Lada Niva Building instructions

Lada Niva Manual - Maintenance Page 1
Table of Contents
MAINTENANCE............................................................................................................................2
ENGINE LUBRICATION..............................................................................................................2
Oil Sump.................................................................................................................................2
Oil Filter ................................................................................................................................3
VALVE GEAR ............................................................................................................................4
Valve Clearances......................................................................................................................4
Tensioning the Valve Gear Chain................................................................................................5
FUEL SYSTEM...........................................................................................................................5
Air Cleaner .............................................................................................................................6
Car urettor.............................................................................................................................7
Idling speed adjustment .............................................................................................................7
CRANKCASE BREATHING SYSTEM...........................................................................................9
COOLING SYSTEM ....................................................................................................................9
Coolant ..................................................................................................................................9
COOLING SYSTEM THERMOSTAT....................................................................................................10
ALTERNATOR DRIVE BELT............................................................................................................10
IGNITION SYSTEM...................................................................................................................11
Ignition Distri utor ................................................................................................................11
SPARK PLUGS.............................................................................................................................12
TRANSMISSION.......................................................................................................................12
Clutch Fluid Reservoir ............................................................................................................ 12
ADJUSTING THE CLUTCH CONTROL MECHANISM .............................................................................. 12
GEARBOX TRANSFER CASE. .........................................................................................................14
Front and Rear Axles .............................................................................................................. 14
Propeller Shaft Splined Connections and Crosses ........................................................................14
Joints of Front Wheel Drive Propeller Shafts............................................................................... 14
HYDRAULIC SHOCK ABSORBERS AND ANTIROLL BAR .........................................................14
STEERING GEAR AND WHEELS...............................................................................................14
Steering Gear Clearances.........................................................................................................14
Front Wheel Hu Bearings.......................................................................................................15
Examining the Front Suspension Ball Supports and Steering Rod joints...........................................17
Tyres....................................................................................................................................17
Replacing the Wheels...............................................................................................................19
Front-End Alignment...............................................................................................................19
BRAKES.................................................................................................................................. 20
Brake Hydraulic System ........................................................................................................... 20
Brake Fluid Reservoir..............................................................................................................21
Flexi le rake hoses................................................................................................................21
FRONT BRAKES .......................................................................................................................... 21
REAR BRAKES ............................................................................................................................23
Bleeding the Brake System........................................................................................................24
Adjusting the Free Travel of Brake Pedal....................................................................................25
Brake Vacuum Booster.............................................................................................................25
Parking Brake........................................................................................................................25
ELECTRICAL EQUIPMENT .......................................................................................................25
Wiring diagram......................................................................................................................26
Storage Battery ......................................................................................................................27
Alternator .............................................................................................................................27
Starter..................................................................................................................................27
Voltage Regulator...................................................................................................................28
Aiming the Headlight Lower Beam ............................................................................................28
Replacing the Bul s ................................................................................................................ 28
Tail lights.............................................................................................................................29
Fuses....................................................................................................................................29
Fuse-Protected Circuits ........................................................................................................... 29
BODY......................................................................................................................................31
Care of Body ......................................................................................................................... 31
Windshield and Headlight Washers............................................................................................ 33
Windshield and Headlight Wipers..............................................................................................33
Fastening of Units and Mechanisms to Car Body.........................................................................33
MAINTENINCE IN LONG-TERM STORIGE.................................................................................33

Lada Niva Manual - Maintenance Page 2
MAINTENANCE
The mechanisms units and parts subject to scheduled maintenance are indicated by reference
numbers in Figs 25 and 26. Table 1 contains the lubricating instructions and Table 2
maintenance instructions (cleaning checking and adjustment).
The car should be serviced every 10 000 Km. However during the initial period of operation
when working-in of all the units and mechanisms takes place the car should be serviced after
covering the first 2 000-3 000 Km. This will ensure superb performance and long service life
of the car.
The list of the tools and accessories delivered with the car for Owner’s services is given in
Appendix 3.
ENGINE LUBRICATION
Oil Sump
Every 500 Km check the oil level in a cold engine and add oil if
necessary. The oil level should be between marks MIN and MAX on
oil dipstick 1 (Fig. 27).
On a new engine change oil after the first 2 000-3 000 Km then at
10 000 Km and thereafter every 10 000 Km. Change oil while the
engine is still hot. Drain used oil after removing the plug of the hole
in the bottom of the engine sump. Pour fresh oil through oil filler
neck 2 located on the cylinder head cover.
The seasonal change of oil depends on the change of season as
different temperature conditions call for the employment of different grades of oil (see
Appendix 2).
Every 30 000 Km wash the lubricating system. Wash the system earlier only when sticky
gum deposits accumulate on the camshaft housing.
Perform this operation on a hot engine as follows:
• Drain used oil from the engine sump.
• Fill the engine with a special detergent oil to the MIN mark and let the engine run idle at a
speed of about 1 000 rpm for 10 minutes.
• Drain the detergent oil replace the oil filter and pour in fresh oil of the grade recommended
for the season.
note. When using equivalent oils produced by different firms wash the lubricating system
each time before the oil change.

