Content

General information

• Overall dimensions of cars and placement of passenger seats
• Vehicle data sheet
• Vehicle specifications

Controls and instruments

Repair safety instructions

Engine ZMZ-4063

• Design description
• Changing the oil and oil filter
• Replacing oil pressure sensors
• Intake manifold removal
• Removing the exhaust manifold
• Replacing the front cuff of the crankshaft
• Replacing the rear cuff of the crankshaft
• Powertrain support replacement
• Camshaft replacement
• Replacing hydraulic pushers
• Removing and installing hydraulic tensioners
• Removing hydraulic tensioners
• "Charging" the hydraulic tensioner
• "Discharge" hydraulic tensioner
• Dismantling the timing gear
• Dismantling the oil pump drive
• Removing the cylinder head
• Dismantling and repair of a head of the block of cylinders
• Lapping valves
• Engine removal
• Removing the engine assembly with accessories
• Removing the engine with partial disassembly
• Engine disassembly
• Dismantling the crankshaft
• Dismantling the cylinder head cover
• Dismantling the oil pump
• Assembly of the connecting rod and piston group
• Engine assembly

Power system

• Design description
• Replacing the air filter element
• Removing and disassembling the filter sump
• Replacing 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 air filter housing

Carburetor K-151 43

• Design description
• Removing the carburetor fuel filter
• Adjustment of carburetor damper actuators
• 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 the health of the EPHX system
• Exhaust gas recirculation system

Removing the recirculation valve and thermal vacuum switch

Cooling system

• Design description
• Coolant replacement
• Replacing and adjusting the tension of the auxiliary drive belt
• Replacing the idler pulley and the accessory drive belt tension mechanism
• Replacing temperature gauge and coolant overheat warning sensors
• Checking the thermostat in a car
• Removing and checking the thermostat
• Removing the radiator
• Coolant pump replacement

Exhaust system

• Design description
• Replacing the silencer, resonator and exhaust pipe
• Replacing the exhaust pipes

Grip

• Design description
• Bleeding hydraulic clutch and replacing the working fluid
• Removing the hydraulic master cylinder
• Removing hydraulic drive cylinder
• Replacing the hydraulic hose
• Clutch housing removal
• Removing the clutch discs

Gearbox

• Design description
• 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 description
• Inspection, inspection and lubrication of the driveline
• Removing the driveline
• Disassembling the driveline
• Dismantling the universal joint

Rear axle

• Design description
• Gearbox oil change
• Axle removal
• Wheel bearing adjustment
• Drive cuff replacement
• Replacing rear 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 description
• Wheel removal
• Wheel bearing adjustment
• Replacing bearings and hub cups
• Ball bearing lubrication
• Shock absorber replacement
• Replacing the anti-roll bar and its rubber elements
• Replacing the upper ball joint
• Replacing the lower ball joint
• Removing the upper arm
• Removing the front suspension strut
• Suspension spring replacement
• Removing the lower arm
• Removing the front suspension

Rear suspension

• Design description
• Replacing the compression progress buffer
• Shock absorber replacement
• Removing the anti-roll bar and replacing its bushings
• Removing, disassembling the spring and replacing its rubber-metal hinges

Steering

• Design description
• Steering column adjustment
• Lubricating the cardan joints of the steering shaft
• Lubricating the pivot arm axles
• Checking the technical condition of the steering
• Removing and disassembling the steering column
• Replacing steering rods and their hinges
• Swing arm adjustment
• Replacing bearings and bushings for swing arm
• Topping up the power steering system
• Changing the oil and filter element
• Bleeding the hydraulic steering system
• Power steering pump removal
• Power steering valve flushing
• Replacing the pump cuff
• Replacing the rotor, stator and pump seals
• Power steering removal
• Power Steering Adjustment
• Adjustment of thrust bearing bearings
• Gear adjustment
• Replacing hydraulic hoses
• Topping up the steering gear without power steering
• Removing and adjusting steering gear without power steering

Brake system

• Design description
• 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 wheel
• Replacing the rear brake hose
• Removing the brake master cylinder
• Replacing the brake master cylinder linings
• Replacing the vacuum booster
• Removing the foot switch
• Regulator drive adjustment
• Regulator replacement
• Adjustment of the parking brake actuator
• Replacing parking brake cables
• Dismantling the parking brake mechanism

