. Shock absorber eye rubber bush16. Underbody crossmember
17. Additional compression buffer18. Spring washer19. Spacer sleeve20. Rubber bush21. Lower longitudinal arm mounting bracket22. Upper longitudinal arm mounting bracket23. Shock absorber24. Body-to-transverse arm mounting bracket25. Pressure regulator
26. Boot, pressure regulator27. Operating rod shaft, pressure regulator28. Securing bolts29. Pressure regulator operating rod30. Clamp31. Thrust bush32. Transverse arm33. Mounting plate, transverse arm mounting bracket
22
SHOCK ABSORBERS
1. Shock absorber eye, lower2. Compression valve housing3. Compression valve discs4. Compression valve throttle disc5. Compression valve cap
6. Compression valve spring7. Compression valve retainer8. Recoil valve nut9. Recoil valve spring10. Shock absorber piston11. Recoil valve cap12. Recoil valve discs
13. Piston ring14. Recoil valve nut washer15. Recoil valve throttle disc16. By-pass valve cap17. By-pass valve spring18. By-pass valve restricting plate19. Reservoir
20. Rod21. Cylinder22. Casing23. Guide sleeve24. Reservoir sealing ring25. Oil seal retainer26. Oil seal
27. Gasket28. Guard ring29. Reservoir nut30. Shock absorber eye, upper31. Upper shock absorber end securing
nut32. Spring washer
33. Washer34. Mounting rubber35. Spacer sleeve36. Shock absorber casing37. Silent block
I. Shock absorber operation diagram
II. Compression stroke
III. Recoil stroke
23
STEERING
1. Track rod2. Drop arm3. Relay rod4. Idler arm5. Tie-rod adjuster pin6. Lower balljoint7. Stub axle8. Upper balljoint
9. Upper shaft bearing10. Steering wheel mounting bracket11. Upper shaft12. Idler bracket13. RH chassis arm, underbody14. Lower contact ring15. Lower contact ring retainer16. Horn clamp17. Upper contact ring18. Horn spring
19. Horn push button20. Cover plate21. Lead22. Upper washer23. Seal24. Idler arm shaft bush25. Lower washer26. Oil filler plug27. Protective cap28. Steering box
29. Steering shaft seal30. Middle shaft31. Securing plate, bracket front part32. Upper column shroud33. Wipe / wash lever34. Steering wheel35. Turn signal lever36. Headlight lever37. Lower column shroud38. Pinch bolt
39. LH chassis arm, underbody40. End cover41. Shims42. Roller spindle, drop arm shaft43. Thrust washer44. Roller45. Adjuster screw plate46. Lockwasher47. Adjuster screw48. Locknut
49. Top cover50. Worm gear51. Bearing52. Worm shaft53. Oil seal54. Bush, drop arm shaft55. Oil seal, drop arm shaft56. Drop arm shaft57. Ballpin protective cap58. Ballpin liner
59. Ballpin60. Spring61. End plug
24
BRAKE MECHANISM
1. Carrier2. Stub axle3. Splash guard4. Caliper5. Brake hoses6. Union to expel air7. Front brake wheel cylinder piston8. Sealing ring9. End piece
10. Hose union bolt11. Piston protective cap12. Cylinder housing13. Brake pad14. Caliper clamping lever15. Front brake splash guard 16. Brake disc17. Clamping lever shaft18. Gaskets19. Detent20. Detent spring
21. Clamping lever spring22. Shoe manual return lever23. Shaft24. Shoe abutment plate25. Wheel cylinder piston26. Seal27. Backing cup28. Spring29. Retainers30. Thrust ring31. Thrust screw
32. Brake fluid inlet union33. Rear brake bleed screw34. Rear brake wheel cylinder35. Dust seal36. Brake pad37. Upper return spring38. Mounting rubber39. Expander strut40. Steady post41. Oil deflector42. Rear cable end
43. Friction linings44. Cover plates45. Rivet46. Lower return spring47. Mounting plate48. Handbrake rear cable49. Cable return spring50. Rear cable end51. Rear brake backplate52. Cable guide plate53. Brake shoe
54. Bolt retainer 55. Spring cups56. Spring
25
BRAKE OPERA TION DIAGRAM
