"Gazelle": replacement of gasoline pump and filter in the tank

Engines of cars with an injector power system among the first start to produce Zavolzhsky factory of motors (ZMZ). Four-cylinder engine ZMZ 405 is a successful representative of this category, it is installed on the car "Gazelle". The replacement of the gasoline pump, carried out in time, allows the engine to work properly and reliably for a long time.

Since this engine was first installed on a car, it has been more than 16 years. The manufacturer positions it as an engine for small trucks and buses, such cars are put on such cars - Gazelle, Sobol, etc. The motor works unpretentiously, it perceives difficulties on the road confidently. The unit is arranged simply and the replacement of the gasoline pump on the "Gazelle" 405 can be performed independently by the driver with minimal experience in an ordinary garage. The same can be said about the repair of the fuel system.

Fuel system of the car

The system of the car "Gazelle" consists of mechanisms and devices interacting with each other to ensure a course. It includes:

• fuel tank;
• carburetor;
• A coarse and fine filter;
• gasoline pump.

The capacity of the fuel tank is 64 liters. The hole for pouring is located on the left side and is connected to the tank by means of a rubber tube. At the entrance to the hole, inside there is a non-return valve, which does not allow fuel to flow out. The tank is fixed with clamps and brackets to the longitudinal members. When installing the clamps, between them and the walls of the tank are made cardboard pads.

The neck is closed with a stopper. The space in the tank above the fuel surface by means of a two-way valve is associated with an atmosphere that passes air as the liquid level decreases or releases pressure if the ambient temperature becomes higher. The valve is attached to the neck of the tank and connected to the vent by means of a plastic tube. The fitting is screwed to the top of the tank.

The fuel system of cars is installed in the tank, the petrol pump is easily replaced. "Gazel" minivan combines the module with the device of the fuel level reading. The fuel fluid comes from the fuel tank, is passed through the filter net, which is mounted on the fuel pump.

The fuel pipelines are made of brass. Tubes interact with the tank, filter-settler, gasoline pump, fine filter. For connection, use nakidnye nuts, tie clamps, tapered couplings and fittings. The pipeline to drain fuel residues from the carburettor improves the functioning of the power system and allows you to start the heated engine in hot weather.

The aluminum fuel rail is needed to transfer the fuel liquid to the injectors and is attached to the incoming pipeline using two bolts. The brass connector is connected to the fuel supply line, installed in the front part of the ramp.

The role of the gasoline pump

From the normal operation of this small device depends on the injection of fuel liquid and the determination of the amount of incoming gasoline into the heating system. In modern cars "Gazelle" the replacement of the gasoline pump, which is an electrical device, occurs after removing the upper protective cover.

The petrol pump serves to provide low pressure by pumping the fuel with a manual lever. If the pump is diaphragm type, the gasoline is fed to the carburetor (K-) through the fuel channels. The fuel pump facilitates the uninterrupted supply of fuel to the carburettor in outdoor air conditions from + 50 ° C to -40 ° C, which allows its efficient operation in various temperature zones. If the supply of gasoline is violated, the petrol pump is replaced. "Gazelle" 406, the carburetor of which suffers from a faulty device, is put in a repair shop.

Fastening of the gasoline pump is carried out by nuts through the gasket, the pull is made evenly from all sides. If there is a leak of gasoline along the diaphragm perimeter, the work of the gasoline pump can be considered dangerous because of the possibility of pump breakage and diaphragm stratification.

If improper operation is recommended replacement of the gasoline pump. "Gazelle" Business is equipped with a device that is activated when the command comes from the control system and reaches a pressure of about three bar. Next, gasoline under pressure comes through the fuel line, passing through the filter into the ramp.

Diaphragm fuel pump

Operates from camshaft cams. It consists of separate assembled mechanisms of the body with a drive lever and diaphragm. The pump valve contains a zinc holder, a rubber valve, a brass plate sprung with a spring of bronze alloy. To filter the fuel, a brass strainer is installed over the pump valves.

If the engine is not turned on, the carburetor can be filled with fuel using a hand lever. To prevent the ingress of gasoline, the device is equipped with a screen filter. If the fuel stops pumping, then the petrol pump is replaced. "Gazelle" Business 4216 type with carburetor assumes an easy replacement, since the device is located outside the fuel tank.

Sump filter for fuel

It is installed on the left side of the machine and serves for cleaning gasoline from mechanical debris and water. The filtered sludge is collected in the bottom drain box. As a filtering element, a set of metal thin plates is used.

Fine fuel filter

It is placed in front of the carburettor on the motor and contains in the structure of the body from a sealing sleeve made of rubber, a gasket, a filter of their ceramics or thick paper, a settler in the form of a glass, a spring and fasteners.

In order to limit the exhaust of toxic gases into the surrounding atmosphere, a recirculation system of gases produced as a result of mining is put on the car. A portion of the exhaust gas is recycled by coming from the outlet to the engine. Recirculation of exhaust gases occurs when the engine is heated to a temperature of up to 40 ° C at partial overloads.

Location of the gasoline pump

Gasoline pump "Gazelle" with a motor injector is installed not separately, but in the form of a side in the gas tank. This arrangement successfully combines the work of devices and increases the efficiency of individual elements of the unit. The petrol pump, remaining immediately after the filter, draws fuel directly through the pump grid, increasing the degree of fuel cleaning. Installation and maintenance of the fuel level sensor become more comfortable, as the wires to the gas tank and to the pump pass in one place.

The guarantee of high-quality operation of the fuel system is the faultlessly working gasoline pump "Gazelle". The installation of the 402 system will allow the fuel to be delivered in the prescribed volume at a specific time.

