"Gazelle": replacing the fuel pump and filter in the tank

2024 Author: Erin Ralphs | [email protected]. Last modified: 2024-02-19 11:42

Car engines with an injection power system are among the first to be produced by the Zavolzhsky Motor Plant (ZMZ). The four-cylinder engine ZMZ 405 is a successful representative of this category; it is installed on a Gazelle car. Replacing the fuel pump, carried out on time, allows the engine to work efficiently and reliably for a long time.

It has been more than 16 years since this motor was first installed on a car. The manufacturer positions it as an engine for small trucks and buses, and it is installed on such cars - Gazelle, Sobol, etc. The motor works unpretentiously, perceives difficulties on the road with confidence. The unit is simple and the replacement of the gas pump with the Gazelle 405 can be done independently by the driver with minimal experience in an ordinary garage. The same can be said about repairing the fuel system.

Car fuel system

The Gazelle car system consists of mechanisms and devices that interact with each other to ensure movement. It includes:

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

The capacity of the fuel tank is 64 liters. The filling hole is located on the port side and is connected to the tank with a rubber tube. At the entrance to the hole, inside there is a check valve that does not allow fuel to flow out. The tank is fixed with clamps and brackets to the spars. When installing the clamps, cardboard spacers are made between them and the walls of the tank.

The neck is closed with a cork. The space in the tank above the fuel surface is connected to the atmosphere by means of a two-way valve, which lets air through as the liquid level decreases or depressurizes if the ambient temperature rises. The valve is mounted on the neck of the tank and connected to the ventilation fitting with a plastic tube. The fitting is attached with a threaded connection at the top of the tank.

The car fuel system module is installed in the tank, it is easy to replace the fuel pump. "Gazelle" minibus combines the module with a fuel gauge. The fuel fluid comes from the fuel tank, passes through a filter screen that is mounted on the fuel pump.

Fuel lines are made of brass. The tubes interact with the tank, sediment filter, gasoline pump, fine filter. For connection, union nuts, coupling collars, conical couplings and fittings are used. Piping to drain residual fuel from the carburetor improves performancepower system and allows you to start a warm engine in hot weather.

An aluminum fuel rail is needed to transfer fuel fluid to the injectors and is attached to the incoming pipeline with two bolts. A brass nipple is connected to the fuel supply line, installed in the front of the ramp.

The role of the fuel pump

The injection of fuel liquid and the determination of the amount of gasoline entering the heating system depend on the normal operation of this small device. In modern Gazelle cars, the replacement of the fuel pump, which is an electrical device, occurs after removing the top protective cover.

The fuel pump is used to provide low pressure by pumping fuel with a manual lever. If the pump is a diaphragm type, then gasoline is supplied to the carburetor (K-) through the fuel channels. The gasoline pump contributes to the uninterrupted supply of fuel to the carburetor in outdoor air conditions from + 50ºС to -40ºС, which allows its efficient operation in various temperature zones. If the supply of gasoline is disrupted, then the fuel pump is replaced. "Gazelle" 406, the carburetor of which is suffering from a faulty device, is put in a workshop for repair.

The fuel pump is fastened with nuts through the gasket, the attraction is done evenly from all sides. If gasoline leaks along the diaphragm perimeter, then the operation of the gasoline pump can be considered dangerous due to the possibility of pump failure and diaphragm separation.

In case of incorrect operationIt is recommended to replace the fuel pump. Gazelle Business is equipped with a device that turns on when a command is received from the control system and reaches a pressure of about three bar. Further, gasoline under pressure enters through the fuel pipeline, passing through the filter into the ramp.

Diaphragm fuel pump

Powered by camshaft eccentrics. Consists of separate prefabricated body mechanisms with drive lever and diaphragm. The pump valve contains a zinc clip, a rubber valve, a brass plate, expanded by a bronze alloy spring. To filter the fuel, a brass strainer is installed above the pump valves.

If the engine is not running, the carburetor can be filled with fuel using the hand lever. To prevent the ingress of gasoline, the device is equipped with a mesh filter. If the fuel stops pumping, then the fuel pump is replaced. "Gazelle" Business 4216 type with a carburetor is easy to replace, since the device is located outside the fuel tank.

Fuel sediment filter

Installed on the left side of the machine and serves to clean gasoline from mechanical debris and water. The filtered sludge is collected in the bottom drain box. A set of metal thin plates is used as a filter element.

Fine fuel filter

It is placed in front of the carburetor on the motor and contains in the construction of the body of a sealing sleeve made of rubber, a gasket, a filter of their ceramics or densepaper, cup-shaped sump, spring and fasteners.

To limit the emission of toxic gases into the surrounding atmosphere, a system for recirculating gases obtained as a result of mining is installed on the car. Part of the exhaust gases is reused by passing from the outlet to the engine. Recirculation of exhaust gases occurs when the engine is heated to a temperature of up to 40ºС at partial overloads.

Location of fuel pump

The gas pump of the Gazelle car with an injector motor is not installed separately, but as a side in the gas tank. This arrangement successfully combines the operation of devices and increases the efficiency of individual elements of the unit. The gasoline pump, remaining immediately behind the filter, draws fuel directly through the pump mesh, increasing the degree of fuel purification. Installation and maintenance of the fuel level sensor become more comfortable, since the wires to the gas tank and to the pump run in one place.