1. Brake pads2. Hold-down lever shaft3. Carrier4. Caliper hold-down lever5. Caliper6. Piston sealing ring7. Wheel cylinder pistons, primary circuit8. Brake hose, secondary circuit9. Cylinder housing
10. Brake disc11. Master cylinder primary circuit operating
piston12. Hydraulic fluid reservoir13. Sliding contact14. Fixed contact15. Float16. Vacuum valve17. Servo unit valve housing18. Diaphragm19. Tie-rod
20. Reaction disc21. Rear shell22. Vacuum unit valve23. Return spring24. Input rod25. Pedal return spring26. Stop light switch27. Stop light switch tip28. Brake pedal29. Valve spring30. Piston
31. Valve housing return spring32. Output rod33. Retainer34. Sealing ring35. Piston stroke limiter screw36. Bush37. Secondary circuit operating piston38. Seal39. Secondary circuit pipeline40. Brake shoes41. Rear brake wheel cylinder piston
42. Piston seal43. Thrust rings44. Pressure regulator operating rod45. Sealing ring46. Spring seat47. Piston head seal48. Bush49. Pressure regulator piston50. End plug
A. Vacuum cavityB. Atmosphere - to - valve inner cavity portC. Valve inner cavity - to - vacuum portK. To engine intake pipeD. Atmospheric cavity
I. Brake pedal releasedII. Brake offIII. Brake applied
26
WIRING DIAGRAM FOR ELECTRIC EQUIPMENT
OF VAZ 21213 VEHICLE
1. Front lights2. Headlights3. Headlight wiper motor4. Horn 5. Headlight washer motor6. Windscreen washer motor7. Alternator
8. Turn indicator side repeater lights9. Battery10. Heater unit motor11. Additional resistor for heater motor12. Intermittent wiper relay13. Starter motor14. Windscreen wiper motor15. Carburettor limit switch16. Carburettor electromagnetic valve17. Carburettor electromagnetic valve control
unit18. Ignition module
19. Spark plugs20. Ignition distributor21. Oil pressure warning light sensor22. Temperature indicator sensor23. Socket for inspection lamp24. Ignition coil25. Brake fluid level warning lamp sensor26. Headlight wipe/wash relay27. Heated rear window relay28. Headlight main beam relay29. Headlight dipped beam relay30. Ignition relay
31. Starter “on” relay32. Differential lock warning lamp switch33. Exterior lighting switch34. Cigarette lighter35. Stop-signal switch36. Reversing light switch37. Intermittent direction indicator / hazard
warning lights relay38. Main fuse box39. Additional fuse box40. Heater controls illumination bulbs41. Rear fog light switch
42. Heated rear window switch43. Heater motor switch44. Rear window wipe/wash switch45. Hazard warning lights switch46. Ignition switch47. Carburettor choke warning lamp48. Instrument lighting switch49. 3-lever column switch50. Choke warning lamp switch51. Rear window washer motor52. Door pillar light switch53. Interior lights
54. Instrument cluster55. Number plate lights56. Handbrake warning light switch57. Fuel level / fuel remainder sensor58. Tail lights59. Rear window wiper motor60. Rear window heating element
A. Pin numbers for column switch connectors
27
ALTERNATOR
SpecificationMax.current at 13 V and rotor rate 5,000 RPM, A . .55Adjustable range of voltage, V . . . . . . . . . . .14.1 ± 0.5Engine-to-alternator ratio . . . . . . . . . . . . . . . . .1 : 2.04
1. Slip ring end housing2. Casing3. Securing bolt, diode plate-to-stator winding phasedpins
4. Slip rings5. Armature shaft ballbearing, slip ring end6. Rotor shaft7. Condenser 2.2 uF± 20%8. Common output lead, supplementary diodes9. Terminal bolt extension (alternator ‘30’ output for power
consumption)10. Air intake11. Alternator output ‘61’ lead12. Voltage regulator output ‘Å’ lead13. Brush connected to voltage regulator ‘B’output 14. Voltage regulator