Troubleshooting and repair

A pump failure or defective operation leads to malfunctions of the engine or other systems and components. From the operative performance of repair depends on the working condition of the car "Gazelle". Replacing the gasoline pump is an effective way to repair the car.

To determine if it is worth changing the pump, or if it is enough to repair it, diagnose the operation of the device and detect malfunctions. The most frequent symptom of malfunctioning is the intermittent operation of the motor and the movement of the machine by jerks. Another sign is a long time of the plant, at the standard speed of starting work with a half-turn. This sign will indicate the deterioration of the work and the fact that the gasoline pump will soon fail, although it is still able to work out a certain time.

If you do not pay attention to such "bells" and continue to operate the car, then one day the car may not start. The reason for the inoperative condition is the pressure drop in the fuel system, and this is affected by the faulty pump.

Instrumental inspection of the gasoline pump is performed using an indicator that is sold in a specialized store. To find out if the pressure pump, or the pressure regulator, nozzles or other devices do not work in the pressure drop, set the indicator on the gasoline pump. Fastening of the device is done in accordance with the attached instructions, the engine is switched off and waiting for about 10 minutes. If after that there is a significant decrease in pressure, then the gasoline pump is working.

Detection of a malfunction of a gasoline pump using a manometer

With the help of this device, it is determined whether replacement of the gasoline pump is necessary. "Gazelle" is checked for changes in pressure in the fuel network. The help of specialists is not required in this case. The manometer is connected to the nozzle frame and fixed in such a position that the readings can be seen from the passenger compartment. When the ignition is switched on, the pressure gauge works and shows the pressure created by the pump. Pressure from 310 to 380 kPa is considered normal. On this check does not end, passing by on the road in the third gear. Pay attention to the change in pressure. Normally it is considered that if the pressure remains normal, the gasoline pump must not be repaired.

In another case, the car stalls, the problem is electricity. The test consists in connecting the test lamp to the relay with the ignition on. After that, it lights up for a few seconds. The leak is determined at low pressure. If the cause of the inoperative condition of the machine is a fuel sump, the petrol pump is replaced. "Gazelle" The farmer has to be put on repairs in the workshop.

Before determining whether a replacement of the gasoline pump is necessary, the "Gazelle" 406 is checked for correct operation of the filtration system. Fuel filters are placed in the engine compartment or near the gas tank. To filter the incoming fuel, a special grid inside the shell is provided. Before replacing the filter, remove the gasoline pump from the tank if it is a submersible pump.

Determination of filter contamination

The mesh is removed, after removing the lid, if it is soiled, it is cleaned and washed. If the grid is badly worn, it is changed. Electric pumps are structurally more complex, they are used in the car "Gazelle". The replacement of the gasoline pump and filter in the tank is sometimes done simultaneously. To do this, buy a special repair kit.

Filter contamination gives jerks when speed dials the car, causing a decrease in engine power. The inability of the grid to pass fuel affects the operation of the electric motor, which functions with increased loads. As a result, the plastic parts fail, the moving parts wear out. Determine the clogging of the grid, listening to the sounds of the work of the gasoline pump. Compared to the standard state, it emits additional sounds and noise. Before the replacement of the gasoline pump, the "Gazelle" is completely de-energized, the power supply system of the engine is switched off.

Selecting a filter element

The main problem is the lack of initial experience and basic knowledge for the repair of the Gazelle car. Replacement of the gasoline pump and filter is much more effective to conduct independently, as the official dealers in specialized workshops sometimes change the filter element, while not paying proper attention to cleaning the separator flask.

The problem with the damaged filter is the wear of the nozzle center and the drainage of the fuel in the opposite direction. The nozzle is blurred with particles of pollution coming under high pressure, the phenomenon resembles the work of a sandblaster. If you use filtering elements of poor quality, then with poor care, you have to change the fuel system, which is an expensive repair. Some substandard filters are equipped with weak rings that fall off or dangle, because of this, raw fuel is sucked. Sometimes new grids of poor quality do not provide the required degree of gasoline filtration or have a sparse structure.

In order to distinguish a good filter from a substandard look at the junction of the filter. It should be visible strip of pink color. It can be an active substance for gluing or an element showing the pouring rate, in any case such a sign indicates a filter check for quality in the factory.

The order of replacing the filter element

Before starting the work, turn off the fuel heating with a wrench and disconnect the main connection. Unscrewing a small valve at the bottom of the tank, drain the gasoline from the separator flask. Then disconnect the fuel preheater connector in the car separator "Gazelle". The replacement of the gasoline pump, the photo of which, like the filter, can be viewed in the catalog, is produced independently, without the involvement of a specialist.

Using a screw cap, pull out the filter. It can be completely or partially contaminated. Inspect the separator flask, at the bottom of which it is possible to detect large and small particles of contamination. To remove them, use a lint-free cloth and tweezers.

A new filter is placed until a slight click is heard. The separator is poured about a liter of cooked diesel to ensure that there are no problems with pumping the system. Before putting on the separator cover, a new ring of rubber is treated with oil. This will help to easily insert the cover with a slight pressure and tighten it until it stops.

The fuel is pumped, the procedure makes several pressures on the button until it stops giving way. If previously the flask is not filled with diesel, then press a few minutes for a complete pumping. Check the work of the machine factory. Sometimes the engine immediately works smoothly, but there are cases of small breaks, until the excess air leaves the system.

In conclusion, it should be noted that the repair and replacement of the gasoline pipeline and the filter must be carried out in a timely manner, too many subtleties of the engine depend on the correct operation of these devices.