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General information
Vehicle specifications
Repair safety instructions
Engine UMZ-4215.10
Design features
Removing the engine mudguard
Changing the oil and oil filter
Replacing the cylinder head gasket
Adjustment of thermal clearances in the valve actuator
Removing the oil pan
Replacing the front cuff of the crankshaft
Removing the oil cooler
Replacing lubrication sensors
Removing and disassembling the oil pump
Removing the intake manifold, exhaust manifold and replacing the gaskets
Powertrain support replacement
Removing the axis of the rocker arm and rod pushers
Removing the cylinder head and replacing its gasket
Replacing valve stem seals
Dismantling the cylinder head
Replacing the rear cuff of the crankshaft
Removing the UMZ-4215 engine
Removing the engine assembly with attachments
Removing the engine with partial disassembly
Engine disassembly
Assembly of the connecting rod and piston group
Engine assembly
Engine ZMZ-402
design features
Features of maintenance and repair of the ZMZ-402 engine
Changing the oil and oil filter
Engine repair
Assembly of the ZMZ-402 engine
Dismantling the oil pump
Engine ZMZ-406
Design Features
Changing the oil and oil filter
Replacing oil pressure sensors
Intake manifold removal
Replacing the front cuff of the crankshaft
Replacing the rear cuff of the crankshaft
Replacing the front engine mounts
Camshaft replacement
Replacing hydraulic pushers
Removing and installing hydraulic tensioners
Removing hydraulic tensioners
"Charging" hydraulic tensioners
"Discharge" of hydraulic tensioners
Dismantling the timing gear
Dismantling the oil pump drive
Removing the cylinder head
Dismantling and repair of the cylinder head
Lapping valves
Engine removal
Removing the engine assembly with attachments
Removing the engine with partial disassembly
Engine disassembly
Dismantling the crankshaft
Removing the oil pan
Dismantling the cylinder head cover
Dismantling the oil pump
Assembly of the connecting rod and piston group
Engine assembly
Power system
Design features
Replacing the air filter element
Removing and disassembling the filter sump
Replacing the filter element of the fine filter
Removing and disassembling the fuel fine filter
Removing the fuel gauge and fuel intake gauge
Removing the fuel tank
Removing the fuel filter strainer
Removing and disassembling the fuel pump
Removing the fuel pump engine ZMZ-4063
Removing the air filter housing
Carburetor K-151
Design Features
Removing the carburetor fuel filter
Carburetor drive adjustment
Idle adjustment
Fuel level adjustment
Carburetor removal
Trigger adjustment
Dismantling the carburetor
Forced idle economizer system
Removing and checking the solenoid valve of the EPPC system
Checking and replacing the control unit of the EPHX system
Adjustment of the microswitch of the EPHX system
Exhaust gas recirculation system
Removing the thermal vacuum switch and recirculation valve
Engine cooling system
Design features
Engine cooling system UMZ-4215, ZMZ-402
Coolant replacement
Replacing and adjusting the tension of the drive belts of the units
Replacing idler pulley bearings
Replacement of coolant temperature sensors (UMZ-4215)
Removing and checking the thermostat
Removing the radiator
Coolant pump replacement
Fan bearing replacement
Replacing the expansion tank
Engine cooling system ZMZ-406
Coolant replacement
Replacing and adjusting the drive belt tension
Replacing the idler pulley and the drive belt tensioning mechanism of auxiliary units
Replacing temperature gauge and coolant overheat warning sensors
Checking the thermostat in a car
Removing and checking the thermostat
Removing the engine radiator
Coolant pump replacement
Replacing the thermostat
Exhaust system
Design features
Replacing the silencer and resonator
Replacing the exhaust pipes
Diaphragm clutch
Design features
Spring clutch
Design features
Bleeding hydraulic clutch and replacing the working fluid
Removing the hydraulic master cylinder
Removing hydraulic drive cylinder
Replacing the hydraulic hose
Removing the clutch housing (engine ZMZ-406)
Clutch disassembly
Gearbox
Design features
Oil change
Replacing a speedometer drive
Replacing front input shaft bearing
Cuff replacement
Replacing the reversing light switch
Gearbox Removal
Gearbox disassembly
Cardan transmission
Design features
Inspection, inspection and lubrication of the driveline
Removing the driveline
Disassembling the driveline
Dismantling the universal joint
Rear axle
Design features
Removing the rear wheels
Gearbox oil change
Removing popooshi
Wheel Bearing Adjustment
Drive cuff replacement
Replacing wheel bearings and axle cups
