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1. Exhaust valve seat. 2. Exhaust valve with spring. 3. Fuel pump upper housing 4. Filter. 5. Discharge pipe. 6. Bolt. 7. Pump cover. 8. Suction pipe. 9. Inlet valve seat. 10. Inlet valve with spring. 11 Upper aperture plate. 12. Internal spacer. 13. Working diaphragms. 14. External spacer. 15. Lower diaphragm. 16. Rod with spring. 17. The lower housing of the fuel pump. 18. Manual paging lever with return spring. 19. Balancer. 20. Fuel tank. 21. Fuel gauge sensor. 22. Fuel tank ventilation tube. 23. Fuel pump. 24. Carburetor. 25. Cylinder block. 26. Fuel pump drive eccentric. 27. Pusher. 28. Adjusting gasket. 29. Heat-insulating spacer. 30. Power feed lever with return spring. 31. Warm air intake pipe. 32. Hose for supplying crankcase gases to the spool device. 33. Exhaust manifold of the crankcase ventilation system. 34. Air filter housing. 35. Exhaust pipe for crankcase ventilation. 36. Filter element of the crankcase ventilation system. 37. An axis of fastening of a cover. 38. Filter element. 39. Cover. 40. Partition. 41. Cold air intake pipe. 42. Spool. 43. Throttle valve. 44. Pillow of fastening of an exhaust pipe. 45. Belts for attaching the main muffler. 46. Main muffler. 47. Coupling collar. 48. Additional muffler. 49. An arm of fastening of a reception pipe to a transmission. 50. Gas receiver. 51. Downpipe. 52. Additional front muffler. 53. Decorative nozzle.
Fuel supply system
The fuel supply system consists of a fuel tank, a fuel line and a fuel pump.
Fuel tank 20 - welded, stamped from leaded steel sheet, painted with black enamel. On VAZ-2101 and 2103 cars, the tank is installed in the luggage compartment (right along the way) on rubber gaskets and is attached to the body with two clamps, tightened by a central bolt. Rubber gaskets are also installed between the clamp bands and the tank body.
The filler neck is brought out through a rubber casing-lining to the hatch on the rear right wing and is closed with a plastic-lined blind screw plug. The sensor 21 of the fuel level indicator is installed in the tank, complete with a fuel receiving tube equipped with a strainer.
The tank is ventilated through the air tube 22 and a plastic hose put on it, led out under the filler hatch. The tank has a ground wire and a drain plug, for access to which there is a hole in the trunk floor, closed with a rubber plug. The fuel level indicator sensor is connected to a device mounted on the instrument panel and equipped with a red reserve lamp that lights up when 4-6 liters of gasoline remain in the tank. tank capacity (with reserve) 39 l.
On VAZ-2101 vehicles, all fuel and electrical connections are covered with a shield; on VAZ-2103 cars, the fuel tank is closed by the inner lining of the trunk.
On cars VAZ-2102 (station wagon) the fuel tank is located under the floor of the trunk and has access to the fuel gauge sensor from the side of the luggage compartment of the body through a special hatch. tank capacity (with reserve) 45 l.
The gasoline used is AI-93.
Fuel lines. Fuel from the fuel tank to the fuel pump 23 is supplied through two steel, two-layer tubes connected by rubber hoses, and from the fuel pump 23 to the carburetor 24 through a rubber hose.
The fuel pump is diaphragm type, equipped with a manual priming lever. The pump consists of the following main parts: lower housing 17 with drive levers, upper housing 3 with valves and nozzles, diaphragm assembly and pump cover 7. In the lower housing of the fuel pump are located: lever 18 for manual fuel pumping with a return spring and an eccentric equipped with sealing rings, a working diaphragm spring; mechanical fuel balancer 19 mounted on the axis together with the mechanical feed lever 30 and its return spring. The axis of the balancer and the lever of the mechanical fuel supply is installed in the holes of the lower housing 17, which are punched from the outside and smeared with sealant.
In the pump housing, outlet 2 and inlet 10 valves with seats 1, 9 are installed and the discharge 5 and suction 8 nozzles of the fuel pump are pressed in. Non-separable valves are made of textolite and have a hexagonal shape; valve seats are brass.
Cover 7 is attached to the fuel pump housing with a central bolt 6. A plastic mesh filter 4 is installed between the cover and the housing, having a special sealing shoulder, which, when the filter is installed, is inserted into the intake valve seat.
The diaphragm unit consists of two working diaphragms 13, working in contact with gasoline, and one safety diaphragm 15, working in contact with crankcase oil. The safety diaphragm prevents crankcase gases from affecting the working diaphragms, as well as the ingress of gasoline into the engine crankcase in case of failure of the working diaphragms.
Diaphragms together with plates are mounted on stem 16 and attached to it with a central nut. Distance gaskets are installed between the working and safety diaphragms - inner 12 and outer 14. The outer gasket has a through hole through which gasoline flows out when the working diaphragms break through. The rod 16 has an L-shaped shank, which is inserted into the slot of the balance bar and, after turning the diaphragm assembly, engages with it. This design allows you to replace the diaphragm assembly without removing the pump from the engine.
