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Repair and operation instructions for the VAZ 2106. What needs to be done before removing the engine

The “Six” in all modifications with power plants of 1.3, 1.5, 1.6 liters is a 4-door “passenger car”, structurally made in a sedan body with 5 seats and a rear-wheel drive transmission. This most popular VAZ model range includes an instruction manual for the VAZ 2106, which outlines the most necessary issues to ensure the correct functioning of this vehicle.

In 1976, the starting model of the “six” came off the assembly line of the Volzhsky Automobile Plant, which was the result of the modernization of the Italian car RAT 124 Speciale produced in 1972. This vehicle was adapted to Russian operating conditions and all these design changes were reflected in the repair and operation manual for the VAZ 2106, which is a manual for the car enthusiast.

This car differed from its Russian prototype, the VAZ 2103″, by a more dynamic 1.6-liter engine with an output of 80 “horses”, a more advanced and modern electrical system, an “advanced” exterior body elements and interior, a description of which is in the operating manual car VAZ 2106, which is compiled in sufficient detail.

Exterior features of the “six”

In the external design of the “six”, PVC appeared - the lining of the headlights, the radiator lining was modernized, the vehicle was given bumpers at the front and at the stern with “fangs” made of rubber and “corners” made of plastic.

The stern lights were made together with license plate lighting; rubber moldings were installed along the entire perimeter of the car, which were no longer available on the latest cars. All these innovations are reflected in the vehicle’s operation, maintenance and repair manual, which clearly shows and describes methods for attaching mounted exterior elements.

Power plants and other vehicle systems

By the end of the 70s of the twentieth century, the “six” finally secured its leadership in such segments as dynamism, speed and comfort among a very small range of Russian (then Soviet) passenger cars. At the same time, it continues to be quite high in the Zhiguli price line and has complex electronics for those times compared to its brothers in the brand.

Having opened the repair and operation manual for the VAZ 2106, we will be convinced that the top speed of 150 km/h and the acceleration value of 16 seconds to a speed of 100 km/h were considered excellent characteristics for our automobile industry. And the presence in the interior of the cabin of seats with embossed headrests, a comfortable dashboard with a tachometer and good sound insulation put the car in an advantageous position.

In 1979, AvtoVAZ released two other models, the power of which was slightly lower than the prototype. This is a VAZ 21061 with a 1.5-liter triple engine with a power of 71 hp. and VAZ 21063 with a power unit from the “eleventh” model with a volume of 1.3 liters and a power of 64 hp.

They were far from the popularity of the “six,” but the shortage of good cars and the desire to operate a decent vehicle forced car enthusiasts to buy these cars. Differences in the device could be found in the VAZ 2106 instruction manual, which were described in detail in this printed publication.

In 1982, the first restyling of the “six” was carried out. A power plant with a capacity of 75 “horses” was installed; changes to the exterior included reflectors, which were removed from the aft wing in the molding area. Modernization improved the electrical system, and in 1988 innovations were introduced in the exhaust gas exhaust system. All these changes in the design of the VAZ 2106 are perfectly explained by the maintenance and repair manual and show how to operate the car with the changes that have been made.

In 1990, the “six” model range was supplemented with an elite package, called the VAZ-21065. This car was equipped with a “sixth” engine, a non-contact type SZ, a Solex carburetor, halogens, updated seats with high-quality upholstery and an improved headrest configuration. This model was equipped with bumpers from the VAZ 2105, a 5-speed transmission and a powerful generator device, the connection procedure for which can be found in the VAZ 2106 “Operation, Maintenance and Repair Manual” of the new edition.

VAZ 21064 (export version) had some differences from the modifications supplied to the domestic market: they concerned bumpers with integrated turn indicators and a modified electrical circuit.

Attached manual for repair and operation of VAZ "Six"

In the printed version and on the website, the operating manual for the VAZ 2106 car contains all the necessary data related to the functionality and maintenance of this vehicle.