Removing the rear axle
Dismantling the rear axle
Assembling the rear axle and adjusting the final drive
Front suspension
Design features
Removing the front wheel
Pivot joint grease
Front wheel bearing adjustment
Replacing bearings and front wheel hub cuffs
Removing, disassembling the spring and replacing its rubber-metal hinges
Replacing the rubber buffer
Shock absorber replacement
Removing the front axle
Pivot joint disassembly
Rear suspension
Design description
Removing, disassembling the spring and replacing its rubber-metal hinges
Shock Absorber Replacement
Removing rubber cushions for additional springs
Steering
Design features
Steering column adjustment
Topping up the steering oil sump
Lubricating cardan shaft swivel joints
Checking the technical condition of the steering
Removing and disassembling the steering column
Steering gear removal
Steering adjustment
Replacing steering rods and their hinges
Front wheel alignment
Brake system
Design features
Bleeding the brake system, replacing the brake fluid
Replacing the brake pads of the front wheel
Replacing the brake caliper front wheel
Replacing the brake disc
Replacing the front brake hose
Replacing the brake drum and rear wheel pads
Replacing the brake cylinder on the rear wheels
Replacing the rear brake hose
Removing the brake master cylinder
Replacing the brake master cylinder linings
Replacing the vacuum booster
Removing the foot switch
Adjusting and replacing the pressure regulator
Regulator adjustment
Regulator replacement
Adjustment of the parking brake actuator
Replacing parking brake cables
Dismantling the parking brake mechanism
Electrical equipment
Design features
Checking electrical circuits
Check for dead circuits
Checking live electrical circuits
Fuse replacement
Replacing central fuses for the vehicle electrical system
Replacing fuses for electrical circuits
Battery
Replacing the battery switch
Engine Generator ZMZ-402, UMZ-4215
Checking the generator on the car
Removal and repair of the generator
Replacing voltage regulator and generator brush holder
Starter
Design features
Removing the starter from the engine
Starter Relay Replacement
Dismantling and checking the starter
The ignition system of engines ZMZ-402 and UMZ-4215
Design features
Replacing the ignition switch
Ignition timing
Replacing the slider and distributor cap
Removing the distributor
Disassembly of the distributor sensor
Replacing the ignition coil
Switch replacement
Replacing spark plugs
Lighting, light and sound alarms
Replacement of lamps, removal of a headlight
Headlight adjustment
Replacing headlamp and control unit
Replacing the central light switch
Replacing the direction indicator relay
Replacing the lamp, removing the front direction indicator
Replacing the lamp, removing the side direction indicator
Replacing the brake light switch
Replacing the alarm switch
Removing the interior and rear fog light switches
Replacement of lamps, removal of a back lamp
Removing the license plate light, replacing the lamp
Removing the lights of the cabin and the ceiling of the cargo compartment
Removing and adjusting the horn
Gearshift paddles
Replacing the shift paddles
Windshield wiper and washer
Removing and disassembling the wiper, replacing its relay
Removing the windshield washer
Removing the electric pump
Nozzle removal
Testing devices
Removing instrument cluster, replacing lamps
Checking control instruments and sensors
Oil pressure gauge
Coolant temperature gauge
Fuel gauge
Speedometer
Voltmeter
Features of electrical equipment of cars with an engine ZMZ-406
Generator
Checking the generator on the car
Removal and repair of the generator
Alternator voltage regulator replacement
The ignition system of engines ZMZ-4061, -4063
Control unit (controller)
Operating mode
Diagnostic information output mode
Diagnostic equipment mode
Trouble code removal mode
Sync sensor
Knock sensor
Coolant temperature sensor
Absolute pressure sensor
Ignition coils
High voltage wires and candle tips
Checking and replacing the synchronization sensor
Removing and checking the knock sensor
Removing and checking the temperature sensor
Checking and replacing ignition coils
Checking wires and candle tips
Removing the spark plugs
Removing and checking the absolute pressure sensor
Frame, cab, body
Design features
Removing the front bumper
Removing the radiator grill
Removing the upper radiator trim panel
Removing the hood lock and its drive
Removing the hood
Front wing removal
Removing the exterior rearview mirror
Replacing the windshield
Removing the upholstery of the windshield strut
Adjusting and removing the driver's seat
Removing passenger seats
Removing seat belts