The pump works as follows. When the eccentric 26 runs on the pusher 27, the latter moves in the direction of the arrow (see diagram «suction) and acts on the lever 30 of the mechanical fuel supply. The lever 30 turns the balancer 19, which pulls the rod 16 together with the diaphragms down. The diaphragm spring is compressed. As a result, a vacuum is created above the diaphragms, under the action of which the exhaust valve 2 closes, and the inlet valve 10 opens and the fuel from the line fills the working cavity above the diaphragms.
When the eccentric runs off the pusher, the lever 30 moves to the left under the action of the return spring (see diagram «Injection»), releases the balancer 19 and the rod 16, which, together with the diaphragms, moves upward under the action of the spring, and creates pressure in the working cavity. Under the influence of this pressure, inlet valve 10 closes, and outlet 2 opens and fuel enters the carburetor.
The pump is self-regulating - at low fuel consumption, the stroke of the diaphragms is underused and the stroke of the lever 30 and balancer 19 will be partially idle.
The fuel pump is attached to the cylinder block on two studs through a heat-insulating spacer 29 and shims 28. Gaskets are made in three types and have a thickness of 0.3, 0.75 and 1.25 mm. When installing the fuel pump, the gaskets are selected so that the minimum protrusion of the pusher 3 above the mating plane of the spacer (taking into account the gasket between the spacer and the fuel pump) was 0.8-1.3 mm.
Pump capacity not less than 60 l/h at a frequency of 2000 cycles per minute; pressure developed with closed drain 0.2–0.3 kgf/cm2.
Air supply system
Air enters the engine through an air filter, which consists of a housing 34 with a base and nozzles, a dry filter element 38 and a cover 39. At the base of the housing, three axles 37 of the cover fastening and an exhaust pipe 35 of the engine crankcase ventilation are installed uniformly through 120 through 120. A branch pipe 41 for cold air intake from the engine compartment, a branch pipe 31 for warm air intake from a deflector located on the exhaust manifold, and an exhaust manifold 33 are welded to the housing. Branch pipes of the filter element 36 of the crankcase ventilation system are installed in the housing.
The crankcase gases are supplied to the exhaust manifold 33 through a hose and are sucked out at high air flow rates through the pipe 35 to the carburetor inlet, and in modes where the vacuum at the oblique cut of the pipe 35 is not enough, through the hose 32 and the fitting through the carburetor spool directly into the throttle space. If the throttle valve is closed, then the exhaust of crankcase gases occurs through a calibrated hole (scheme a), and when opening the throttle - through the groove located in the spool (scheme b), which maintains the necessary intensity of ventilation of the crankcase of the engine and does not allow an excessive decrease in the vacuum behind the throttle valve of the carburetor.
The filter housing mounts directly to the carburetor housing studs and is secured with four self-locking nuts.
Dry filter element has the form «accordion», which is made of special filter cardboard and is filled together with perforated casings made of tin or mesh into elastic covers made of self-hardening sealant. Covers on external surfaces have sealing elastic collars. When the element is installed in the housing and the nuts are tightened, the filter cover is pressed against the remote protrusions of the fastening axles 37, which achieves the elastic deformation of the collars necessary for sealing; this ensures a tight connection between the element, housing and cover and prevents deformation of the element or filter cover.
To increase the dust capacity, the filter element is equipped with a pre-cleaner lining made of non-woven synthetic material, which acts as an air pre-cleaner element.
The air filter cover has a segmental baffle 40, which, depending on the location, provides seasonal adjustment of the temperature of the air entering the engine. To control the correct installation of the cover, depending on the season, two marks are applied to the cover: red (winter installation) and blue (summer installation), and an arrow is stamped on the cold air intake pipe.
The term for replacing the filter element is 10,000 km in urban and highway conditions. On dusty country roads, replacement should be more frequent - 3000-4000 km.
The factory does not recommend cleaning and restoring the filter element, since this may damage the filter curtain, and therefore, there is a possibility of abrasive wear of the engine cylinders.
Exhaust system
The exhaust system consists of three main non-separable units: exhaust pipe 51, additional 48 (cars VAZ-2101, 2102) or two additional, front and rear (cars VAZ-2103) mufflers with pipes assemblies and the main silencer 46 with pipes assemblies. These nodes are connected by pushing pipes one into the other (moreover, one of the connected pipes has a flared end with two longitudinal diametrically located slots), and are fixed with clamps 47.
The downpipe consists of a flange, two pipes and a gas inlet 50, welded from two stamped halves and closed on both sides with asbestos heat-insulating gaskets and thin-walled protective casings. All mufflers also have similar thermal insulation. The exhaust pipe is attached to the exhaust manifold with four brass nuts, as well as to the bracket 49, mounted on the gearbox. Between the intake pipe and the collector, a sealing gasket is installed, made of asbestos, reinforced with perforated steel tape. The exhaust pipes of VAZ-2101, 2102 and 2103 cars are unified.
Additional and main mufflers consist of two forged half-shells, perforated pipes and baffles. The main mufflers of VAZ-2101, 2102 and 2103 cars are unified and differ only in the exhaust pipe; for the VAZ-2103 car, it has a decorative nozzle 53 made of stainless steel tape, for the VAZ-2102 car, it has a modified configuration associated with changes in the rear of the body.
The additional muffler 48 of VAZ-2101 and 2102 cars differs from the rear additional muffler of the VAZ-2103 car by the presence of a throttling diaphragm in its inner pipe, therefore, when repairing, installing it on a VAZ-2103 car is not recommended due to the inevitable loss of power.