Vaz-21215-10 Vehicle - Vaz 21213 Repair Manual

VAZ-21215-10 vehicle

The VAZ-21215-10 vehicle is fitted with the diesel engine
DHW (XUD-9SD).
The section gives a brief description of diagnostic procedures
for fuel and electrical systems, engine removal and refitting,
repair procedures for engine systems.
For detailed design, repair and diagnostic procedures with
respect to all engine systems using specialized tools and diag-
nostic charts, refer to PEUGEOT Repair Manual for Diesel
Engine.
The diesel engine operation depends much on the sound fuel
injection system, this is why this section focuses on the fuel sup-
ply units and components.
In the event the injection system has failed, do not blame the
high pressure pump, first check the following:
– fuel tank and fuel level;
– delivery and return fuel lines;
– fuel filter;
– injectors;
– glow plugs;
– engine stop solenoid resistance.
Examine the engine, since higher flash-point temperature
depends on compression, valve and piston ring condition.
Inspect the air cleaner, battery, starter motor, check the oil
level.
Major faults and remedial actions
1. Engine does not start, emitting no smoke:
- check fuel level in fuel tank;
- set engine manual stop device to normal position;
- check fuel delivery pipes; in case of leaks, tighten connections or
replace pipes;
- check engine stop solenoid for resistance, wiring conductivity and fuel
inflow.
If engine still fails to start after all these checks and remedial actions,
remove high pressure pump and test it using specialized equipment.
2. Engine does not start, emitting black smoke:
- when engine speed is below 150 rpm, check condition and fitting of bat-
tery terminals and starter motor, battery charge, oil grade and oil level;
- when engine speed is over 150 rpm, start engine without using air
cleaner; when no smoke is evident, renew filter element, check proper
mounting of air cleaner housing;
- check injection timing is correct, check fuel injectors are sound;
- check valve adjustment and compression in cylinders.
Should smoke persists despite all remedial actions, remove and test
pump using specialized equipment.
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3. Engine does not start, emitting white smoke (cold engine):
Check the following items:
- glow plugs;
- secondary warming-up system;
- cylinder head gasket;
- injection timing.
If smoke persists after repair work, remove pump for inspection.
4. Difficult cold engine start with black smoke:
Check the following items:
- glow plugs;
- fast idle thermostat;
- injection timing;
- injectors;
- hydraulic lifters and valve clearances;
- compression.
Should smoke persists after repair, remove and test pump using spe-
cialist equipment.
5. Engine starts and stalls:
Check the following items:
- idle adjustment;
- oil grade and oil level;
- ventilation system;
- fuel feed system;
- solenoid;
- secondary warming-up system;
- air cleaner;
- non-return valve on LUCAS pump.
Should engine stalls despite repair performed, remove fuel pump.
6. Unstable idle:
Check the following items:
- settings of engine stop prevention system and idle (for LUCAS);
- settings for idle and fuel remainder return (for BOSCH);
- accelerator lever spring;
- fuel feed system;
- injectors;
- valve clearances;
- cam belt tension.
In case of failure to adjust idle speed, remove and examine pump on
a specialist test bench.
Engine - removal and refitting
Place the vehicle on the lift or over an inspection pit, chock
the front wheels and raise the rear axle from one or both sides.
Withdraw the bonnet, disconnect wiring from the battery and
electrical units fitted to the vehicle. Remove the battery and
underbonnet lamp.
Drain fluid form the cooling system and heater; to do this
unplug the expansion tank, undo the drain plugs on the radiator
(underneath, left-hand side) and on the cylinder block (left-hand
side).