Yugo Zastava All Models 1981-90 Owners Workshop Manual (Haynes Manuals)

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Own ers Work s hop Manu al

Owners Workshop Manual

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Yugo/ Zastava Owners Workshop Manual

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Co li n Brown Models covered All Yugo and Zastava models Saloon, Hatchback and Van 903 cc, 1116 cc, 1298 cc & 1301 cc (1453-5T2)

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, Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes Publi cations , Inc 861 Lawrence Drive Newbury Park Ca liforn ia 91320 USA

Restoring and Preserving ou r Motoring Heritage Few people can have had Ihe luck 10 reaUse their dreama to qulle the same ell tent and In such a remarkable fashiOn 8S John Haynes, Founder and Chairman 01 the Haynes Publishing Group.

Since 1965 his unique approach to wor1cal comact (eg fan blade) Worn drlvebelt Worn valvegecu (tapping noises from tOp of engllle) or I"correct clearance Pellpheral compc)f)ent faull (generator. coolant pump) Worn big-end bearings (regular heavy kno~klllg . perhaps less under load) Worn main beanngs (rumbllllg and knocking . perhaps worsening under load) Small-end bushes Of gudgeon pins worn (light metallic tapping) Piston slap (most notl~eabl e when engine cold)

Chapter 2 Cooling and heating systems Cont ents Coolant rnl~tures Caolanllemperature send er - remal/i11 ilnd re flHln g Cool1ng system - d ra In ing , Il ushlll9 Md roWling Fault diagnosis - coolIng and healing General deSCrfpllon Heater ~ removal ilnd retItling Healer COnlro ls and c ables - rem o val. refilling and

adjustment

3 11

, " 1 12

13

Radiator - removal and refltWlg

5

Radiator Iilrl - removal ilnd refltllng

Radl.uor I~n IhermOSli1I1C swit c h wfit ung Roullne maintenance Thermostat - removal and retitling Thermostat - tes ting

_........ _........... .

remo\l ~ I ,

6

c hecking and 7

2

8 9 >0

WOller pump - removal and refilling

Specifications

General Type (aU mod Ills)

liqUid cooled , With engine driven centrifugal pump Radlalor w'lh

e xpill'Isio n lank and Illermaliy o perated openrng 01 engine outlet to radrator

el~ln c

Iiln Therm051aIlC

Cooling fan thermal switch Sw'tche5 fan on at .... .,.. .......... . Swilches fan off at ..•.••.....•....

90 to 94' C (194 10 201' F) 85 to 89' C (185 to 192' Fj

Thermostat Opening temperature: OHVengine OHC engines Valve travel: OHVeng,ne OHC engines

85 to 89' C (185 to 192"F) 80 to 84' C (176 \0 183' F) 75mm (029 in )

B.O mm (O 31 '1'1)

Radiator cap Opening pressure

0.8 bar (11 .6 Ibl / 'n' )

Coolant Capacity •• Type ...•.•...

5.0 IItres (8.8 pints) Ethylene glycol based anll/reele ( Duckhams Universal Anli freeze lind Summer Coolant)

Torque wrench settings

NO'

Ibf ft

Cooling Ian ...... ,............... Waw pump pulley ...•...... Radia tor th ermal switCh . Temperature sender

39 39 49

29 29 36 36

................................. .

49

Chapter 2 Cooli ng and heating sys tems

72

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+ 44----foblem IS the buold·up 01 stat.c elec trlc.ty in non·dllven wheels and th e acqUisi tion of charge on the body shelt II IS pOSSible to lit spung · loaded con tacts at the wheels to 91~e good conduct'on be tween the 'Qlary wheel !la.IS and the ~ehlcle frame Changing a tyre sometimes helps - because of lyres' ~arymg reSis tances. In dlfhcuit cases a tr ailing "ex whi ch touches Ihe g round will cUle the problem If thi S IS nOt acceptable It IS wonh trVmg condUCtive pain t on Ihe tvre walls