Sections of the VAZ 2106 operating manual

“Design of a VAZ 2106 car” (General information about the vehicle, a complete description of the controls of instrument devices and locks with keys;
“Car defects” (types of faults and options for eliminating them with photographs);
“Practical recommendations for using a vehicle” (advice to the motorist when making trips, equipping with spare parts, preventive preparation for trips, running in the vehicle under “warranty”);
“Electrical equipment” (electrical diagram, functional connection of devices and systems);
“Appendices” (required data on operational characteristics, maintenance and repair activities). This contains information on tightening torques, information for adjustment, types of operating materials and other reference data.

Repair and maintenance of VAZ 2106, 21061 (Zhiguli)

VAZ-2106 Zhiguli/Lada 1600/Lada 1500L/Lada 1300SL is a four-door, five-seater car with a sedan body and rear-wheel drive. Perhaps one of the most popular VAZ models.

In 1976, at the plant in Togliatti they mastered and launched production of the VAZ-2106 model, the model for which was the RAT 124 Speciale produced in 1972. Then no one thought that this model would become so widespread and popular among all the products of the Volzhsky Automobile Plant.

The “Six”, unlike the VAZ-2103, has a more powerful 80-horsepower VAZ-2106 engine with a displacement of 1.6 liters, a different electrical circuit, as well as a modified body and interior design. For example, it has different bumpers with plastic “fangs” and “corners”, the radiator trim has been changed, the front dual headlights have received plastic “glasses”, and the rear lights are combined with a license plate light and plastic “gaskets” between the radiator grille and headlights.

In 1979, the plant began producing less powerful modifications of the VAZ-21061 with a 1.5 liter 71-horsepower VAZ-2103 engine and VAZ-21063 with a 1.3 liter 64-horsepower VAZ-21011 engine. Since 1980, cars have been equipped with Ozone carburetors type 2107.

In 1982, the Six was modernized. Modified 75-horsepower VAZ-2106 engines began to be installed on it according to the new GOST. Reflectors were no longer installed along the molding line on the rear wing. In 1988, modernization affected the exhaust system: it was equipped with a disposable gasket and nut.

In 1990, the plant launched a modification that can be called the Lux package - VAZ-21065 with a standard VAZ-2106 engine with a contactless ignition system, a Solex carburetor (21053-1107010-03), improved upholstery, different seat headrests and halogen headlights. This modification was made with “five-speed” bumpers, a 1500 engine, an electrically heated rear window, a five-speed gearbox and a more powerful generator. The VAZ-21064 models going for export differed externally from the VAZ-21065 in a modified electrical circuit and bumpers with built-in turn signals. Since 1985, first for export modifications, and later for “domestic” ones, they began installing a 5-speed gearbox of the VAZ-2112 and VAZ-21074 type, which significantly reduces fuel consumption on the roads and engine noise.

The VAZ 2106 engine is repaired if it has lost compression, or there is a malfunction of the gas distribution mechanism, or the cylinder-piston group is destroyed.

Almost everyone can carry out repairs with their own hands. True, for this you need to have certain skills. Of course, you can’t do it without a special tool. You will need a special set of tools, such as a micrometer, a torque wrench.

What needs to be done before removing the motor

So, you need to disconnect all attachments. Disconnect the battery, remove the air filter housing, as well as the carburetor. Then drain all fluids from the engine. Antifreeze, if it is not replaced, must be drained into a container with a volume of about 10 liters. Motor oil should not be used after major repairs. It's better to fill it fresh. However, most of the preparatory work is the same, no matter what kind of repair of VAZ 2106 cars is carried out. You overhaul the engine, or remove the gearbox. The difference is in the nuances. For example, when dismantling the gearbox, you will not need to drain the antifreeze.

The car is installed as level as possible; special stops must be placed under the rear wheels. This will prevent the car from rolling away spontaneously. If necessary, you can remove the hood from its hinges. This will increase the space for work. Try to dismantle the engine as carefully as possible so as not to damage its components and elements. Remember that every broken part is another blow to your pocket. But engine repair itself costs a pretty penny even without these expenses.