Removing the front seat belts
Removing seat belts of the second row of seats
Removing the sun visor
Removing the dashboard
Removing the door handle
Upholstering the center pillar
Removing the front door trim
Removing the front door lock
Replacing the front door glass
Power window removal
Removing the front door
Removing the door trim
Removing the sliding door lock
Replacing the sliding door and side window panes
Removing the sliding door and disassembling the mechanism for moving it
Removing the sliding door mechanisms
Sliding door adjustment
Door height adjustment
Depth adjustment of the door
Removing the cab floor
Removing the upholstery
Removing the cab partition
Removing the rear door lock
Removing the lock on the right rear door
Removing the left rear door lock
Removing the back door
Removing the rear bumper
Removing the filler cap on the fuel tank
Ventilation and heating system
Design features
Replacing the heater tap
Removing the main heater radiator
Removing the electric heater for the main heater
Removing the main heater
Dismantling the main heater
Removing the fan motor for the auxiliary heater
Removing an additional heater radiator
Removing the auxiliary heater electric pump
Design changes since 2003
Engine ZMZ-40522
Design features
Intake manifold removal
Dismantling the timing gear
Removing the oil cooler
Coolant replacement
Removing the expansion tank of the engine cooling system
Engine management system ZMZ-40522
Design features
Engine control module
Engine control fault codes
Control relays and fuses
Replacing the engine control module
Replacing the mass air flow sensor
Checking and replacing the throttle position sensor
Camshaft position sensor
Intake manifold air temperature sensor
Engine power system ZMZ-40522
Design description
Replacing the air filter element
Replacing the fuel filter
Throttle actuator adjustment
Checking the pressure in the fuel system
Removing the fuel rail and injectors
Injector testing
Pressure regulator replacement
Removing the receiver
Replacing the throttle cable
Removal and check of the regulator of idling
Removing the fuel module
Replacing the fuel pump
Replacing the fuel gauge gauge
Throttle removal
Upgraded gearbox
Description of design changes
Gearbox disassembly
Anti-lock braking system (ABS)
Design features
Bleeding the brake system
Replacing wheel speed sensors
Replacing the valve body ABS
Electrical equipment
Design Features
Removing and disassembling the 3212.3771 generator
Fuse protected circuits
Replacing the headlight bulbs
Removing the headlight
Headlight adjustment
Removing instrument cluster, replacing lamps
Removing the side direction indicator, replacing the lamp
Replacing the backlight for the heating and ventilation control panel
Speed ??sensor replacement
Ventilation and heating system
Design features
Replacing the heater tap
Removing the main heater radiator
Replacing the electric fan and resistor of the main heater
Removing the heating and ventilation control panel
Removing the main heater
Dismantling the main heater
Body
Design description
Removing and disassembling the instrument panel
Removing the radiator grill
Removing the front panel of the radiator lining
Front wing removal
Removing the exterior rearview mirror
Removing the upper radiator trim panel
Diagnostics of malfunctions
Diagnostics of malfunctions of the engine and its systems
Clutch fault diagnosis
Gearbox diagnostics
Power Steering Diagnostics
Diagnostics of malfunctions of the driveline, rear axle, chassis, steering (except for the hydraulic booster) and brake system
Diagnostics of cab and body malfunctions
Battery diagnostics
Diagnostics of malfunctions of the generator
Lighting and light alarm
Applications
Tools used besides staffing
Layout of rolling bearings
Rolling bearings
Balloons. Reinforced rubber rollers, cuffs for shafts (oil seals)
Lamps used in the car
Tightening torques for threaded connections
Applicable fuels, oils and fluids
Electrical circuit of a car with engines ZMZ-402, UMZ-4215 (old-style instrument panel)
The electrical circuit of cars with engines ZMZ-4061, -4063 (instrument panel of the old model)
The electrical circuit of vehicles with an engine ZMZ-4063 (dashboard of a new sample)
The electrical circuit of vehicles with an UMZ-4215 engine (a new type of instrument panel)
The electrical circuit of vehicles with engines UMZ-4216, ZMZ-40522 (a new type of instrument panel)
Diagram of a microprocessor ignition system for engines ZMZ-4061, -4063
Electrical diagram of the anti-lock brake system
The scheme of the engine control system ZMZ-40522, UMZ-4216 |
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