GAZ 3110 Volga / 310221 Volga since 1981, service e-manual (in Russian)

Content General information Vehicle specifications Vehicle data sheet Repair safety Diagnostics of malfunctions Diagnostics of malfunctions of the engine and its systems Clutch fault diagnosis Gearbox diagnostics Power steering diagnostics Diagnostics of malfunctions of the driveline, rear axle, chassis, steering (except for the hydraulic booster) and brake system Diagnostics of body malfunctions Diagnostics of malfunctions of electric equipment Engine ZMZ-402 Design description Changing the oil and oil filter Replacing the air filter Replacing fan belts Fan belt tension adjustment Clearance between valves and rocker arms Replacing the thermostat Removing the coolant pump Removing the radiator Replacing the front cuff (gland) of the crankshaft Collector removal Dismantling the oil pump Removing the axis of the rocker arm and rod pushers Removing the cylinder head Dismantling the cylinder head Dismantling the crankshaft Removing and disassembling the ZMZ-402 engine Assembly of the ZMZ-402 engine Engine power system ZMZ-402 Design description Removing the fuel tank Removing the fuel gauge Removing and disassembling the fuel pump Removing and disassembling the fuel fine filter Carburetor K-151 Carburetor scheme Design description Carburetor removal Dismantling the carburetor Idle adjustment Forced idle economizer system (EPHX) Checking the bandwidth of jets Exhaust gas recirculation system Engine ZMZ-4062 Design description Changing the oil and oil filter Replacing the air filter element Replacing and adjusting the drive belt tension Removing auxiliary components and equipment from the engine 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 Dismantling the timing gear Dismantling the oil pump drive Removing and installing cylinder head Engine removal Engine disassembly Dismantling and repair of a head of the block of cylinders Lapping valves Assembly of the connecting rod and piston group Engine assembly Integrated engine control system ZMZ-4062 Design description Engine control module Engine management system diagnostics Fault codes for the engine control system ZMZ-4062 Replacing the control unit Replacing the main relay Control system sensors Ignition system Power system Air intake system Idle system Engine power system maintenance Precautions for the diagnosis of the engine management system ZMZ-4062 and car repair Engine cooling system ZMZ-4062 Design description Coolant replacement Replacing temperature gauge and coolant overheat warning sensors Checking the thermostat in a car Removing and checking the thermostat Replacing the heater faucet Replacing the sensor for turning on the electric fan Replacing the electric fan Replacing the radiator Coolant pump replacement Exhaust system Design description Replacing the silencer and both resonators Replacing the intake pipes of the ZMZ-406 engine Replacing the intake pipes of the ZMZ-402 engine Diaphragm clutch Design features Bleeding the clutch release hydraulic Removing the clutch slave cylinder Removing the clutch master cylinder Replacing the rubber hose for the clutch release actuator Removing the clutch housing (shown for the ZMZ-406 engine) Removing the clutch master and slave discs Spring linkage Design features Removing and installing clutch Five-speed gearbox Design description Changing the oil and flushing the gearbox Speedometer sensor replacement Replacing the reversing light switch Replacing front input shaft bearing Transmission cuff replacement Gearbox removal Gearbox disassembly Four-speed gearbox Design description Gearbox oil change Transmission cuff replacement Gearbox disassembly and assembly Cardan transmission Design description Removing and installing cardan transmission Dismantling and assemblage of a two-shaft driveshaft Inspection, inspection and lubrication of the driveline Dismantling and assembling the universal joint Rear axle Design description Removing the rear axle from the car Axle removal Replacing the axle sleeve Replacing the axle bearing Dismantling the rear axle Drive cuff replacement Replacing pinion bearings Dismantling the differential Pinion bearing adjustment Adjustment of differential bearings and lateral clearance in gearing of final drive gears Main gear adjustment for tooth contact stain Front suspension Design features Maintenance Removing the upper arms and replacing their rubber bushings Removing the lower levers Removing the upper arm axle Removing the anti-roll bar Removing the front suspension strut and replacing the threaded joints Removing and installing front wheel hub Wheel bearing adjustment Removing the front suspension from the car Removing the king pin Removing the front suspension spring Shock absorber removal Checking and adjusting wheel alignment Rear suspension Rear suspension Replacing anti-skid gaskets springs Shock absorber replacement Replacing springs and rubber bushings Power steering Design description Steering gear oil change Steering adjustment Removing and disassembling the steering column Removing and installing steering gear Dismantling and assembling the steering gear Checking the wear of ball joints and tie rods Removing and disassembling the steering trapezoid Dismantling and lubrication of steering link hinges Steering link hinge replacement Power steering combined with steering gear Design description Changing the working fluid (oil) and filter Bleeding the hydraulic steering system Flushing the flow and safety valves of the power steering pump Power steering pump removal Power steering removal Steering propeller thrust bearings Adjustment of the engagement of the piston-rail-shaft-sector