15. Brushes connected to voltage regulator ‘ò’ output16. Alternator - to - tensioner securing stud17. Drive end housing18. Fan impeller with alternator pulley19. Rotor pole tip, drive end20. Bearing securing washers21. Spacer22. Rotor shaft ballbearing, drive end23. Steel sleeve24. Rotor winding (field winding)25. Stator26. Stator winding
27. Rotor pole face, slip ring end28. Rectifier unit29. Alternator pinch bolt30. Buffer bush31. Bush32. Hold-down bush33. Negative gate with “-” rectified current on the housing34. Negative gate retainer35. Stator winding phase pinout36. Positive gate with “+” rectified current on the housing37. Positive gate retainer38. Brush holder
39. ‘61’ output (common output of supplementary diodes)40. Supplementary diode (for field winding) 41. Alternator42. Instrument cluster43. Battery charge warning light44. Diode45. Resistor 51 Ohm 5 W46. Ignition relay47. Ignition switch48. Main fuse box49. Battery
28
ALTERNATOR 94.3701(for injection vehicles)
SpecificationMaximum current at 13 v and rotor 6000 RPM, A . . . . . . . . . . . . . . .80Adjustable range of voltage, v . .13,2–14,7Engine - to - alternator ratio . . . . . . . .1 : 2.4
1. Housing 2. “B+” terminal for power consumption 3. Interference suppression capacitor 2.2 uF 4. Common terminal of additional diodes (con-
nected to “D+” terminal of voltage regulator) 5. Holder for rectifier positive diodes 6. Holder for rectifier negative diodes 7. Startor winding terminals 8. Voltage regulator
9. Brush holder 10. Rear cover 11. Front cover 12. Stator core 13. Stator winding 14. Spacer 15. Washer 16. Taper washer 17. Pulley
18. Nut 19. Rotor shaft 20. Rotor shaft bearing, front 21. Rotor pole ends 22. Rotor winding 23. Bush 24. Clamp screw 25. Rotor bearing, rear 26. Bush, bearing
27. Slip rings 28. Negative diode 29. Positive diode 30. Additional diode 31. “D” terminal (common terminal of additional
diodes) 32. Battery 33. Alternator 34. Ignition relay
35. Ignition switch 36. Fusebox 37. Battery charge warning light 38. Brush 39. Earth terminal, voltage regulator 40. “DF” terminal, voltage regulator 41. “D+” treminal, voltage regulator
29
STARTER MOTOR
Specification
Rated power , kW . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3Current consumption at rated power , A, not greater . . . . . . . . . . . . . . . . 260Current consumption at “brake on”, A,not greater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500Current consumption at idle, A, not greater . . . . . . 60Rotation direction (drive end) . . . . . . . . . . . clockwise
1. Armature shaft2. Bush, starter motor cover3. Pinion stop collar4. Driving pinion / clutch inner ring assy5. Thrust half-ring6. Overrun clutch roller7. Overrun clutch casing8. Operating lever pivot pin9. Plug10. Relay armature drive link11. Operating lever12. Drive-end cover13. Relay armature return spring
14. Starter motor relay armature15. Front relay flange16. Relay holding winding17. Relay plunging winding18. Armature core bar 19. Relay core20. Core flange21. Contact disc22. Relay cover23. Relay contact bolts24. Commutator end cover25. Positive brush holder26. Starter motor cover bush
27. End float shim28. Lock washer29. Clamp bolt30. Casing31. Stator winding series coils pinout32. Commutator33. Stator winding series coil34. Stator pole35. Starter motor housing36. Armature core37. Limiter plate38. Drive ring39. Hub / clutch outer ring
40. Overrun clutch hub liner41. Ignition switch42. Alternator43. Battery44. Starter motor45. Starter relay46. Guide bar47. Plunger48. Flywheel
I. Overrun clutch operating diagramII. Starter motor connection diagram30
IGNITION SYSTEM
1. Semiconductor element with integrated circuit2. Permanent magnet3. Insulator4. Ignition coil housing5. Secondary winding6. Primary winding7. Outer magnetic duct 8. Primary winding end ‘K’ terminal 9. Cover