Removing the VAZ 2106 engine

To remove the engine you will need a winch with a cable. Moreover, the latter must withstand a weight of at least 150 kg. Before starting work, you will need to disconnect the terminals from the battery. After this, remove the battery completely from the car. It is also necessary to remove all attachments. The carburetor, electric fan, muffler pants, and all electrical wiring must be disconnected. When you do a major overhaul of a VAZ 2106 engine with your own hands, you have to remove all the attachments, which means you will accumulate a lot of elements. And they will come in handy during assembly.

Then you need to install a jack under the engine, put a crossbar on top, from which you hang the engine on cables. Once the engine is installed, it can be disconnected from the gearbox. To do this, you need to unscrew the four bolts using a 19mm wrench. And don’t forget to unscrew the mountings of the cushions on which the motor is mounted. To pull the engine out of the engine compartment, you will need a winch. With its help, you will cope with this difficult matter alone. But if you have the opportunity to use the help of a partner, then do not refuse. Even if he is not strong in technology, he will at least hand over the keys and also perform physical work. As a last resort, make tea or coffee.

Disassembling the VAZ 2106 engine

So, when you have the motor outside, you can completely disassemble it. Do not place the engine on a hard surface. It is best to use an old tire as a support. Disconnect all elements that interfere with disassembly. Then you need to unscrew the nuts that secure the cylinder head cover. Try to carefully place all the nuts, washers, and bolts so that you don’t lose them later. In the future, the VAZ 2106 engine head will be repaired; you will learn about this procedure a little later.

Remove the timing cover by unscrewing the fastening nuts. Then remove the intake and exhaust manifolds. Now it's time to remove the cylinder head. Please note that there is no need to use a torque wrench when disassembling the engine. It will be needed when assembling the motor. You have a view of the pistons, pay attention to the amount of carbon deposits and the condition of the cylinders.

Is it necessary to bore the cylinders?

If your engine has completely lost compression, then you will need to bore the cylinders. There are cases when it is impossible to carry it out, since the last repair of the VAZ 2106 engine has been carried out. Then a relining is done. New liners are being installed into the engine block. This work requires professional skills; you cannot do it yourself. If you are boring a block, you have two options - you can use honing, or you can give the liners a mirror look.

You can argue a lot about the advantages and disadvantages of each type of boring, but it is better to choose a mirror. The reason is that honing wears off over time. In addition, it destroys the piston rings, which causes premature loss of compression in the engine. The result is that you get a mirror bore, but at a higher price.

What to do when repairing an engine

If you plan to repair the engine of a VAZ 2106 yourself without outside intervention, then boring will not work. The reason is that this procedure must be performed on special equipment. In addition, the person who makes it must have all the necessary skills. If you decide to simply change the rings or pistons, the scope of work is reduced. You need to purchase a set of pistons, rings, pins, and it is also recommended to replace the main and connecting rod bearings.

In addition, it is mandatory to grind in the valves in the cylinder head. It is recommended to replace valve guides and seals, so they must be purchased in advance. You must also have the necessary tools, in particular an electric or hand drill. Moreover, it should have a reverse function. You will also need to replace the timing chain, damper, and all gaskets.

How to tune an engine

To improve the VAZ 2106 engine, you will need to lighten all components. Namely:

Pistons.
Flywheel.
Crankshaft.

In addition, you need to improve the cooling and lubrication systems. As for the pistons, here you need to grind off the inner surface of the skirt. This work should be done by a specialist on a good lathe. Do not forget that the quality of the work performed determines how the engine will function in the future. As for the crankshaft and flywheel, they must be additionally centered after lightening. To do this, you will need to drill holes so that these nodes have the same center of gravity.

Tuning of other car systems

But don't forget that after all these improvements, standard cooling and lubrication will not be enough. Therefore, you will need to carry out all the work to improve the water pump and oil pump. The latter will have to be completely rebuilt to ensure a uniform supply of lubricant to all engine components. The cooling system should function with faster circulation of antifreeze. In addition, it is necessary to improve the radiator airflow system.

But the work is not finished yet. You need to calculate the brake system. It is possible that you will have to install brake pads with a larger contact area. When a major overhaul of a VAZ 2106 engine is carried out, it would be a sin not to modernize it. Just keep in mind that not only the engine will have to be improved.

