Content

General information

• Vehicle specifications
• Vehicle data sheet

Repair safety

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 body malfunctions
• Diagnostics of malfunctions of electric equipment

Engine ZMZ-402

• Design description
• Changing the oil and oil filter
• Replacing the air filter
• Replacing fan belts
• Fan belt tension adjustment
• Clearance between valves and rocker arms
• Replacing the thermostat
• Removing the coolant pump
• Removing the radiator
• Replacing the front cuff (gland) of the crankshaft
• Collector removal
• Dismantling the oil pump
• Removing the axis of the rocker arm and rod pushers
• Removing the cylinder head
• Dismantling the cylinder head
• Dismantling the crankshaft
• Removing and disassembling the ZMZ-402 engine
• Assembly of the ZMZ-402 engine

Engine power system ZMZ-402

• Design description
• Removing the fuel tank
• Removing the fuel gauge
• Removing and disassembling the fuel pump
• Removing and disassembling the fuel fine filter

Carburetor K-151

• Carburetor scheme
• Design description
• Carburetor removal
• Dismantling the carburetor
• Idle adjustment
• Forced idle economizer system (EPHX)
• Checking the bandwidth of jets
• Exhaust gas recirculation system

Engine ZMZ-4062

• Design description
• Changing the oil and oil filter
• Replacing the air filter element
• Replacing and adjusting the drive belt tension
• Removing auxiliary components and equipment from the engine
• 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
• Dismantling the timing gear
• Dismantling the oil pump drive
• Removing and installing cylinder head
• Engine removal
• Engine disassembly
• Dismantling and repair of a head of the block of cylinders
• Lapping valves
• Assembly of the connecting rod and piston group
• Engine assembly

Integrated engine control system ZMZ-4062

• Design description
• Engine control module
• Engine management system diagnostics
• Fault codes for the engine control system ZMZ-4062
• Replacing the control unit
• Replacing the main relay
• Control system sensors
• Ignition system
• Power system
• Air intake system
• Idle system
• Engine power system maintenance
• Precautions for the diagnosis of the engine management system ZMZ-4062 and car repair

Engine cooling system ZMZ-4062

• Design description
• Coolant replacement
• Replacing temperature gauge and coolant overheat warning sensors
• Checking the thermostat in a car
• Removing and checking the thermostat
• Replacing the heater faucet
• Replacing the sensor for turning on the electric fan
• Replacing the electric fan
• Replacing the radiator
• Coolant pump replacement

Exhaust system

• Design description
• Replacing the silencer and both resonators
• Replacing the intake pipes of the ZMZ-406 engine
• Replacing the intake pipes of the ZMZ-402 engine

Diaphragm clutch

• Design features
• Bleeding the clutch release hydraulic
• Removing the clutch slave cylinder
• Removing the clutch master cylinder
• Replacing the rubber hose for the clutch release actuator
• Removing the clutch housing (shown for the ZMZ-406 engine)
• Removing the clutch master and slave discs

Spring linkage

• Design features
• Removing and installing clutch

Five-speed gearbox

• Design description
• Changing the oil and flushing the gearbox
• Speedometer sensor replacement
• Replacing the reversing light switch
• Replacing front input shaft bearing
• Transmission cuff replacement
• Gearbox removal
• Gearbox disassembly

Four-speed gearbox

• Design description
• Gearbox oil change
• Transmission cuff replacement
• Gearbox disassembly and assembly

Cardan transmission

• Design description
• Removing and installing cardan transmission
• Dismantling and assemblage of a two-shaft driveshaft
• Inspection, inspection and lubrication of the driveline
• Dismantling and assembling the universal joint

Rear axle

• Design description
• Removing the rear axle from the car
• Axle removal
• Replacing the axle sleeve
• Replacing the axle bearing
• Dismantling the rear axle
• Drive cuff replacement
• Replacing pinion bearings
• Dismantling the differential
• Pinion bearing adjustment
• Adjustment of differential bearings and lateral clearance in gearing of final drive gears
• Main gear adjustment for tooth contact stain

Front suspension

• Design features
• Maintenance
• Removing the upper arms and replacing their rubber bushings
• Removing the lower levers
• Removing the upper arm axle
• Removing the anti-roll bar
• Removing the front suspension strut and replacing the threaded joints
• Removing and installing front wheel hub
• Wheel bearing adjustment
• Removing the front suspension from the car
• Removing the king pin
• Removing the front suspension spring
• Shock absorber removal
• Checking and adjusting wheel alignment

Rear suspension

• Rear suspension
• Replacing anti-skid gaskets springs
• Shock absorber replacement
• Replacing springs and rubber bushings

Power steering

• Design description
• Steering gear oil change
• Steering adjustment
• Removing and disassembling the steering column
• Removing and installing steering gear
• Dismantling and assembling the steering gear
• Checking the wear of ball joints and tie rods
• Removing and disassembling the steering trapezoid
• Dismantling and lubrication of steering link hinges
• Steering link hinge replacement

Power steering combined with steering gear

• Design description
• Changing the working fluid (oil) and filter
• Bleeding the hydraulic steering system
• Flushing the flow and safety valves of the power steering pump
• Power steering pump removal
• Power steering removal
• Steering propeller thrust bearings
• Adjustment of the engagement of the piston-rail-shaft-sector pair

