Vaz Lada Niva 1600 User manual

Lada Niva 1600
Maintenance Manual
For VAZ 2121 21212 cars
This manual comprises pages 27 to 64 of the official car
manual which is not copyright. The manual is intended for
owners of Lada Nivas who were not provided with a manual for
their car. This manual may not be sold for profit.
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Lada Niva Manual - Maintenance Page 1
Table of Contents
MAINTENANCE .................................................................................................................................................. 3
ENGINE LUBRICATION ................................................................................................................................. 3
Oil Sump ........................................................................................................................................................ 3
Oil Filter ........................................................................................................................................................ 3
VALVE GEAR................................................................................................................................................... 4
Valve Clearances ........................................................................................................................................... 4
Tensioning the Valve Gear Chain.................................................................................................................. 5
FUEL SYSTEM ................................................................................................................................................. 5
Air Cleaner .................................................................................................................................................... 5
Carburettor .................................................................................................................................................... 6
Idling speed adjustment ................................................................................................................................. 6
CRANKCASE BREATHING SYSTEM ........................................................................................................... 7
COOLING SYSTEM ......................................................................................................................................... 7
Coolant .......................................................................................................................................................... 7
COOLING SYSTEM THERMOSTAT ......................................................................................................................... 8
ALTERNATOR DRIVE BELT .................................................................................................................................. 8
IGNITION SYSTEM ......................................................................................................................................... 9
Ignition Distributor........................................................................................................................................ 9
SPARK PLUGS .................................................................................................................................................... 10
TRANSMISSION............................................................................................................................................. 10
Clutch Fluid Reservoir................................................................................................................................. 10
ADJUSTING THE CLUTCH CONTROL MECHANISM .............................................................................................. 10
GEARBOX, TRANSFER CASE. ............................................................................................................................. 11
Front and Rear Axles................................................................................................................................... 11
Propeller Shaft Splined Connections and Crosses ...................................................................................... 11
Joints of Front Wheel Drive Propeller Shafts.............................................................................................. 11
HYDRAULIC SHOCK ABSORBERS AND ANTIROLL BAR .................................................................... 11
STEERING GEAR AND WHEELS ................................................................................................................ 11
Steering Gear Clearances............................................................................................................................ 11
Front Wheel Hub Bearings.......................................................................................................................... 12
Examining the Front Suspension Ball Supports and Steering Rod joints.................................................... 14
Tyres ............................................................................................................................................................ 14
Replacing the Wheels................................................................................................................................... 15
Front-End Alignment ................................................................................................................................... 15
BRAKES .......................................................................................................................................................... 16
Brake Hydraulic System............................................................................................................................... 16
Brake Fluid Reservoir.................................................................................................................................. 17
Flexible brake hoses .................................................................................................................................... 17
FRONT BRAKES ................................................................................................................................................. 17
REAR BRAKES ................................................................................................................................................... 19
Bleeding the Brake System........................................................................................................................... 20
Adjusting the Free Travel of Brake Pedal ................................................................................................... 21
Brake Vacuum Booster ................................................................................................................................ 21
Parking Brake.............................................................................................................................................. 21
ELECTRICAL EQUIPMENT........................................................................................................................... 21
Wiring diagram............................................................................................................................................ 22
Storage Battery ............................................................................................................................................ 23
Alternator..................................................................................................................................................... 23
Starter .......................................................................................................................................................... 23
Voltage Regulator........................................................................................................................................ 24
Aiming the Headlight Lower Beam.............................................................................................................. 24
Replacing the Bulbs ..................................................................................................................................... 24
Tail lights ..................................................................................................................................................... 25
Fuses............................................................................................................................................................ 25
Fuse-Protected Circuits............................................................................................................................... 25
BODY............................................................................................................................................................... 26
Care of Body ................................................................................................................................................ 26
Windshield and Headlight Washers............................................................................................................. 27
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Lada Niva Manual - Maintenance Page 2
Windshield and Headlight Wipers ............................................................................................................... 28
Fastening of Units and Mechanisms to Car Body ....................................................................................... 28
MAINTENINCE IN LONG-TERM STORIGE ...............................................................................................28
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Lada Niva Manual - Maintenance Page 3
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.
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.
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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 N·m (11.5 kg · m),
and bolt 11 to a torque of 38 N·m (3.8 kg · m).
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
Tighten the nuts of the camshaft
bearing housing by applying a torque
of 22 N·m (2.2 kg m) according to
the sequence shown in pig. 31.
Fig 31. Sequence of tightening
camshaft bearing housing nuts
To adjust the valve clearances, proceed as follows:
• Remove the cylinder head cover with its gasket; if necessary,
first remove the heater air intake box;
Fig 32.
Setting No. 4 Cylinder piston in TDC
Fig 33. Adjusting valve clearances: 1-
adjusting bolt, 2- adjusting bolt
locknut
• 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 N·m (5.2 kg · 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.
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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 4 8 3 6
180 2 2 4 4 7
360 1 1 1 2 3
560 3 3 5 1 2
• Reinstall the cylinder head cover with its gasket. Adjustment over, check the tightening
torque of the crankshaft jaws, which should be 122 N·m (12.2 kg · m).
Tensioning the Valve Gear Chain
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
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.
Figure 35. Air Cleaner 1- nut, 2-
cover, 3- filter, 4- thermo-regulator, 5-
handle
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).
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Lada Niva Manual - Maintenance Page 6
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.
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.
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 37. Idling system adjustment screws: 1- Idle
speed screw limiting bushing, 2- idle mixture screw
limiting bushing.
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
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Lada Niva Manual - Maintenance Page 7
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.