Valve lapping tool

You all know why valves are needed in an engine. They serve for proper gas distribution. In other words, fuel must enter the combustion chamber in a timely manner, and the situation is similar with exhaust gases. But if there is no gap between the valve plate and the seat, or it is too large, then the gas distribution will be impaired. To get rid of this trouble, you need to grind in the valves. To do this, you will need two types of lapping paste: for rough and fine work. The required tools are a drill with a reverse function, as well as an attachment for it. You can make the latter from an old valve; to do this, cut off its stem.

Carrying out lapping

To make work more convenient and efficient, a rubber tube is installed between the drill and the valve. Its thickness should be the same as that of the valve stem. To prevent rotation, the tube is fixed using worm-drive clamps. The grinding procedure is quite simple. It is necessary to lubricate the valve plate and seat first with rough paste. After all minor surface irregularities have disappeared, this paste is washed off and a new one is applied for fine processing. The main thing in this matter is not to mix up the valves after grinding. At this point, the major overhaul of the VAZ 2106 engine can be considered almost complete. It is impossible to tell about it in a nutshell; reference books are needed to carry out all the work.

The appearance of corrosion, numerous chips, dents and microcracks in the paintwork is not a complete list of problems that owners of VAZ 2106 cars have to face. Despite the complexity of many damages, they are repaired with their own hands.

Body repair of VAZ 2106 has the following types:

Redecorating. The paintwork and bumpers are restored, scratches, chips and areas of corrosion are eliminated.
Treatment of internal cavities. Spars, sills, door and luggage niches are difficult to access for anti-corrosion treatment. To prevent parts from rusting, they are treated with special protective agents.
Car underbody treatment. The working surface is covered with special protective mastics.
Removing dents. To level the dented area, various impact pads, spoons, hooks, suction cups and reverse hammers are used.
Major body repairs. It is carried out in case of violation of the geometry of the vehicle body, excessive damage to the paintwork, or the presence of a large number of dents, chips and scratches. Also, major repairs are necessary when corrosion has spread to more than 50% of the surface area of the vehicle body.

When carrying out restoration work, the specifics of the car body are taken into account.

Specifics of the VAZ 2106 body

The Lada sixth model has a sedan body type; it consists of a main load-bearing all-metal frame and various attachments. The units and parts that are installed on models from the classic series are made using the stamping method and are connected to each other by welded seams.

The body includes the following parts: engine frame, front fenders, roof, floor panels, left and right side panels. The front and rear bumpers of the car are chrome-plated; they are attached to the body using special brackets. The trunk and hood are quite bulky.

As for the doors, they are made of two panels: outer and inner, they are connected by welding. Both front and rear doors have the same type of attachment to the body.

Six models produced in the mid-90s and early 2000s have thinner body metal compared to cars produced between 1976 and 1990.

Straightening VAZ 2106 as the main type of body repair

Numerous chips and scratches, dents, and corrosion require timely elimination. Repair of the VAZ 2106 body is carried out using straightening: dents are leveled, rust is removed and the paintwork of the car body is restored.

To complete the work, you need to prepare a vehicle and stock up on the necessary set of tools. Before straightening, assess the degree of damage to the car body, wash, dry and degrease the working surface.

Tools

To carry out work on restoring the body of the “six”, we will need the following set of tools:

A set of hammers of different types and weights. Rubber mallets and percussion instruments with a grooved working surface.
Special hooks.
Reverse hammers.
Impact spoons.
Jack.
Anvils and substrates of various shapes and sizes.

You should also stock up on 8 and 22 wrenches, as well as a screwdriver. You will need these tools to remove body parts such as bumpers or trim moldings.

Process technology

The VAZ 2106 body is straightened immediately before painting the restored part:

The surface to be treated is cleaned of dirt, washed, dried and degreased. Remove old paint from the working surface.
Use frequent gentle blows of a hammer to smooth out the dent. If the defect is deep, then the process is performed from the edge of the damage, and gradually moves towards its center. Metal substrates are placed on the reverse side of the area to be restored. They must have the appropriate shape.
Metal breaks are repaired using a welding machine. Next, the weld is ground.
The area restored from damage is covered with putty. It levels the work surface.
The putty part is sanded and painted.

