Workshop Manuals Factory service & repair Yugo

Yugo common faults and how to fix them

Faults that are well known on Yugo models we hold manuals for: what the owner notices, what causes it, and the pages in our manuals that cover the repair.

Yugo GV hot starting problems: hard to restart when hot

Symptoms

In hot weather, the engine is hard to restart after a short stop, once it is fully warm. It starts normally from cold.

Cause

Yugo bulletin 1-04 (June 1986) covers the 1986 Yugo GV with the 1.1 carburettor engine. It lists several contributing factors: fuel of the wrong grade, and gasohol, which is more volatile in warm weather; incorrect starting technique; valve clearances, ignition or emission settings out of specification; an idle speed set too low; the air cleaner's air blend flap in the wrong position; and antifreeze mixed stronger than 50/50. The bulletin also aims to lower under-bonnet temperatures, which affect hot restarting.

Fix

Work through the checks in order: use 87-octane unleaded, set the valve clearances, ignition timing and idle speed (850–875 rpm), and check the air blend flap and coolant mix. If the problem persists, the Yugo GV bulletin fits a radiator fan switch that switches on at 85°C instead of 92°C, and moves the fuel filter to the pump's inlet side, away from the carburettor.

Repair instructions on this site

Sources: Yugo service bulletin 1-04 (June 1986).

Yugo head gasket: fitted upside down, it starves the camshaft of oil

Symptoms

Engine trouble soon after a head gasket replacement. If the gasket went on the wrong way up, the camshaft gets no oil and the engine can be damaged.

Cause

Yugo bulletin 1-05 (July 1986) covers head gasket replacement on the Yugo GV. The head gasket must be fitted with the side marked "GORE" (meaning "top") facing up towards the cylinder head. If the gasket is fitted the wrong way up, it blocks the oil passage to the camshaft housing, which can result in engine damage.

Fix

When replacing the gasket, clean both mating faces and check them with a straight edge: no more than 0.05 mm (0.002 in) of distortion on the block, and 0.10 mm (0.004 in) on the head. Reface either if needed, removing as little material as possible, and check the combustion chamber depth as the Yugo head gasket bulletin describes. Fit the gasket with "GORE" facing upwards, and tighten the head bolts in sequence to the figures in the manual.

Repair instructions on this site

Sources: Yugo service bulletin 1-05 (July 1986).

Yugo clutch cable: plastic disc at the bulkhead breaks

Symptoms

The clutch pedal suddenly goes slack or to the floor and the clutch won't disengage, so gears can't be selected with the engine running.

Cause

Yugo bulletin 2-01 (July 1986) covers clutch cable failures on the Yugo GV caused by the plastic disc at the bulkhead (pedal) end of the cable breaking. The disc bears against the clutch pedal support, and once it fails the cable can no longer operate the clutch.

Fix

Fit a new cable, together with the extra parts the bulletin specifies. From the engine bay, snap a grommet into the cable hole in the pedal support, flat side towards you, trimming excess bulkhead insulation if needed. Glue a support washer centrally on the grommet, cut the two locking tabs off the back of the new cable's plastic disc, then fit the cable so the disc bears on the washer. The Yugo clutch cable bulletin lists the part numbers.

Repair instructions on this site

Sources: Yugo service bulletin 2-01 (July 1986).

Yugo GV Plus recall: water can reach the fuel injection ECU (1990–1991)

Symptoms

Often no warning. Look for damp carpet or water marks under the passenger side of the dashboard, where the engine control unit (ECU) is mounted.

Cause

Yugo America voluntary recall 91V-130 (September 1991) covers 1990 and some 1991 Yugo GV Plus cars with electronic fuel injection. Yugo identified a production defect: water can get in at the three studs that support the ECU.

Fix

Disconnect the battery, remove the knee bolster and the plastic shield under the ECU, then take off the three nuts and washers and lower the ECU. Push the supplied sealing washers all the way up the three studs, refit the ECU, shield and knee bolster, and reconnect the battery. Cars that have had the recall have a coloured sticker on the trim panel under the passenger side of the dashboard. The Yugo GV Plus recall bulletin gives the details.

Repair instructions on this site

Sources: Yugo America voluntary recall 91V-130 (September 1991).