10. High tension terminal11. ‘ Å’ terminal, primary winding start /
secondary winding end12. Core13. Contact nut14. Spark plug insulator15. Core bar16. Spark plug body17. Sealing ring18. Heat screening washer19. Centre electrode20. Side electrode
21. Distributor shaft22. Shaft oil slinger23. Socket24. Diaphragm25. Vacuum advance cover26. Vacuum advance housing27. Vacuum unit operating arm28. Advance unit bearing plate29. Distributor rotor30. Side electrode with terminal for lead to
ignition switch31. Ignition distributor cap
32. Centre electrode with terminal for coil lead33. Centre electrode carbon contact34. Centre rotor contact35. 1000 Ohm resistor for interference
suppression36. Outer rotor contact37. Centrifugal regulator plate38. Advance unit governor weight39. Screen40. Hall sensor plate41. Hall sensor42. Distributor body
43. Oiler body44. Bearing lock plate 45. Bearing46. Spark plugs47. Ignition coil48. Ignition module49. Ignition relay50. Ignition switch I. Vacuum advance unit performance:
A - timing angle, degreesP - vacuum, gPa (Hg mm)
II. Centrifugal advance unit performance:
A - ignition timing, degreesn - distributor shaft rotation rate, RPM
III. Centrifugal advance operation diagram:A - ignition timing
IY. Hall sensor operation diagram:B - voltage pulses (U) at sensor outputC - current pulses (I) in ignition coil primary winding; t - current accumulation time
Y. Ignition system diagram 31
WINDSCREEN WIPER
1. Linking rod2. LH operating arm3. Inner mounting bush4. Outer mounting bush5. Shaft6. Bushes
7. Felt 8. Bracket9. Wiper arm10. RH operating arm11. Yoke12. Wiper gear motor13. Crank14. Connecting rod15. Spacer spring16. Inserts17. Relay casing
18. Relay armature19. Conductive plate20. Contact mounting plate21. Base plate22. Relay winding23. Resistor24. Breaker bracket25. Breaker bimetal plate26. Gear shaft27. Gear motor wheel28. Spring plate
29, 30 - Contact posts31. Cover32. Armature shaft33. Gear motor cover34. Blade35. Blade holder36. Permanent magnet37. Felt ring38. Thrust bearing39. Bush40. Housing
41. Armature, motor42. Cover securing plate43. Commutator44. Windscreen washer motor45. Windscreen wiper motor46. Thermal bimetal fuse47. Ignition switch48. Ignition relay49. Fuse box50. Windscreen wipe/wash switch51. Intermittent wipe relay
A. Pin numbers in relay / wiper motor connector
B. Pin numbers in wiper switch connector
I. Wiper gear motor åù-241II. Windscreen wiper relay PC-514III. Operation diagram of windscreen
wipe / wash motors
32
BODY
1. Bonnet2. Upper bulkhead stiffener3. RH body side 4. Windscreen scuttle panel 5. Roof panel6. Rear floor panel7. Rear body side post8. Roof stiffener
9. Tailgate outer panel10. Tailgate inner panel11. Side door outer panel12. Side door inner panel13. LH body side 14. Floor - to - body side connection15. Front wing16. Front inner wing17. Bulkhead18. Radiator trim panel
19. Securing clip20. Upper door trim retainer21. Door trim22. Inner wing and body side liner23. Headliner24. Headliner support25. Bush26. Trim securing clip27. Floor carpet retaining clip28. Door sill trim
29. Rear floor carpet30. Front floor carpet31. Front side panel trim32. Side cover plate33. Connecting piece34. Securing bolt35. Bracket36. Bumper bar37. Retainer38. Rubber cover plate
39. Quarter light seal40. Sliding glass lower seal41. Seal cord42. Side door seal43. Sliding glass seal44. Tailgate seal45. Rear window seal46. Side panel glass seal47. Rubber bush48. Windscreen scuttle panel seal
49. Windscreen glass seal50. Bonnet seal51. Air box seal52. Seal, front bumper connecting piece
I. Rear bumperII. Rubber sealsIII. Interior trim
33
BODY FITTINGS