The putty should be applied in a thin layer. Otherwise, the paint will become covered with numerous cracks and begin to fall off.

Threshold replacement

The thresholds on the VAZ 2106 during long-term use of the car become covered with rust and, as a result, rot. To replace damaged body elements, perform the following algorithm of actions:

The doors are removed, the floor mats are removed, and the aluminum trim is dismantled.
Remove the rusted body element. To do this, use the thresholds, dismantle them using a drill, and cut them out of the fastening with a grinder.
Clean the work surface from dirt and remove rust.
Next comes the installation of new thresholds. To do this, weld the connector in place of the dismantled parts.
After adjusting the elements to size, they are welded to the car body.
At the end of the work, a trim is attached to the thresholds, it is primed and painted.

When performing repair work to replace thresholds, the trim is washed, corrosion is removed from it, and old paint and primer are removed.

Spar repair

When carrying out a major overhaul of the body of a VAZ 2106 with your own hands, first of all it is necessary to pay attention to the condition of the underbody of the car, including the side members. They represent the main strength element of the entire structure. On a car they are located on the bottom and have the length of the entire vehicle.

Spars can shift as a result of a violation of the body geometry, and burst due to mechanical damage. If a part has moved, it is “restored” to its place. To do this, use a jack or a cable, which is tied to a pole or tree, and the other end of the rope is secured to the spar. Next, the car is “pulled” with small jerks, and the element to be straightened is tapped with a hammer. After the work is completed, additional beams are welded to the side members, since the restored part requires reinforcement.

Rusted elements are cleaned, dirt and corrosion are removed from them. Using a welding machine, metal patches are made on the surface, the welds are ground, and the part is processed. Cracks in the side members are also repaired using welding.

Anti-corrosion treatment

To increase the durability of the VAZ 2106 car body, the body, bottom and hidden cavities are treated with special compounds. Anti-corrosion agents are divided depending on the area of their application:

Movili are suitable for processing hidden cavities.
Wax mastics, PVC compounds or “liquid” plastic are used to treat the surface of a car body.
Anticorrosion agents for the bottom - bitumen and oil mastics.

When performing rust protection, a number of nuances are taken into account:

To gain access to the hidden cavities of the car, use standard technological holes, or drill them yourself. In this case, the cavities are plugged to protect against negative environmental influences.
When corrosion appears, it is removed with a metal brush, and only then an anti-corrosive agent is applied to the rusted area.
Car treatment is carried out as a preventive measure against the appearance of corrosion and rust.

Installing fender liners will protect the vehicle's wings from corrosion.

VAZ 2106 is one of the oldest domestic models; it began production in 1976, and only in 2006 the car finally rolled off the assembly line. The machine is distinguished by its maintainability and reliability, which allows you to repair the vehicle yourself.

The fairly simple and familiar design of the legendary “classic” Zhiguli allows you to carry out routine repairs of the VAZ 2106 yourself, in a garage. The point is not only the simplicity of the design, but also the affordable cost of spare parts, as well as the small number of necessary tools and special devices.

Repair and operation of the VAZ 2106, as a rule, are inexpensive. A car in good technical condition and with a calm driving style in practice consumes fuel moderately, while not being too demanding on its quality. The “Six” and its modification VAZ 21061 with a 1.5 liter engine when driving on the highway at speeds of up to 100 km/h fit into 8-8.5 l/100 km, and the VAZ 21063 model consumes even less - up to 8 l/100 km.

Possible engine malfunctions

The resource of the power unit depends on the conditions in which it is operated. On average, a factory-assembled engine travels 150 thousand km before overhaul, sometimes the mileage reaches 200 thousand. During this period the following work will need to be completed.