Brake system

• Design description
• Bleeding the brake system, replacing the brake fluid
• Replacing the brake pads of the front wheels
• Replacing the brake disc and caliper
• Replacing the front brake hose
• Removing and installing brake drum
• Removing and replacing brake pads on rear wheels
• Replacing the brake cylinder on the rear wheel
• Replacing the rear wheel brake cylinder linings
• Replacing the rear brake hose
• Removing the brake master cylinder
• Replacing the brake master cylinder linings
• Removing the brake servo
• Removing the pressure regulator
• Pressure regulator actuator adjustment
• Removing the parking brake mechanism
• Replacing the parking brake cable
• Adjustment of the parking brake actuator
• Removing the foot switch

Electrical equipment

• General information
• Replacing fuses and relay box
• Battery
• Engine generator ZMZ-4062
• Checking the engine generator ZMZ-4062 in a car
• Dismantling and checking the engine generator ZMZ-4062
• Replacing the engine voltage regulator ZMZ-4062
• Generator 1631.3701 engine ZMZ-402
• Checking the engine generator ZMZ-402 in a car
• Removing the generator
• Dismantling and checking the engine generator ZMZ-402
• Replacement of voltage regulator and brush holder of engine generator ZMZ-402
• Starter
• Starter removal
• Dismantling and checking the starter
• The ignition system of the engine ZMZ-402
• Ignition timing
• Replacing the slider and distributor cap
• Removing the ignition distributor
• Removing and installing ignition distribution sensor assembly with oil pump drive
• Disassembly of the distributor sensor
• Replacing ignition system components
• Cooling fan motor
• Removing the electric fan
• Dismantling the electric fan
• Checking the electric fan activation circuit
• Removing the electric fan relay
• Lighting and light alarm
• Replacing the lamp in the main headlight
• Headlight removal
• Headlight corrector
• Headlight adjustment
• Replacing the fog lamp
• Fog light adjustment
• Removing the fog lamp
• Replacement of side-light bulbs, brake light and direction indicator, lamp removal
• Removing license plate lights and luggage compartment, replacing lamps
• Replacing rear fog lamps and reversing lights
• Removing front and side direction indicators, replacing bulbs
• Replacing bulbs and removing the optional brake light
• Removing the brake light switch
• Removing the interior light, replacing the lamp
• Removing the light switch
• Windshield wiper and washer
• Removing the electric pump and washer nozzles
• Removing and disassembling the windshield wiper
• Sound signals
• Removing, checking and adjusting the sound signal
• Replacing the horn switch
• Heater fan motor
• Instrument cluster
• Checking control devices and their sensors

Body

• Design description
• Removing the front bumper
• Removing the upper front panel
• Removing the front mudguard and radiator trim
• Front wing removal
• Front wing position adjustment
• Removing the hood lock
• Removing and disassembling the hood
• Removing the hood
• Removing the hinges of the hood
• Buttonhole adjustment
• Bonnet adjustment
• Windshield removal
• Windshield installation
• Removing the dashboard console
• Removing the dashboard
• Removing heater fan and additional resistor
• Removing the heater radiator
• Removing heater distributors
• Heater disassembly
• Removing and adjusting the front seat
• Removing the front door lock
• Removing the switch (larva) of the front door lock
• Installation of the switch (larva) of the front door lock
• Removing the front door trim
• Removing the door with hinges
• Removing the front door glass
• Removing the front door window lifter
• Removing the front door seals
• Installing the front door seal
• Complete disassembly of the front door
• Removing the rear seat
• Removing the lower and fixed windows of the rear door
• Removing the lever and pull rods for locking the tailgate
• Removing the rear power window
• Removing the door lock
• Installing the door lock
• Removing the rear door seal
• Removing the front trim
• Removing floor mats and floor seals
• Removing the front rug and floor seal
• Removing the rear floor mat and floor seal
• Removing the side handrails
• Removing the rear shelf
• Removing the rearview mirror
• Removing the sun visor
• Removing the seat belt and middle pillar linings
• Removing the tailgate lock
• Removing the boot lid seal
• Seal installation
• Removing the boot lid
• Removing torsion bars
• Removing the tailgate hinges
• Buttonhole adjustment
• Trunk lid adjustment
• Removing the spare wheel shelf and trunk trim
• Removing the bottom panel of the tail
• Removing the fuel filler flap
• Removing the rear bumper

Features of service and repair of the car GAZ-310221

• Removing the rear interior light
• Removing rear light diffusers and replacing bulbs
• Removing the taillights
• Removing the additional brake light
• Removing license plate lights and replacing bulbs
• Removing the deflector lamp
• Removing the rear seat
• Removing the optional seat
• Removing the rear wheel arches
• Removing the trunk lining
• Removing the tailgate lock
• Removing the spring mechanism of the tailgate
• Removing the tailgate
• Removing the spare wheel niche cover and its lock
• Removing the roof deflector and tailgate hinges
• Removing the rear bumper

Applications

• A tool used in addition to the staffing
• Checking electrical circuits
• Tightening torques for threaded connections
• Dimensions of interfaced engine parts ZMZ-4062
• Automotive rolling bearings
• Balls
• Rollers (needles)
• Electrical circuit with engine ZMZ-402
• The scheme of electrical equipment with an engine ZMZ-4062
• The scheme of the engine control system ZMZ-4062
• Lamps used in the car
• Spark plugs
• Used fuel, oil and operating fluids
• Reinforced rubber cuffs for shafts (oil seals)
• Dimensional groups for the ZMZ-4062 engine