Lada Niva Manual - Maintenance Page 3
Oil Filter
Every 10.000 Km replace the filter. Do it after the first 2 000-
3 000 Km on a new car. To replace the filter unscrew it from the
cylinder block (pig. 28). Screw the new filter in place only hand-
tight.

Lada Niva Manual - Maintenance Page 4
VALVE GEAR
Valve Clearances
Every 10.000 Km and also in case of abnormal knocking in the
valve mechanism check clearances A (Fig. 29) between the
cams and valve rockers which should be 0.15 mm on a cold
engine both for the intake and exhaust valves. On a new engine
perform this operation after the first 2 000-3 000 Km upon
checking and tightening the fasteners of the cylinder head
camshaft bearing housing and intake and exhaust manifolds.
Loosen the cylinder head bolts preliminarily through about
30" each and then tighten them according to the sequence
shown in fig. 30.
Tighten bolts 1 through 10 to a torque of 115 NÆm (11.5 kg Æ m)
and bolt 11 to a torque of 38 NÆm (3.8 kg Æ m).
Tighten the nuts of the camshaft
bearing housing by applying a torque
of 22 NÆm (2.2 kg m) according to the
sequence shown in pig. 31.
To adjust the valve clearances, roceed as follows:
• Remove the cylinder head cover with its gasket; if necessary
first remove the heater air intake box;
• Rotate the crankshaft clockwise to align mark A (Fig. 32) on
the sprocket with mark B on the camshaft housing; in this case
the piston of the No. 4 cylinder will be on TDC at the end of
the compression stroke and both valves will be closed
• Adjust the rocker-to-cam clearances of the exhaust valve on
the No. 4 cylinder (8th cam) and of the intake valve on the No.
3 cylinder (6th cam); for this purpose loosen locknut 2 (Fig.
33) and rotate adjusting bolt 1 to set the required clearance
using a flat feeler gauge inserted between the cam and the
rocker (the feeler gauge should move in this case with a slight
biting)
• Holding bolt 1 in this position with a wrench tighten locknut
2 by applying a torque of 52 NÆm (5.2 kg Æ m) and recheck the
clearance
• Turning the crankshaft each time through hall a revolution
adjust the clearances of other valves following the sequence
given in Table 3 below.
Valve Gear
A - Valve rocker to cam clearance 1 -
cam 2 - valve rocker 3 - valve oil
deflecting cap 4 - valve 5 - rocker
adjusting bolt 6 - adjust bolt locknut.
Figure 30 - Sequence of tightening
cylinder head bolts
Fig 31. Sequence of tightening
camshaft bearing housing nuts
Fig 32.
Setting No. 4 Cylinder piston in TDC
Fig 33. Adjusting valve clearances:
1- adjusting bolt 2- adjusting bolt
locknut

Lada Niva Manual - Maintenance Page 5
Table 3 - Sequence of Valve Clearance Adjustment.
Crankshaft No of cylinder in which piston is on
TDC
Valves under adjustment
angle at end of compression stroke exhaust intake
degrees Cylinder
No.
Cam No. Cylinder
No.
Cam No.
0 4 4836
180 2 2447
360 1 1123
560 3 3512
• Reinstall the cylinder head cover with its gasket. Adjustment over check the tightening
torque of the crankshaft jaws which should be 122 NÆm (12.2 kg Æ m).
Tensioning t e Valve Gear C ain
Every 10.000 Km adjust the tension of
timing chain 2 (Fig. 34). Do it on a new car
after the first 2 000- 3 000 Km. For this
purpose loosen retaining nut 7 and turn the
crank- shaft through 1-1~5 revolutions in the
direction of its normal rotation. In this case
spring 10 actuates shoe 6 through plunger 11
and automatically sets the required chain
tension. Adjustment over tighten nut 7.
Adjust chain tension also in case of excessive
operation noise in the valve gear.
Fig 34. Valve Gear Drive. 1 - camshaft sprocket 2 - chain 3 -
dampener 4 - oil pump drive shaft sprocket 5 - crankshaft
sprocket 6 - chain tensioner shoe 7 tensioner rod retaining nut 8 -
retainer 9 - tensioner adjusting rod 10 - plunger spring 11 -
tensioner plunger
FUEL SYSTEM

Lada Niva Manual - Maintenance Page
Air Cleaner
Every 10.000 Km replace filter element 3 (Fig. 35); to this end
unscrew nuts 1 and remove cover 2. When driving on extremely dusty
roads replace the filter element every 5 000 Km.
Seasonal adjustment of the air cleaner is required for delivery of fresh
or warm air (warmed by the exhaust manifold). If the average ambient
temperature in the season is below 15 "C slightly pull and then shift
the handle 5 of the gate on the housing of thermo-regulator 4 in the
upper position (HOT) and if the average temperature is above 15 "C
shift the handle to the lower position (COLD).
Figure 35. Air Cleaner 1- nut 2-
cover 3- filter 4- thermo-regulator 5-
handle