Irom Ihe main chargIng cable which goes from Ihe battery 10 the output termma! of the a!tamator. usually via the ... lefmlnal 01 the Staller mO tOI relay In SOme vehicles thiS cab le IS rou ted under the dashboard. so Ihe solut,on IS 10 plovide a dlrllC t cab le loute. DetaCh the ollglnal cable !rom the alterna tor output terminal and make up a new cable 01 at least 6 mm' cross·sectlonal area to go flom alterna tor to batte.y wllh the Shortest pOSSIble rou le Remomber do /lot run Ihe engine Wltlr Ille alternator dlscrmnected Irom the battery Ignlllon breakth.ough on AM and l or cassette plav can be a d,lfocult problem It IS worlh wrapping earthed 1011 , ound the offending cable run near Ihe equ ipment, or making up a deflector plale well scrt!wed down 10 a good earth Anolhel POSSIbIlity rs the use 01 a su 'table relay to SWitch on the .gnltlon co.1 The .elav should be moun ted close 10 Ihe -co--'

Gr/Rd-

4

J

Rd

2 IGNITI ON

SW ITCH

Sk H 1'1912

Fig . 12 .20 (co nt inued) Wi r ing diagram fo r 45. 55 a nd 65 models - elCl8rio r lighlS

1

23.

LH.REAR LAMP

r--

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8 WAY BLOCK CONNECTOR AT -A" POST

BLlBK

BLlBK BLlBK

r". BK

BL

L-

ELECTRONIC FLASHER UNIT

AT REAR_ , PANE L ' Ir BK

T,- , 49a ,

PL

~~+

BL PL

BLlBK

BLlBK

~ BK

\

I

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V

11K

$ -+--1 . 1

AT REAR PANEL

' 1' ,I

z

::;:

=> -"

8

HAZZARD WARNING SWITCH

R.H . REAR LAMP

~

Ir

r".

BK

J ,-, ,

I

I \

\I I

I

I

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T

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INSTRUMENT CLUSTER Fig . 12.21 Wiring diagram lor late 45.55 {lnd 65 models - indicalors and huard warnlllg lights

,------------------------------------------------------------235 L.H.WING .-, LA MP

h"

BUBK BLl BK

BK BUBK

~ BK

(.

WIPER MOTOR PLU G

1(. I'

BATTERY

-

-

+

RD

I

BK ~:-

-

BL

L.H.FRONT LA MP

J

STARTER MOTOR

BR 4 WAY BLOC K CONN ECTOR

_ AT HEATER -_ BOX

PL BUBK

BK

(

BL BK ft-K

I

BR

\

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L R/FOG SWITCH

-~" CD

>

zr ~u :H-

H.RW SWITCH 10

63

I IGN. SWITCH

1 FUSES

Utfl

PL OR H.RW RELAY

"-,

T I

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\

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c::;"'- BK/PL.T

V-

L -~ ~\

--

BL

CLUSTER

BL

INDICATOR

I / W/L AMP

• IGN. COIL MOUNTING

-ffi .J

"'-

BK

-&-

R.H. FRONT LAM P

H 20{;'1(,

"-

~

I,

RHWING LAMP

Fig . 12.21 (continued) Wi rin g diagram t or late 45. 55 and 65 m ode ls- Indicat ors and hazard w arnin g lights

,

,.

I

~-

'-l l.H INTERIOR LAMP

W

~

-

+

~

l. H, DOOR SWITCH

/

G,

/ 1 ~

N

BATTERY

,.

rP l/ Bk

PI/WI

L...

I'\. Sk/Pl

~ 2ATWAY CON NECTOR 'S' POST

ill

3 WAY BLOCK CONNEClOR AT r.:. POST

"1

STARTER

-

I~I

MOTOR

PI/ Wt

~ 0:

~

, WAY BLOCK CONNECTOR 1 j-:

FUSE I 9

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