Content

General information

• Vehicle specifications
• Basic data for adjustments and control
• Vehicle data sheet

Controls and instruments

• Location of controls and appliances
• Location of controls on the floor tunnel lining and front seat adjustment controls
• Key switch block and heating and ventilation control panel
• Instrument cluster

Safety precautions for maintenance and repair

Engine

• Design description
• Changing the oil and oil filter
• Adjusting the tension and replacing the auxiliary drive belt
• Replacing the tension pulley of the auxiliary drive belt
• Replacing the front cuff of the crankshaft
• Replacing the rear cuff of the crankshaft
• Removing the oil cooler
• Removing the tap and oil cooler hoses
• Replacing the intake manifold
• Replace exhaust gaskets
• Camshaft removal
• Replacing hydraulic pushers
• Removing and installing hydraulic tensioners
• Dismantling the timing gear
• Dismantling the oil pump drive
• Removing and repairing the cylinder head
• Powertrain support replacement
• Engine removal
• Engine repair

Engine management system

• Design description
• Engine management system diagnostics
• Replacing engine control relay and fuses
• Replacing the engine control module
• Checking and replacing the synchronization sensor
• Checking and replacing the camshaft position sensor
• Checking and replacing the throttle position sensor
• Replacing the mass air flow sensor
• Checking and replacing the coolant temperature sensor
• Checking and replacing the intake air temperature sensor
• Check and replace knock sensor
• Replacing spark plugs
• Checking and replacing high voltage wires
• Checking and replacing ignition coils

Power system

• Design description
• Replacing the air filter element
• Replacing the fuel filter
• Replacing the fuel intake filter
• Throttle actuator adjustment
• Checking fuel pressure
• Removing the fuel pump and fuel gauge sender
• Removing the fuel tank

Exhaust system

• Design description
• Replacing suspension components for exhaust system
• Replacing exhaust system components

Engine cooling system

• Design description
• Coolant replacement
• Replacing the coolant drain cock
• Replacing temperature gauge sensors and coolant overheat warning lamp
• Removing the expansion tank
• Checking and replacing the thermostat
• Replacing the sensor for turning on the electric fan
• Removing the electric fan
• Removing the radiator
• Coolant pump replacement

Grip

• Design description
• Clutch release adjustment
• Bleeding hydraulic clutch and replacing the working fluid
• Replacing the hydraulic hose
• Replacing the hydraulic master cylinder
• Replacing hydraulic drive cylinder
• Replacing the clutch release fork
• Replacing the slave and master drives

Gearbox

• Design description
• Oil change
• Replacing extension cuffs
• Gearbox removal
• Replacing input shaft seal
• Replacing front input shaft bearing
• Gearbox repair

Cardan transmission

• Design description
• Grease cardan joints
• Removing the driveline
• Cardan repair

Rear axle

• Design description
• Axle bearing lubrication
• Oil change
• Axle removal
• Replacing the axle sleeve
• Replacing the final drive gear cuff
• Rear axle repair
• Main gear adjustment for tooth contact stain
• Removing the rear axle

Front suspension

• Design description
• Front wheel alignment
• Wheel bearing adjustment
• Shock absorber replacement
• Replacing the upper ball joint
• Replacing the lower ball joint
• Spring replacement
• Removing the upper arm
• Removing the lower arm
• Replacing the anti-roll bar
• Removing the anti-roll bar
• Replacing the hub bearings

Rear suspension

• Design description
• Replacing anti-skid spring pads
• Shock absorber replacement
• Removing the anti-roll bar
• Replacing silent blocks and pillows
• Removing and disassembling the spring

Steering

• Design description
• Changing the fluid and filter element
• Bleeding the hydraulic drive power steering
• Checking the technical condition of the steering
• Flushing the flow and safety valves of the power steering pump
• Power steering pump removal
• Steering wheel removal
• Steering column removal

Brake system

• Design description
• Bleeding the brake system, replacing the brake fluid
• Adjustment of a drive of a regulator of pressure of brake mechanisms of back wheels
• Adjustment of the parking brake actuator
• Replacing the brake pads of the front wheels
• Replacing the front wheel brake hose
• Removing the front brake caliper bracket body
• Removing the brake disc
• Replacing the brake pads of the rear wheels
• Replacing the rear brake hose
• Replacing the wheel cylinder of the rear wheel brake mechanism
• Removing the rear brake pressure regulator
• Replacing the brake master cylinder
• Replacing the vacuum brake booster
• Replacing the parking brake cable
• Removing the parking brake mechanism
• Removing the foot switch

Electrical equipment

• System description
• Check for dead circuits
• Checking live electrical circuits
• Replacing fuses and relays
• Battery
• Ignition switch contact group replacement
• Generator
• Design description
• Checking the generator on the car
• Replacing the alternator voltage regulator 2502.3771
• Replacing the 3212.3771 / 9422.3701 generator voltage regulator
• Removing the generator
• Repair of the generator 2502.3771
• Repair of the generator 3212.3771 / 9422.3701
• Starter
• Starter removal
• Starter repair
• Lighting, light and sound alarm
• Replacing the headlight bulbs
• Headlight adjustment
• Removing the headlight
• Removing the headlight range adjuster
• Removing the fog lamp, replacing the lamp
• Fog light adjustment
• Removing the central light switch
• Removing the steering column switches, hazard warning light switch
• Removing the side direction indicator, replacing the lamp
• Replacing the brake light switch
• Replacing lamps in the rear light, removing the light
• Replacing the reversing light switch
• Removing the additional brake light, replacing the lamps
• Removing the interior light, replacing the lamp
• Removing the light under the hood, replacing the lamp
• Replacing the glove compartment lamp lamp
• Removing and adjusting the horn
• Removing and disassembling the horn switch
• Windshield wiper and washer
• Removing and disassembling the windshield wiper
• Removing the electric pump and washer nozzles
• Instrument cluster
• Checking control devices and their sensors
• Removing instrument cluster
• Replacing instrument cluster lights
• Speed ??sensor replacement
• Replacing oil pressure sensors
• Replacing the fuel gauge gauge

Body

• Design description
• Removing the engine mudguard
• Removing the front bumper
• Front wing removal
• Replacing the windshield
• Replacing the rear window
• Removing the floor tunnel
• Removing the dashboard
• Adjusting and removing the front seat
• Removing the rear seat
• Removing the side rearview mirror
• Removing the front door trim
• Removing the lock and front door handles
• Removing the front door glass
• Removing the power window front door
• Removing the front door
• Removing the rear door trim
• Removing the rear door windows
• Removing the rear power window
• Removing the rear door lock
• Removing the tailgate lock
• Removing the boot lid
• Removing the tailgate hinges
• Removing the spare wheel mounting frame
• Removing the rear bumper

Heating and ventilation system

• Design description
• Replacing heater tap and solenoid valve (pneumatic actuator)
• Replacing the heater tap (mechanical drive)
• Replacing heater resistor
• Replacing the electronic heater speed controller
• Removing the heating and ventilation control panel
• Replacing heater electric fan
• Heater removal
• Replacing the heater radiator

Diagnostics of malfunctions

• Engine and its systems
• Transmission, chassis, steering, brake system
• Electrical equipment
• Body, heating and ventilation system

Applications

• Repair tools
• Tightening torques for critical threaded connections
• spark plugs used in a car
• Automotive rolling bearings
• Applicable fuels, lubricants and operating fluids
• Lamps used in the car

Electrical diagrams

• Vehicle electrical diagram
• The scheme of the engine control system ZMZ-406 (SUD)
• Diagram of an electronic heater control system