Lada Niva Manual - Maintenance Page 7
Carburettor
Every 10.000 Km (and also after the first 2 000-
3 000 Km if the car is new) wash the carburettor
fuel filter and the fuel pump filter with gasoline and
blow them out with compressed air.
Every 20 000 Km clean the carburettor from the
inside wash it with gasoline or benzene and blow
out with compressed air. When cleaning the
calibrated orifices of the jets use a wooden stick or
match with a pointed end wetted with acetone. Do
not use wire even soft not to disturb the
dimensions and finish of the orifices. When screwing the jets in or out avoid damaging the
thread in the holes.
Check and if necessary adjust the fuel level in the float chamber and the float travel for
which purpose.
• Make sure that the mass of float 9 (Fig. 36) complete with arm 7 is 12+1 g the float has no
holes or dents and can freely rotate on its pin.
• Make sure that seat 2 of needle valve 4 is tightened reliably and that damper ball 5 built
into needle valve 4 does not stick
• Set upper body 1 vertically so that the fuel inlet union is directed upwards the needle
valve is closed and float tongue 8 lightly contacts the needle valve ball.
• With the parts in this position measure the distance between the float and the surface of
gasket 10 which fits the upper body; the distance should be 6.5 mm
• Change the position of the tongue if necessary to obtain the required distance; the tongue
must be perpendicular to the valve axis and the contacting surface of the tongue should
have no defects that may cause sticking of the valve.
• Check the float travel which should be 8 mm changing the position of stop 3 if necessary.
• Check that pull-back yoke 6 of the needle valve does not interfere with free travel of the
valve.
• Reinstall the carburettor upper body after making sure that the float is free to move
without brushing against the chamber walls.
Note. When replacing the needle valve also replace the gasket between the seat and the upper
body.
Idling speed adjustment
Every 10.000 Km (and also after the first 2 000-
3 000 Km if the car is new) adjust the minimum
idling speed of the engine. Have this adjustment
done at a service station. The Owner is allowed
only to carry out fine adjustment of the engine
idling speed within the range permitted by idle
speed screw limiting bushing 1 (Fig. 37) and by
idle mixture screw limiting bushing 2. Attempts to
turn the bushings through a larger angle will
destroy them. In this case the Manufacturer bears
no responsibility for excessive content of carbon monoxide (CO) in the exhaust gases and for
excessive fuel consumption.
Fig. 36.Adjusting Fuel Level In Carburettor
Float Chamber: 1- carburettor upper body 2 -
needle valve rest 3 - stop 4 - needle valve 5-
ball 6- pull-back yoke 7 arm 8 lounge 9-
float l0- gasket.
Fig 37. Idling system adjustment screws: 1- Idle
speed screw limiting bushing 2- idle mixture screw
limiting bushing.

Lada Niva Manual - Maintenance Page 8
Perform the fine adjustment with the engine warmed-up valve clearances adjusted and a
spark advance angle set properly. Proceed as follows.
• Start the engine and turn idle mixture screw limiting bushing 2 all the way out.
• Using idle speed screw limiting bushing 1 set the engine speed within 850-900 rpm

Lada Niva Manual - Maintenance Page 9
Check the engine idling performance. For this purpose abruptly depress and release the
accelerator pedal; in this case the engine speed should increase smoothly without missing. The
engine should not stall when the idling speed is reduced to minimum. If the idling speed fine
adjustment fails to ensure normal running of the engine without missing apply to a service
station for a qualified help.
CRANKCASE BREATHING SYSTEM
Every 20.000 Km clean and wash with gasoline the hoses of the crank- case breathing
system the shut-off valve on the carburettor throttle valve shaft and the flame arrester
located in the exhaust hose running from the engine to the air cleaner.
COOLING SYSTEM
Coolant
The cooling system of the cars leaving the plant is filled with
special fluid A-40M. This fluid is an ethylene glycol mixture with
a freezing point of minus 40"C and anticorrosive antifoaming and
antiscaling properties. It needs no replacement within a period of
three years. Therefore care of the cooling system during this
period consists only in checking at regular intervals the fluid level
in the expansion tank.
The fluid level should always be 3-4 cm above the MIN mark
(Fig. 38). Check the fluid level on a cold engine only since when
the engine is hot the level may rise significantly; expansion of the fluid volume may also take
place immediately after engine shutdown.
If the fluid level is below the MIN mark replenish the expansion tank with fluid of the same
grade. If the coolant level drops constantly and frequent replenishments are required check the
cooling system for leakage and eliminate the trouble. In an emergency the cooling system may
be filled with clean water. In this case proceed as follows:
• Cool the engine.
• Remove the caps from the radiator and expansion tank.
• Pour water into the radiator (keep pouring water until it starts flowing out of the radiator
filler neck).
• Reinstall the radiator cap.
• Add water into the expansion tank until its level is 3-4 cm above the MIN mark.
• Reinstall the expansion tank cap.
In cold seasons if water has been added into the cooling system and before placing the car in
motion warm the engine up to 85-90"C to make the fluids mix. Bear in mind that water added
into the cooling system raises the freezing temperature of the mixture; therefore per- form the
necessary repairs of the cooling system at the first opportunity and fill it with the coolant of
the prescribed grade.
Fig 38 Cooling system expansion tank