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GAS 2217 / Sable since 1998, repair e-manual (in Russian)

GAS 2217 / Sable since 1998, repair e-manual (in Russian)
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Only original manuals
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Publisher: © "Za Rulem"
ISBN: 978-5-9698-0287-2
Number of pages: 248
Format: file PDF

About the manual

Engine type: ZMZ-4063 / ZMZ-40522

Engine capacity: 2.3 / 2.5 liters.

Power: 98 / 145 hp

In the manual you will find

  • Instructions for repair of various vehicle components
  • Information on self-service car
  • Information on the design of the car and how to prevent failure
  • The information for the trip to the service station, if the self-repair is impossible
Publisher: Za Rulem
Categories: Gaz , GAZ
Only original manuals
Available immediately after payment
Full compliance with the paper edition
100% protection of your payments
Publisher: © "Za Rulem"
ISBN: 978-5-9698-0287-2
Number of pages: 248
Format: file PDF

About the manual

Engine type: ZMZ-4063 / ZMZ-40522

Engine capacity: 2.3 / 2.5 liters.

Power: 98 / 145 hp

In the manual you will find

  • Instructions for repair of various vehicle components
  • Information on self-service car
  • Information on the design of the car and how to prevent failure
  • The information for the trip to the service station, if the self-repair is impossible

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

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