Electrical equipment

• System description
• 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
• Generator
• Checking the generator on the car
• Removal and repair of the generator
• Replacing the voltage regulator
• Starter
• Starter removal
• Starter Relay Replacement
• Dismantling and checking the starter

Ignition system

• Control unit (controller)
• 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 high voltage wires and candle tips
• Removing the spark plugs
• Removing and checking the absolute pressure sensor

Lighting, light and sound alarms

• Replacing the headlamp bulb and removing the headlamp
• Headlight adjustment
• Replacing headlamp and control unit
• Replacing the central light switch
• Replacing the direction indicator relay
• Replacing the front direction indicator lamp and removing it
• Replacing the side direction indicator lamp and removing it
• Replacing the brake light switch
• Replacing the alarm switch
• Removing the interior and rear fog light switches
• Replacing the taillight lamps and removing it
• Removing the license plate light, replacing the lamp
• Removing cabin and interior lights
• 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
• Nozzle removal
• Removing the electric pump

Testing devices

• Removing instrument cluster, replacing lamps
• Checking control instruments and sensors
• Coolant temperature gauge
• Oil pressure gauge
• Fuel gauge
• Speedometer
• Voltmeter
• Ignition switch
• Replacing the ignition switch

Frame, cab, body

• Design description
• Removing the front bumper
• Removing the engine mudguard
• 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 belt
• 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 sliding door openers
• Sliding door adjustment
• Door height adjustment
• “Depth” door adjustment
• Removing the flooring
• Removing the upholstery
• Removing the cab partition
• Removing the rear door locks
• Removing the right rear door lock
• Removing the left rear door lock
• Removing the back door
• Removing the rear bumper
• Removing the filler cap on the fuel tank
• Features of the repair of the interior modification "Lux"
• Removing the front seat belt
• Removing the front seat belt,
• Removing the rear seat belts
• Removing the passenger seat of the cab
• Removing the front seats
• Removing the rear seats
• Removing the interior partition and its upholstery
• Table removal
• Removing the side panel trim and rear wheel arch cover
• Removing the floor and side deck footboard flooring

Ventilation and heating system

• Design description
• 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 and disassembling the additional heater
• 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 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

ABS brake system

• 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
• 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

Heating and ventilation system

• Design features
• Replacing the heater tap
• Removing the main heater radiator
• Removing 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 features
• Removing and disassembling the instrument panel
• Removing the radiator grill
• Removing the front panel of the radiator lining
• Removing the front wings
• Removing the exterior rearview mirror
• Removing the upper radiator trim panel

Diagnostics of malfunctions

• Engine and its systems
• Clutch
• Gearbox
• Power Steering
• Cardan drive, rear axle, chassis, steering and brakes
• Cab and body
• Battery
• Generator
• Starter
• Ignition system and EPHC
• Lighting and light alarm
• Wiper
• Sound signal
• Electric fan cooling system
• Testing devices
• Heating and ventilation system

Applications

• A tool used in addition to the staffing
• The scheme of the engine control system ZMZ-40522
• Scheme of the microprocessor ignition system of the engine ZMZ-4063
• Electrical diagram of the anti-lock brake system
• Electrical equipment diagram of a car with an engine ZMZ-40522
• Electrical circuit of a car with an engine ZMZ-4063 (dashboard of a new sample)
• Electrical circuit of a car with an engine ZMZ-4063 (old-style instrument panel)
• Scheme of additional electrical equipment for various modifications of the Sobol car
• Diagram of an electric fan radiator and fog lights (for a bus for 6 passenger seats)
• Precautions for the diagnosis of the engine ignition system ZMZ-4063 / engine control ZMZ-40522 and car repair
• Connector layout for the new instrument cluster
• Tightening torques for critical threaded connections
• Layout of rolling bearings
• Rolling bearings
• Balls
• Rollers (needles)
• Reinforced rubber cuffs for shafts (oil seals)
• Applicable fuels, oils and operating fluids
• Lamps used in the car