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1986 1987 1988 YUGO Maintenance And Service Repair Manual

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🏷️ Basic Information Identification Make: Yugo (Zastava) Model: Yugo (various models including GV, GVL, GVX) Model Years Covered: 1986, 1987, 1988 Codes Chassis Codes: Yugo Koral (various designations based on trim and engine) 👋 Introduction Market Position Market Segment: Subcompact economy car, known for its affordability and simple mechanicals. Competitive Analysis Competitors 1980S: Primarily competed with other budget-friendly imports such as the Hyundai Excel, Kia Pride, and early models of Japanese offerings like the Honda Civic and Toyota Corolla in certain markets, though often positioned at a lower price point. Key Features Yugo Key Features: Front-wheel drive, simple construction, hatchback utility, very low purchase price. Manual Value Proposition Value For Owners: Essential resource for owners seeking to perform maintenance and repairs themselves, reducing reliance on often scarce or specialized service centers. Empowers owners to keep their vehicles operational. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive maintenance, service, and repair for Yugo models 1986-1988 Page Count Estimated Page Count: 300-400 (estimated based on typical service manuals of this era and coverage) Manual Type Manual Type: Service and Repair Manual Language Language: English Format File Format: High-definition PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical (cylinder head, block, pistons, crankshaft, camshaft), fuel system (carburetor, fuel pump, lines), ignition system (distributor, coil, spark plugs, wiring), cooling system (radiator, thermostat, water pump, hoses), lubrication system (oil pump, filter, passages), exhaust system (manifold, pipes, muffler) Drivetrain Systems: Transmission (manual, clutch, gearshift linkage), drive axles, differential Chassis Systems: Suspension (front and rear), steering system (rack and pinion), braking system (front discs, rear drums, hydraulic lines, parking brake) Electrical Systems: Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior), ignition switch, fuse box, wiring diagrams, dashboard instruments, horn Body And Interior: Body panel removal/installation, door mechanisms, window regulators, seat adjustments, interior trim, HVAC system (heater core, fan, controls) Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug replacement, belt adjustments, fluid level checks and top-offs, coolant flushing, brake adjustments, battery terminal cleaning Repair Procedures: Engine component overhaul (e.g., head gasket replacement, piston ring replacement), carburetor rebuilding, clutch replacement, brake pad/shoe replacement, suspension component replacement (shocks, ball joints), alternator/starter replacement, radiator replacement Troubleshooting: Diagnostic charts, common problem identification, symptom-based repair guidance Specifications: Torque specifications for critical fasteners, engine timing settings, valve clearance adjustments, fluid capacities, electrical resistance values Technical Depth Depth Of Information: Detailed, step-by-step instructions for mechanical repairs, electrical diagnostics, and routine maintenance. Suitable for both novice and experienced DIY mechanics. 📊 Manual Specifications File Format PDF Quality: High-definition, ensuring clarity of text and diagrams. Likely scanned from original factory manuals. Print Quality Printability: Printable, allowing users to create physical copies for workshop use. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, SOHC (Single Overhead Camshaft) Displacement Cc: 1116 cc (for most common models) Displacement Ci: 68.1 cubic inches Bore X Stroke: 76 mm x 86 mm (approximate) Compression Ratio: 8.8:1 (typical) Performance Horsepower Hp: Approximately 55-60 hp @ 5500 RPM (varies slightly by year/market) Torque Lb Ft: Approximately 64-67 lb-ft @ 3000 RPM (varies slightly by year/market) Fuel System Fuel Delivery: Weber 32 DFM (or similar single-barrel carburetor) in most North American spec vehicles. Some markets may have different configurations. Fuel Type: Unleaded gasoline (Octane rating as recommended by manufacturer, typically 87 AKI or equivalent) Ignition System Ignition Type: Breakerless (electronic ignition) with distributor Cooling System Cooling Type: Liquid-cooled, pressurized system Lubrication System Oil Capacity Qts: Approximately 3.5 quarts (3.3 liters) with filter change Engine Identification Engine Code Prefix: Varies, but often related to Zastava's internal designations (e.g., 101 series engines adapted). 🔧 Transmission Standard Transmission Type Standard: 4-speed manual transaxle Optional Transmission Type Optional: 5-speed manual transaxle (available on some higher trims like GVX or in specific markets) Features Clutch Type: Dry single-plate clutch, hydraulically actuated Fluid Specs Transmission Fluid Type: API GL-4 gear oil, SAE 75W-90 or 80W-90 recommended. Check manual for exact viscosity and capacity. 📐 Dimensions Exterior Length In: Approx. 152 inches (3860 mm) Width In: Approx. 62 inches (1575 mm) Height In: Approx. 54 inches (1370 mm) Wheelbase In: Approx. 90 inches (2285 mm) Weights Curb Weight Lbs: Approx. 1900-2100 lbs (860-950 kg) Cargo Cargo Volume Cu Ft: Variable due to hatchback design, typically around 8-10 cu ft behind rear seats. Wheels Tires Wheel Bolt Pattern: 4x100mm Standard Tire Size: 155/80R13 or 165/70R13 (common sizes) 🛡️ Safety Features Ratings Crash Test History: Limited official crash test data available for the specific 1986-1988 Yugo models in standardized tests like NHTSA or IIHS. Generally considered to have minimal safety features by modern standards. Active Features Braking System: Front: Disc brakes; Rear: Drum brakes. Vacuum assisted. Steering Type: Rack and pinion, manual Passive Features Seatbelts: Standard front seat belts (lap and...
