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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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