Contents

Introduction

Technical characteristics of the engine and its systems

• Basic data for regulation and control
• Engine design
• Crank mechanism
• Gas distribution mechanism
• Lubrication system
• Cooling system
• Fuel supply system
• Air intake and exhaust system
• Crankcase ventilation system

Integrated microprocessor engine control system (KMPSUD)

• Integrated engine management system operation
• Integrated engine management system troubleshooting instruction
• Troubleshooting procedure and technique
• Diagnostic information output mode
• Diagnostic information output mode request
• The operation of the warning lamp when displaying fault codes
• Diagnostic trouble codes
• List of malfunctions in which the vehicle can move in standby modes

Engine maintenance

• Maintenance types
• Daily maintenance (EO)
• First maintenance (TO-1)
• Second maintenance (TO-2)
• Seasonal maintenance (CO)
• Maintenance features

Possible engine malfunctions and methods of their elimination

Engine repair

• Removing the engine from the vehicle
• Works performed on the left side of the vehicle
• Work performed on the right side of the vehicle
• Work performed at the front of the car
• Work performed underneath the vehicle
• Dismantling the engine
• Repair of engine parts, components and assemblies
• Cylinder block, pistons, connecting rods, intermediate shaft
• Controlled parameters during the repair of the cylinder block, pistons, connecting rods and intermediate shaft
• Crankshaft
• Controlled parameters during crankshaft repair
• Cylinder head, valve train and camshafts
• Hydraulic tensioner
• Water pump
• Oil pump
• Assembling the engine

Clutch

• Clutch maintenance features
• Possible clutch malfunctions and methods of their elimination
• Clutch repair
• Clutch assembly

Electrical equipment

• Generator
• Technical data
• Design and operation
• Installation order
• Technical condition check
• Possible malfunctions and methods of their elimination
• Disassembly and assembly
• Maintenance
• Starter
• Basic technical data
• Design and operation
• Terms of use
• Maintenance
• Possible malfunctions and solutions

Applications

• Wiring diagrams of the elements of the engine control system ZMZ - 409.10
• Dimensions of mating engine parts
• Tightening torques for engine screw connections
• Chemical map of fuels and lubricants and coolants used on the engine
• Refueling tanks
• The tool developed by JSC "ZMZ" and LLC "RusavtoGAZ"
• Checking and adjusting valve timing