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Stichworte: 1986 1987 1988 Car Cars YUGO Zastava
1986 1987 1988 YUGO Maintenance And Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yugo (Zastava)
Model:
Yugo (various models including GV, GVL, GVX)
Model Years Covered:
1986, 1987, 1988
Codes
Chassis Codes:
Yugo Koral (various designations based on trim and engine)
👋 Introduction
Market Position
Market Segment:
Subcompact economy car, known for its affordability and simple mechanicals.
Competitive Analysis
Competitors 1980S:
Primarily competed with other budget-friendly imports such as the Hyundai Excel, Kia Pride, and early models of Japanese offerings like the Honda Civic and Toyota Corolla in certain markets, though often positioned at a lower price point.
Key Features
Yugo Key Features:
Front-wheel drive, simple construction, hatchback utility, very low purchase price.
Manual Value Proposition
Value For Owners:
Essential resource for owners seeking to perform maintenance and repairs themselves, reducing reliance on often scarce or specialized service centers. Empowers owners to keep their vehicles operational.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive maintenance, service, and repair for Yugo models 1986-1988
Page Count
Estimated Page Count:
300-400 (estimated based on typical service manuals of this era and coverage)
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
File Format:
High-definition PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical (cylinder head, block, pistons, crankshaft, camshaft), fuel system (carburetor, fuel pump, lines), ignition system (distributor, coil, spark plugs, wiring), cooling system (radiator, thermostat, water pump, hoses), lubrication system (oil pump, filter, passages), exhaust system (manifold, pipes, muffler)
Drivetrain Systems:
Transmission (manual, clutch, gearshift linkage), drive axles, differential
Chassis Systems:
Suspension (front and rear), steering system (rack and pinion), braking system (front discs, rear drums, hydraulic lines, parking brake)
Electrical Systems:
Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior), ignition switch, fuse box, wiring diagrams, dashboard instruments, horn
Body And Interior:
Body panel removal/installation, door mechanisms, window regulators, seat adjustments, interior trim, HVAC system (heater core, fan, controls)
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, spark plug replacement, belt adjustments, fluid level checks and top-offs, coolant flushing, brake adjustments, battery terminal cleaning
Repair Procedures:
Engine component overhaul (e.g., head gasket replacement, piston ring replacement), carburetor rebuilding, clutch replacement, brake pad/shoe replacement, suspension component replacement (shocks, ball joints), alternator/starter replacement, radiator replacement
Troubleshooting:
Diagnostic charts, common problem identification, symptom-based repair guidance
Specifications:
Torque specifications for critical fasteners, engine timing settings, valve clearance adjustments, fluid capacities, electrical resistance values
Technical Depth
Depth Of Information:
Detailed, step-by-step instructions for mechanical repairs, electrical diagnostics, and routine maintenance. Suitable for both novice and experienced DIY mechanics.
📊 Manual Specifications
File Format
PDF Quality:
High-definition, ensuring clarity of text and diagrams. Likely scanned from original factory manuals.
Print Quality
Printability:
Printable, allowing users to create physical copies for workshop use.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, SOHC (Single Overhead Camshaft)
Displacement Cc:
1116 cc (for most common models)
Displacement Ci:
68.1 cubic inches
Bore X Stroke:
76 mm x 86 mm (approximate)
Compression Ratio:
8.8:1 (typical)
Performance
Horsepower Hp:
Approximately 55-60 hp @ 5500 RPM (varies slightly by year/market)
Torque Lb Ft:
Approximately 64-67 lb-ft @ 3000 RPM (varies slightly by year/market)
Fuel System
Fuel Delivery:
Weber 32 DFM (or similar single-barrel carburetor) in most North American spec vehicles. Some markets may have different configurations.