1. Front seat cushion2. Operating rod, seat back fold-down3. Headrestraint guide4. Front seat back5. Headrestraint 6. Knob, seat back fold-down 7. Headrestraint framework8. Rear seat back9. Seat back base10. Trim
11. Seat back brace12. Seat back stop13. Grommet14. Rear seat cushion15. Base-plate16. Cushion pan17. Hinge18. Seat back rake adjuster19. Retainer20. Side trim21. Front seat trim22. Seat slide
23. Stop24. Roller25. Seat track with catch26. Seat back crossmember27. Adjuster handle, seat sliding 28. Cushion framework29. Door inner handle30. Handle bracket31. Inner handle operating link32. Inner control lever33. Locking rod34. Outer control lever
35. Lock striker retainer36. Lock striker37. Rotor38. Centre shaft mounting39. Lock release rod40. Lock release shaft41. Centre shaft42. Ratchet43. Handle trim cover44. Operating shaft45. Surround46. Brake spring dog
47. Drum / driven gear48. Window winder cover49. Window winder mechanism50. Cable51. Door glass52. Rollers53. Window glass support channel54. Cable retainer55. Pinion56. Drive shaft mounting57. Brake spring58. Winder handle
59. Control cable60. Spring61. Pusher62. Hook 63. Lock housing64. Operating handle65. Bracket66. Operating rod67. Return arm68. Arm69. Lock housing70. Rotor
I. SeatsII. Front door lockIII. Bonnet lockIY. Tailgate lockY. Window winder
34
HEATING AND VENTILATION. WIPER/WASHER.
1. Washer jet2. Tailgate washer fluid container3. Windscreen/headlight washer fluid container4. Gasket5. Atomizer6. Jet body
7. Tailgate washer pump motor8. Windscreen washer pump motor9. Headlight washer pump motor10. Side vent11. Side vent air duct12. Windscreen defroster air duct13. Air intake cover14. Gasket15. Supply and return pipes16. Tap
17. Radiator18. Impeller19. Air distributor cover20. Fan motor 21. Fan spring holder22. Control cable23. Windscreen vent flap control cable24. Bracket, control levers 25. Air intake shutter control lever26. Windscreen vent shutter control lever
27. Tap control lever28. Air intake cover control cable29. Centre vents30. Rubber valve31. Air box32. Centre vent shutter
I. Washer locationsII. Winscreen and tailgate washer jetIII. Tailgate washer pump and fluid containerIY. Windscreen and headlight washer pump
and fluid containerY. Ventilation system operation diagramYI. Heater unit
35
INJECTION SYSTEM DIAGRAM
1. Battery 2. Ignition relay 3. Ignition switch 4. Octane adjust potentiometer 5. Diagnostic plug 6. Temperature regulator 7. «CHECK ENGINE» warning light
8. Idle air control valve 9. Central injection unit10. Throttle position sensor 11. Injector 12. Air temperature sensor 13. Tachometer 14. Preheater “ON” relay 15. Fuel level gauge 16. Electronic control unit
17. Coolant temperature sender 18. Spark plug 19. Ignition module 20. Crankshaft position sensor 21. Airflow meter 22. Speed sender 23. Fuel filter 24. Catalytic converter 25. Fuel pump and fuel level sender
26. Fuel pump “ON” relay 27. Fuel vapour separator 28. Pressure-relief valve 29. Gravity valve 30. Two-way valve 31. Canister with electromagnetic purge valve 32. Oxygen sensor 33. Intake manifold preheater
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INJECTION SYSTEM
1. Throttle valves housing, TBI unit2. Idle speed adjuster3. Throttle operation cam4. Supply unit, TBI5. Fuel pressure regulator
6. Injector7. Securing clip8. Pipe union, fuel supply9. Fuel tank10. Fuel pump with fuel level sender11. Fuel supply pipe12. Fuel return pipe
13. Fuel filter14. TBI unit15. Throttle position sensor16. Fuel pressure regulator valve17. Diaphragm18. Throttle shaft19. Throttle valve
20. Vacuum connection21. Idle speed control valve
a. Fuel supply portb. Fuel return portc. Canister purge hose connectiond. Crankcase ventilation hose connection