Adjustment of valves. On most cars produced, this is done using a dipstick or indicator bar, and only on cars produced in recent years can hydraulic compensators be found.
During operation, it is necessary to change the generator drive belt. This is done after a visual inspection and detection of defects on it.
Replacing the fuel pump rod. Over time, the part works and becomes shorter, the pressure on the pump lever weakens, as a result of which there is a lack of fuel at high speeds.
The timing chain and gears need to be replaced as they wear out. Diagnosis of faults is simple: loud noise and inability to tension the chain. Together with this kit, the tensioner and damper shoe are replaced. Sometimes, along with them, it is necessary to change the drive gears of the oil pump and distributor, the so-called “pig”.
Piston rings are usually replaced after 100 thousand kilometers. Their wear is characterized by loss of power, increased oil consumption and smoke from the crankcase ventilation pipe. To select rings, you should know that the diameter of the pistons in the VAZ 2106 and VAZ 21063 power units is 79 mm, and in the VAZ 21061 engine - 76 mm. Such a repair of the sixth model VAZ involves removing the cylinder head, so it often makes sense to grind the valves into the seats or change them.

Electrical, cooling and fuel supply problems

The electrical part of the car as a whole is quite reliable because it is simple. The following parts often fail:

circuit breakers;
charging voltage regulator;
distributor contacts (on older models), slider fuse;
high voltage wires;
starter and generator brushes;
relay;
The battery terminals are oxidized.

The weakest point of the cooling system is the thermostat. Diagnosis of the malfunction is as follows: there is overheating of the liquid or, conversely, a constantly low temperature. In newer models, the electric fan switch located at the bottom of the radiator sometimes fails. After 40-60 thousand mileage, the water pump (pump) becomes unusable. It cannot be repaired and is completely replaced. The remaining components and parts of the system work reliably and do not have pronounced “diseases”.

In the fuel supply system, the fuel pump requires attention; its diaphragms and valves wear out quickly. In carburetor models of the “six”, major cleaning of this unit is required approximately once every 25 thousand km. In recent years, carburetors 2107 “Ozone” have been installed on the VAZ 21063, modification 2105 “Ozone”. On cars with fuel injection, injectors should be cleaned at the same intervals as carburetors.

Repair of chassis and transmission

Most often, the rubber bushings of the anti-roll bar and rear links, the boots of ball joints and steering rod pins are changed due to wear. Next comes the replacement of the ball joints themselves, the steering linkage and silent blocks. The bearings of the front hubs and rear axle shafts need to be changed as they wear out; a faulty part makes itself felt with a characteristic hum.

Brake pads are a consumable item, but the front discs last quite a long time and are replaced when grooves and grooves are detected on the working surface. Cracks in the front beam are not that uncommon. Minor defects can be eliminated by welding, but you must keep in mind that such car repairs are temporary; the cracked beam will continue to deteriorate.

In the brake system, the working cylinders on the wheels often fail. This happens due to the fact that the rubber sealing rings become unusable. Car enthusiasts are well aware of the rule: it is easier to replace the brake wheel cylinder once than to replace rubber seals many times. Not so often, but still there are problems with the main brake distributor and clutch slave cylinder for the same reason.

Transmission parts that are well known to the owners of the “classic” are clutch parts, which are quite difficult to change on a VAZ 2106 car with your own hands. These are the clutch disc and release bearing, the lifespan of which ranges from 20 to 50 thousand km, depending on the quality of the product.

The difficulty is that to replace these parts you need to remove the gearbox, and before that the driveshaft. The latter has 2 crosspieces installed, which serve approximately 20 thousand km. The transmission unit, which sometimes makes itself felt with a continuous humming sound of varying volume and tonality, is the rear axle gearbox. Repairing it is expensive, since it cannot be done without the involvement of a serious specialist.

In order to save money, a car enthusiast can only remove the gearbox from the car to take it to a mechanic for repairs and subsequent adjustments, and then put it back. The VAZ 2106 gearbox is quite reliable, only in the latest 5-speed models there were sometimes some problems with 5th gear. The result is the same as with the gearbox - a trip to a specialist.

Most of the above work can be done yourself, thereby saving money. Work on repairing the body of the VAZ sixth model was not mentioned, since they need to be done quite rarely, and this requires the qualifications of an automobile master.