Fuel Type:
Unleaded gasoline (Octane rating as recommended by manufacturer, typically 87 AKI or equivalent)
Ignition System
Ignition Type:
Breakerless (electronic ignition) with distributor
Cooling System
Cooling Type:
Liquid-cooled, pressurized system
Lubrication System
Oil Capacity Qts:
Approximately 3.5 quarts (3.3 liters) with filter change
Engine Identification
Engine Code Prefix:
Varies, but often related to Zastava's internal designations (e.g., 101 series engines adapted).
🔧 Transmission
Standard
Transmission Type Standard:
4-speed manual transaxle
Optional
Transmission Type Optional:
5-speed manual transaxle (available on some higher trims like GVX or in specific markets)
Features
Clutch Type:
Dry single-plate clutch, hydraulically actuated
Fluid Specs
Transmission Fluid Type:
API GL-4 gear oil, SAE 75W-90 or 80W-90 recommended. Check manual for exact viscosity and capacity.
📐 Dimensions
Exterior
Length In:
Approx. 152 inches (3860 mm)
Width In:
Approx. 62 inches (1575 mm)
Height In:
Approx. 54 inches (1370 mm)
Wheelbase In:
Approx. 90 inches (2285 mm)
Weights
Curb Weight Lbs:
Approx. 1900-2100 lbs (860-950 kg)
Cargo
Cargo Volume Cu Ft:
Variable due to hatchback design, typically around 8-10 cu ft behind rear seats.
Wheels Tires
Wheel Bolt Pattern:
4x100mm
Standard Tire Size:
155/80R13 or 165/70R13 (common sizes)
🛡️ Safety Features
Ratings
Crash Test History:
Limited official crash test data available for the specific 1986-1988 Yugo models in standardized tests like NHTSA or IIHS. Generally considered to have minimal safety features by modern standards.
Active Features
Braking System:
Front: Disc brakes; Rear: Drum brakes. Vacuum assisted.
Steering Type:
Rack and pinion, manual
Passive Features
Seatbelts:
Standard front seat belts (lap and shoulder belts). Rear seat belts may be lap belts or not present depending on market and specific trim.
Body Structure:
Unibody construction. Lacks modern crumple zones or extensive side-impact protection.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio, often with a single speaker. Cassette player optional on higher trims.
Driver Assistance
Driver Aids:
None (no electronic driver assistance features such as ABS, traction control, airbags, etc.)
Connectivity
Connectivity Features:
None.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 miles (5,000 km) or 6 months, whichever comes first.
Air Filter Replacement:
Every 12,000 miles (20,000 km) or annually.
Spark Plug Replacement:
Every 18,000-24,000 miles (30,000-40,000 km), depending on plug type and condition.
Coolant Flush Interval:
Every 24,000 miles (40,000 km) or 2 years.
Timing Belt Replacement:
Crucial for this engine. Typically every 40,000-50,000 miles (60,000-80,000 km). Failure can cause severe engine damage.
Fluid Specifications
Engine Oil Spec:
API SF or SG, SAE 10W-30 or 10W-40. Consult manual for specific ambient temperature recommendations.
Coolant Spec:
Ethylene glycol-based antifreeze, mixed 50/50 with distilled water. Green in color (standard for the era).
Brake Fluid Spec:
DOT 3 glycol-based brake fluid.
Known Issues
Common Problems:
Carburetor tuning issues, electrical system gremlins (corrosion, loose connections), exhaust system rust, suspension wear (bushings, ball joints), starter motor reliability, potential for head gasket leaks due to overheating if cooling system is not maintained.
Rust Prone Areas:
Wheel wells, rocker panels, door bottoms, floor pans, and rear hatch area are susceptible to rust, especially in humid or road-salt-exposed environments.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Yugo (Zastava) is a brand from Yugoslavia, produced by Zastava Automobiles in Kragujevac, Serbia.
Model Evolution
Design Basis:
Based on the Fiat 128 platform, with styling updates by Giorgetto Giugiaro.
Production
Production Period Yugo:
Early models based on Fiat 128 platform began production in the late 1970s. The specific Yugo (GV, GVL, GVX) models were primarily exported to North America from 1985 through 1992. This manual covers the peak export years.
Manufacturing Location:
Kragujevac, Serbia (Yugoslavia at the time)
🏆 Awards & Recognition
Recognitions
Industry Awards:
None notable. The Yugo is more commonly associated with negative automotive reviews and perceptions in North American markets, often cited for its build quality, reliability concerns, and performance limitations compared to its contemporaries.
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