GAS 2705/3302 Gazelle until 2009, repair e-manual (in Russian)

Content

Background

• Technical description
• Passport data of cars
• Maintenance and repair safety

Diagnosis of gazelle malfunctions

• Engine and its systems
• Clutch
• Transmission
• PTO, rear axle, chassis, steering and brake system
• Cab & body
• Rechargeable battery
• Generator
• Starter
• Lighting & signaling

UMZ-4216 Engine

• Design description
• Checking the oil level in the crankcase of the engine crankcase
• Oil and oil filter replacement
• Adjustment of thermal gaps in the valve actuator
• Removing the receiver
• Removal of intake pipe and exhaust manifold
• Removing the emergency oil pressure sensor sensor
• Replacing the cylinder head cover gasket
• Removing and disassembling the axis of the rocker arm
• Replacing oil reflector caps
• Removing the pusher box covers
• Removing the cylinder head
• Disassembly and assembly of the cylinder head
• Replacing the crankshaft front seal
• Replacing the crankshaft rear oil seal
• Removing the pallet pallet
• Oil pump removal and disassembly
• Dismantling of connecting rod and piston group by car
• Removing the fan drive belt tensioner
• Replacing power bearing supports
• Removing and installing the engine
• Disassembly and assembly of the engine

Engine management system UMZ-4216

• Design description
• Removing the electronic control unit
• Removing the crankshaft position sensor
• Phase sensor removal
• Throttle position sensor removal
• Removal of the inlet pressure and intake air temperature sensor
• Removing the coolant temperature sensor
• Detonation sensor removal
• Removing a rough road sensor
• Removing the speed ​​sensor and its drive
• Removal of oxygen concentration control sensor
• Removal of the oxygen concentration diagnostic sensor
• Ignition coil removal
• Checking and replacing spark plugs

UMZ-4216 engine power system

• Design description
• Removing the fuel tank
• Removing and disassembling the fuel module
• Removal of fuel rail and injectors
• Idling regulator removal
• Removing the throttle assembly
• Throttle drive replacement
• Removal of the solenoid purge valve adsorber
• Removing the adsorber

UMZ-4216 engine cooling system

• Design description
• Fan drive belt condition check
• Replacing the fan drive belt
• Generator drive belt and coolant pump status check
• Alternator drive belt and coolant pump replacement
• Coolant replacement
• Removing and checking the thermostat
• Removing the radiator
• Removing the fan impeller
• Removing the fan switch electromagnetic clutch
• Removing the coolant pump
• Removing the expansion tank

The exhaust system of the UMZ-4216 engine

• Design description
• Removal of the receiving pipe
• Replacing the muffler
• Exhaust pipe replacement

ZMZ-40522 engine

• Design description
• Oil and oil filter replacement
• Oil pressure sensors removal
• Removing the receiver
• Inlet pipeline removal
• Removal of the exhaust manifold
• Replacing the crankshaft front seal
• Replacing the crankshaft rear oil seal
• Removal and installation of hydraulic loaders
• Camshaft removal
• Replacing pushers
• Removing and installing cylinder head
• disassembly and assembly of the cylinder head
• Valve lapping
• Disassembly of the valve actuator
• Disassembling the oil pump drive
• Replacing the power support front supports
• Removing the oil cooler
• Removing the engine from the car
• Disassembly and assembly of the engine

Engine control system ZMZ-40522

• Design description
• Engine control system malfunction codes
• Relays and fuses of the control system
• Removing the electronic engine control unit
• Removing the crankshaft position sensor
• Removing the mass air flow sensor
• Checking and replacing the throttle position sensor
• Phase sensor removal
• Detonation sensor removal and inspection
• Removing and checking the coolant temperature sensor
• Removal of the air temperature sensor in the inlet pipeline
• Checking and removing ignition coils
• Checking and replacing spark plugs

ZMZ-40522 engine power system

• Design description
• Replacing the air filter replacement element
• Replacing the fuel filter
• Throttle drive adjustment
• Fuel system pressure check
• Removal of fuel rail and injectors
• Nozzle check
• Replacing the fuel pressure regulator
• Throttle drive replacement
• Idling regulator removal and inspection
• Removing the fuel module
• Fuel pump replacement
• Replacing the fuel level meter sensor
• Removing the throttle assembly

ZMZ-40522 engine cooling system

• Design description
• Coolant replacement
• Removing the coolant pump
• Removing and checking the thermostat
• Removing the engine cooling system expansion tank
• Removing the radiator
• Replacing and adjusting the drive belt tension of the auxiliary units
• Replacing the temperature sensor and coolant overheating sensors

Clutch

• Design description
• Pumping of the clutch shut-off hydraulic actuator and replacement of the working fluid
• Removing the hydraulic master cylinder
• Removing the hydraulic drive cylinder
• Replacing the hydraulic hose
• Clutch crankcase removal (engine ZMZ-40522)
• Clutch crankcase removal (UMZ-4216 engine)
• Clutch pressure and slave disc removal

Transmission

• Design description
• Oil change
• Primary shaft bearing replacement
• Replacing the cuffs
• Replacing the reverse light switch
• Removing the gearbox
• Disassembly of the gearbox