pair Brake system Design description Bleeding the brake system, replacing the brake fluid Replacing the brake pads of the front wheels Replacing the brake disc and caliper Replacing the front brake hose Removing and installing brake drum Removing and replacing brake pads on rear wheels Replacing the brake cylinder on the rear wheel Replacing the rear wheel brake cylinder linings Replacing the rear brake hose Removing the brake master cylinder Replacing the brake master cylinder linings Removing the brake servo Removing the pressure regulator Pressure regulator actuator adjustment Removing the parking brake mechanism Replacing the parking brake cable Adjustment of the parking brake actuator Removing the foot switch Electrical equipment General information Replacing fuses and relay box Battery Engine generator ZMZ-4062 Checking the engine generator ZMZ-4062 in a car Dismantling and checking the engine generator ZMZ-4062 Replacing the engine voltage regulator ZMZ-4062 Generator 1631.3701 engine ZMZ-402 Checking the engine generator ZMZ-402 in a car Removing the generator Dismantling and checking the engine generator ZMZ-402 Replacement of voltage regulator and brush holder of engine generator ZMZ-402 Starter Starter removal Dismantling and checking the starter The ignition system of the engine ZMZ-402 Ignition timing Replacing the slider and distributor cap Removing the ignition distributor Removing and installing ignition distribution sensor assembly with oil pump drive Disassembly of the distributor sensor Replacing ignition system components Cooling fan motor Removing the electric fan Dismantling the electric fan Checking the electric fan activation circuit Removing the electric fan relay Lighting and light alarm Replacing the lamp in the main headlight Headlight removal Headlight corrector Headlight adjustment Replacing the fog lamp Fog light adjustment Removing the fog lamp Replacement of side-light bulbs, brake light and direction indicator, lamp removal Removing license plate lights and luggage compartment, replacing lamps Replacing rear fog lamps and reversing lights Removing front and side direction indicators, replacing bulbs Replacing bulbs and removing the optional brake light Removing the brake light switch Removing the interior light, replacing the lamp Removing the light switch Windshield wiper and washer Removing the electric pump and washer nozzles Removing and disassembling the windshield wiper Sound signals Removing, checking and adjusting the sound signal Replacing the horn switch Heater fan motor Instrument cluster Checking control devices and their sensors Body Design description Removing the front bumper Removing the upper front panel Removing the front mudguard and radiator trim Front wing removal Front wing position adjustment Removing the hood lock Removing and disassembling the hood Removing the hood Removing the hinges of the hood Buttonhole adjustment Bonnet adjustment Windshield removal Windshield installation Removing the dashboard console Removing the dashboard Removing heater fan and additional resistor Removing the heater radiator Removing heater distributors Heater disassembly Removing and adjusting the front seat Removing the front door lock Removing the switch (larva) of the front door lock Installation of the switch (larva) of the front door lock Removing the front door trim Removing the door with hinges Removing the front door glass Removing the front door window lifter Removing the front door seals Installing the front door seal Complete disassembly of the front door Removing the rear seat Removing the lower and fixed windows of the rear door Removing the lever and pull rods for locking the tailgate Removing the rear power window Removing the door lock Installing the door lock Removing the rear door seal Removing the front trim Removing floor mats and floor seals Removing the front rug and floor seal Removing the rear floor mat and floor seal Removing the side handrails Removing the rear shelf Removing the rearview mirror Removing the sun visor Removing the seat belt and middle pillar linings Removing the tailgate lock Removing the boot lid seal Seal installation Removing the boot lid Removing torsion bars Removing the tailgate hinges Buttonhole adjustment Trunk lid adjustment Removing the spare wheel shelf and trunk trim Removing the bottom panel of the tail Removing the fuel filler flap Removing the rear bumper Features of service and repair of the car GAZ-310221 Removing the rear interior light Removing rear light diffusers and replacing bulbs Removing the taillights Removing the additional brake light Removing license plate lights and replacing bulbs Removing the deflector lamp Removing the rear seat Removing the optional seat Removing the rear wheel arches Removing the trunk lining Removing the tailgate lock Removing the spring mechanism of the tailgate Removing the tailgate Removing the spare wheel niche cover and its lock Removing the roof deflector and tailgate hinges Removing the rear bumper Applications A tool used in addition to the staffing Checking electrical circuits Tightening torques for threaded connections Dimensions of interfaced engine parts ZMZ-4062 Automotive rolling bearings Balls Rollers (needles) Electrical circuit with engine ZMZ-402 The scheme of electrical equipment with an engine ZMZ-4062 The scheme of the engine control system ZMZ-4062 Lamps used in the car Spark plugs Used fuel, oil and operating fluids Reinforced rubber cuffs for shafts (oil seals) Dimensional groups for the ZMZ-4062 engine

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GAZ 3110 Volga / 310221 Volga since 1981, service e-manual (in Russian)