e. MAP sensor hose connection
I. Fuel pressure regulator operation diagramII. Idle air control diagram:
A - air supply by-passing throttle valve
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WIRING DIAGRAM FOR INJECTION SYSTEM (GM)
1. Air temperature sensor2. Idle speed adjuster 3. Electronic control unit (ECU)4. Octane-rating potentiometer5. Spark plugs
6. Ignition module7. Crankshaft sensor8. Fuel pump motor and fuel level sensor9. Instrument cluster including
tachometer and ‘Check Engine’ light10. Main fuse box11. Speed sensor12. Diagnostic plug13. Injector
14. Canister purge valve15. Injection system fuse box16. Ignition relay17. Electric fuel pump ‘on’ relay18. Intake manifold preheating relay19. Intake manifold preheater20. Intake manifold preheating fuse21. Oxygen sensor22. Coolant temperature sensor
23. Throttle position sensor24. Manifold absolute pressure (MAP) sensor
A. To battery ‘+’ terminalB. To ignition switch ‘15’ terminal
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1 - Injectors;2 - Spark Plugs;3 - Ignition Module;4 - Data Link Connector (DLC);5 - Electronic Control Module(ECM);6 - Fusebox;
7 - Main Relay;8 - Electric Fan Relay;9 - Cooling Fans Motors;10 - Mass Air Flow (MAF) and IntakeAir Temperature (IAT) Sensor;11 - Throttle Position (TP) Sensor;12 - Engine Coolant Temperature
(ECT) Sensor;13 - Idle Air Control (IAC) Valve;14 - Heated Oxygen Sensor(HO2S);15 - Knock Sensor (KS);16 - Crankshaft Position (CKP)Sensor;
17 - EVAP Purge Solenoid;18 - Immobilizer Control Module;19 - Immobilizer System KeyReader;20 - Vehicle Speed Sensor (VSS);21 - Fuel Pump Relay;22 - Electric Fuel Pump with Fuel
Level Sensor;23 - Instrument Panel Connector;
A - to battery terminal «+»;B - to courtesy light switch electricconnector;C - to white/black wire disconnectedfrom the courtesy light switch;G1, G2 - Ground Connections.
Alongside letter code of wire colorthis diagram also has digital markingindicating the number of electricalcomponent to which the wire shouldbe connected, e.g. «-3-». Marking «-S7-» or «-SA-» meanes that the wireshould be connected to component
#7 or A, as indicated on the wiringdiagram, through the connection notshown on the diagram.
Important: A dif ferent sequence of fuses maybe used while assembling thevehicle. 39
1- Injectors;2- Spark Plugs;3- Ignition Module;4- Data Link Connector (DLC)5- Electronic Control Module (ECM)6- Fuse Box;7- Main Relay;
8- Fan Relay;9- Cooling Fan Motors; 10- Mass Air Flow (MAF) and IntakeAir Temperature (IAT) Sensors;11- Throttle Position (TP) Sensor;12- Engine Coolant Temperature
(ECT) Sensor;13- Idle Air Control (IAC) Valve;14- EVAP Purge Solenoid;15- Rough Road Sensor (G-Sensor);16- Catalyst Monitor Heated OxygenSensor (HO2S 2);17- Fuel Control Heated Oxygen
Sensor (HO2S 1);18- Knock Sensor (KS);19- Crankshaft Position (CKP)Sensor;20- Immobilizer Control Module;21- Immobilizer System Key Reader;22- Camshaft Position (CMP)
Sensor;23- Fuel Pump Relay;24- Electric Fuel Pump with FuelLevel Sensor;25- Vehicle Speed Sensor (VSS);26- Connector, to instrument panelharness;
A- to battery terminal "+";B- Wiring, to courtesy light switch;C- Wiring, to white/black wire dis-connected from the courtesy light switch;G1, G2 - Ground Connections.
Alongside letter code of wire colorthis diagram also has digital markingindicating the number of electricalcomponent to which the wire shouldbe connected, e.g. «-5-». Marking «-S7-» means that the wire should be
connected to component #7 throughthe connection not shown on the dia-gram. Some markings also indicatepin number (after a slash), e.g. «-5/15-».
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