Cardan gear

• Design description
• Inspection, inspection and lubrication of the driveshaft
• Removing the PTO
• Disassembly of the PTO
• Disassembling the universal joint

Rear bridge

• Design description
• Removing the rear wheels
• Gear oil change
• Shaft removal
• Wheel bearing adjustment
• Drive gear cuff replacement
• Wheel bearing and shaft seal replacement
• Removing the rear axle
• Rear axle disassembly
• Rear axle assembly and main gear adjustment

Front suspension

• Design description
• Removing the front wheel
• Oil seal grease
• Front wheel bearing adjustment
• Front wheel hub bearing replacement
• Removing, disassembling the spring and replacing it with rubber hinges
• Replacing the shock absorber
• Removing the front axle
• Disassembling the pin connection

Rear suspension

• Design description
• Removing, disassembling the spring and replacing it with rubber hinges
• Replacing the shock absorber
• Removal of rubber cushions for additional springs

Steering

• Design description
• Steering column adjustment
• Topping the oil in the crankcase
• lubrication of the cardan shaft joints
• Checking the technical condition of the steering
• Removing and disassembling the steering column
• Removing the steering gear without power steering
• Steering without adjusting the power steering
• Steering pump drive belt condition check
• Steering pump power belt replacement
• topping up the oil in the hydraulic booster system
• Oil and filter element replacement
• Pumping the steering hydraulic system
• Removing the hydraulic pump
• rinsing the hydraulic pump pump valves
• Pump cuff replacement
• Replacement of rotor, stator and pump seals
• Removing the steering gear with the power steering
• Adjustment of the steering mechanism with the hydraulic booster
• Replacing the power hose hoses
• Replacement of steering rods and their joints
• Front wheel alignment

Brake system

• Design description
• Pumping the brake system, replacing the brake fluid
• Replacing front wheel brake pads
• Front wheel brake replacement
• Replacing the brake disc
• Replacing the front brake hose
• Replacing the brake drum and rear wheel brake pads
• Rear wheel brake cylinder replacement
• Replacing the rear brake hose
• Removing the master brake cylinder
• Vacuum amplifier replacement
• Removing the pedal knot
• Adjustment and replacement of the pressure regulator
• Adjusting the parking brake actuator
• Parking brake drive cable replacement
• Disassembling the parking brake mechanism
• Replacing wheel speed ​​sensors
• Replacing ABS hydraulic unit

Electrical equipment

• Design description
• Replacing fuses
• Rechargeable battery
• Replacing the battery switch
• Generator
• Generator removal and disassembly 3212.3771
• Removal of generator 3282m.3771
• Demolition of generator 3282m.3771
• Starter removal and verification
• Disassemble the starter
• Lighting, light and sound alarms
• Replacing the headlamp lamp
• Removing the headlamp
• Adjusting headlights
• Removing lateral turn signal, lamp replacement
• Replacing the brake signal switch
• Replacing the lamp, rear lamp removal
• Removing the license plate light, replacing the lamp
• Replacement of cabin and cabin lighting, ceiling removal
• Windscreen wiper and windshield washer
• Wiper removal & disassembly
• Control devices
• Removing the instrument cluster, replacing the lamps

Frame, cabin, body

• Design description
• Removing the front bumper
• Removing the radiator lining grid
• Removing the radiator panel front
• Removing the bonnet lock and its drive
• Removing the top panel of the radiator lining
• Removing the front fender
• Removing the rear exterior mirror
• Windshield replacement
• Removing the windshield rack upholstery
• Adjusting and removing the driver's seat
• Removal of passenger seats
• Removing the front seat belts
• Removing the seat belts of the second row of seats
• Removal of the sun visor
• Removing the door handle
• Removing the center rack upholstery
• Front door trim removal
• Removing the front door lock
• Front door glass replacement
• Window lift removal
• Removing the front door
• Removing the sliding door trim
• Removing the sliding door lock
• Replacing the sliding door and side windows.
• Removing the sliding door and dismantling its movement mechanism
• Removing the sliding door mechanisms
• Adjustable sliding door
• Removing the cab floor
• Removing ceiling upholstery
• Removing the cabin partition
• Removing the rear door lock
• Removing the rear door
• Removing the rear bumper
• Removal of the fuel filler filler hatch
• Removing and disassembling the dashboard

Ventilation and heating system

• Design description
• Replacement of the heater tap
• Removing the main heater radiator
• Replacing the main heater fan and resistor
• Removing the heating and ventilation control panel
• Removing the main heater
• Disassembly of the main heater

Applications

• Repair tools
• Tightening torques for threaded connections
• Arrangement of rolling bearings
• Rolling bearings
• Rubber reinforced seals (oil seals)
• Fuel, lubricants, and service fluids used
• Car lamps

Electrical equipment diagrams (electrical diagrams) Gazelle

• Engine control system diagram UMZ-4216, ZMZ-40522
• Electrical equipment diagram for vehicles with UMZ-4216, ZMZ-40522 engines
• Wire harness connection diagram for the UMZ-4216 engine control system (Euro 3)
• Electrical equipment diagrams for the anti-lock braking system

Customers reviews