Content

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