Fig 38 Cooling system expansion tank
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.
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Lada Niva Manual - Maintenance Page 8
Every three years or every 60,000 Km (whichever comes
first), flush the cooling system and fill it with fresh coolant.
Fig 39. Cooling system drain holes. 1- drain hole
in radiator bottom, 2- drain hole in cylinder block.
Drain coolant from the system through two drain holes 1 and
2 (Fig. 39), one of which is located in the radiator bottom tank
and the other one in the cylinder block at the left side. In
doing so shift the heater cock control lever to the right most
position.
For screwing the radiator drain hole plug in or out, use two wrenches; one to keep in place
the plug union soldered into the radiator tank, and the other to screw the plug in or out. After
draining the coolant completely from the system through the above holes, remove the coolant
remaining in the expansion tank and hose connecting the tank to the radiator by disconnecting
the hose from the expansion tank or by raising the tank proper to a required height.
To flush the cooling system, proceed as follows.
• Fill the system with clean water, start the engine and run it until the bottom tank of the
radiator gets warmed and, with the engine idling, drain water through the radiator and
cylinder block drain holes.
• Let the engine cool down, refill the system with clean water and repeat the above
operation.
After the flushing pour coolant into the cooling system. If the coolant of the specified grade
is not avail- able, it is permissible (at ambient temperatures above zero) to use clean water, as
soft as possible to avoid heavy scale deposition which leads to engine overheating under
normal operating conditions. When using hard water, flush the cooling system twice a year
with special descaling agents.
If an aluminium radiator is in- stalled in the car do not use water in the cooling system as
water affects corrosion resistance of the radiator.
Cooling System Thermostat
Fig 40. Checking tension of Alternator
drive belt. 1- nut, 2- nut of alternator joint
pin, 3- alternator, 4- thermostat, 5- water
pump, A- belt deflection.
Every 20.000 Km and also in case of abnormal temperature
of the engine (overheating under normal operating conditions
or excessively long warm-up period after starting), check
thermostat 4 (Fig. 40) for normal functioning. A simple check
is the hand- feeling of the thermostat directly on the car.
Upon starting the cold engine with the thermostat service-
able, the bottom tank of the radiator starts getting warm as
soon as the coolant temperature is 80-85 "C.
Alternator Drive Belt
Every 10.000 Km (and after the first 2,000-3,000 Km if the car is new), check the belt for
tension. Normal deflection A (Fig. 40) is 10-15 mm if a force of 100 N (10 kg) is applied.
To increase the belt tension, proceed as follows.
• Loosen nut 1 that fastens the alternator to the adjusting arm.
• Loosen nut 2 of the alternator joint pin.
• Shift alternator 3 away from the engine and tighten the fastening nuts.
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Lada Niva Manual - Maintenance Page 9
Avoid over tightening the belt so as not to overload the bearings of alternator 3 and water
pump 5.
IGNITION SYSTEM
Ignition Distributor
Every 10,000 Km:
1. Check the working surfaces of breaker contacts 3 (Fig.
41). In case of heavy transfer of metal from one
contact point to the other, dress them with a flat
barette file. Do not eliminate completely the crater on
the breaker arm contact point. Check and, if
necessary, dress the contacts in the distributor cap and
on the rotor.
Figure 41. Ignition distributor. 1- noise resistor
suppressor, 2- rotor, 3- breaker contacts, 4- screw,
5- slot, 6- terminal, 7- spring catch, 8- capacitor, 9-
scale, 10- bracket, 11- nut, 12- body, 13- vacuum
spark timer, 14- lubricator, 15- cam
2. Use a piece of clean, gasoline- soaked chamois leather
or some other lint-free material to clean the breaker
contact points, the rotor, and the outer and inner
surfaces of the distributor cap.
3. Check the breaker point gap which should be 0.4+0.05
mm, for which purpose.
• Shift the gearshift lever into the neutral.
• Apply the parking brake;
• Rotate the crankshaft with the starting crank to set cam 15 in the position at which the
breaker contacts are wide open.
• Check the gap with a feeler gauge; if the gap differs from the rated value, loosen screws 4
and, using a screwdriver inserted into special slot 5, shift the breaker con- tact post as
required; adjustment eve, tighten screws 4.
4. Check ignition timing, for which purpose
• Connect one end of the wire of a 12-V test lamp to terminal 6, and ground its other end.
• Turn on the ignition and slowly rotate the crankshaft with the starting crank; with the
ignition set properly, the test lamp should come on when mark 4 (Fig. 42) on the
crankshaft pulley is aligned with mark 2 on the timing gear cover, and the contact of rotor
2 (Fig. 41) should be opposite the contact of the No. 1 cylinder on the distributor cap.
5. If the marks are not aligned at the moment the test lamp
comes on, adjust the ignition timing as follows.
• Rotate the crankshaft with the starting crank to set it in the
position at which the rotor contact faces the contact of the
No. 1 cylinder on the distributor cap, and mark 4 (Fig. 42)
is aligned with mark 2 (in this position the piston of the
No. 1 cylinder will be 5" before TDC as measured in
crankshaft degrees);
• Loosen nut 11 (Fig. 41) and turn distributor body 12
clockwise until the breaker points are closed.
• Slowly rotate the distributor body counter-clockwise until
the test lamp comes on; in doing so, slightly press the rotor counter- clockwise to take up
clearances.
Fig 42. Timing marks on pulley and valve
gear drive cover. 1- 10o, 2- 5 o, 3-0 o, 4-
mark on pulley
• Stop the distributor body exactly at the moment the test lamp comes on (the breaker
contact points are at the beginning of opening phase).
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