The key to the high-quality operation of the fuel system is a perfectly functioning Gazelle fuel pump. Installing a 402 system will allow fuel to be supplied in the prescribed volume at a certain time.

Troubleshooting and repair

Breakdown of the pump or its defective operation lead to malfunctions of the engine or other systems and components. The working condition of the Gazelle car depends on the prompt implementation of repairs. Replacing the fuel pump is an effective way to restore the car.

To determine if the pump should be replaced, orit is enough to repair it, diagnose the operation of the device and identify malfunctions. The most common symptom of a malfunction is an intermittent operation of the motor and jerky movement of the machine. Another sign is the long winding time, at standard half-turn start speed. This sign will indicate deterioration in performance and the fact that the fuel pump will soon fail, although it is still able to work for 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 cause of the non-working state is the pressure drop in the fuel system, and it is the faulty pump that affects this.

Instrumental check of the fuel pump is performed using an indicator sold in a specialized store. To find out if the fuel pump is to blame for the pressure drop or if the pressure regulator, injectors or other devices are not working, install an indicator on the fuel pump. The device is mounted in accordance with the attached instructions, the engine is turned off and wait about 10 minutes. If after that a significant decrease in pressure is detected, then the fuel pump is OK.

Detecting a fuel pump malfunction using a pressure gauge

Using this device, it is determined whether the fuel pump needs to be replaced. "Gazelle" is checked for pressure changes in the fuel network. The help of specialists is not required in this case. The pressure gauge is connected to the frame of the nozzles and fixed in such a position that the readings can be seen from the passenger compartment. When the ignition is turned on, the pressure gauge works and showspressure generated by the pump. Pressure from 310 to 380 kPa is considered normal. The check does not end there, they drive along the road in third gear. Pay attention to pressure changes. It is considered normal if the pressure remains normal, the fuel pump does not need to be repaired.

In another case, the car stalls, the problem is electricity. The check consists in connecting a control 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 reason for the inoperative state of the machine is fuel leakage, then the fuel pump is replaced. Farmer's "Gazelle" will be delivered to the workshop for repairs.

Before determining whether a fuel pump needs to be replaced, the Gazelle 406 is checked for the 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 mesh is provided inside the housing. Before replacing the filter, remove the fuel pump from the tank if it is a submersible pump.

Filter contamination detection

The mesh is removed after removing the cover, if it is dirty, then it is cleaned and washed. If the mesh is very worn, it is changed. Electric pumps are structurally more complex; they are used in the Gazelle car. Replacing the fuel pump and the filter in the tank is sometimes done at the same time. To do this, buy a special repair kit.

Dirty filter produces jerks when picking up speedvehicle, causing a reduction in engine power. The inability of the grid to pass fuel affects the operation of the electric motor, which operates with increased loads. As a result, plastic parts fail, moving parts wear out. Determine the clogging of the grid, listening to the sounds of the fuel pump. Compared to the standard state, it makes additional sounds and noise. Before the replacement of the fuel pump is done, the Gazelle is completely de-energized, the engine power supply system is turned off.

Selecting the filter element

The main problem is the lack of initial experience and basic knowledge for repairing a Gazelle car. Replacing the fuel pump and filter is much more efficient to carry out on your own, as official dealers in specialized workshops sometimes change the filter element, while not paying due attention to cleaning the separator flask.

The problem of a damaged filter is the wear of the center of the nozzle and the fuel drain in the opposite direction. The nozzle is eroded by particles of pollution coming under high pressure, the phenomenon resembles the work of a sandblaster. If you use poor quality filter elements, then with poor care you will have to change the fuel system, which is an expensive repair. Some low-quality filters are equipped with weak rings that fall off or dangle, because of which uncleaned fuel is sucked in. Sometimes new meshes of poor quality do not provide the desired degree of filtrationgasoline or have a sparse structure.

In order to distinguish a good filter from a low-quality filter, look at the filter joint. It should show a pink stripe. It can be an active substance for gluing or an element showing the speed of solidification, in any case, such a sign indicates the quality check of the filter at the factory.

Procedure for replacing the filter element

Before starting work, turn off the fuel heating with a wrench and disconnect the line fitting. Having unscrewed a small valve at the bottom of the tank, gasoline is drained from the separator flask. After that, we disconnect the fuel heating connector in the separator of the Gazelle car. Replacing the fuel pump, the photo of which, like the filter, can be viewed in the catalog, is done independently, without the involvement of a specialist.

Having twisted the screw cap, pull out the filter. It may be completely or partially contaminated. Inspect the separator flask, at the bottom of which large and small particles of contamination can be found. To remove them, use a lint-free cloth and tweezers.

The new filter is placed until a slight click is heard. About a liter of prepared diesel fuel is poured into the separator so that there are no problems with pumping the system. Before putting on the separator cover, a new rubber ring is treated with oil. This will help to easily insert the cap with a little pressure and screw it all the way in.

Fuel is pumped, the procedure is several pressures onbutton until it stops responding. If diesel fuel was not previously poured into the flask, then they press for several minutes to fully pump it. Check the operation of the machine factory. Sometimes the motor runs smoothly right away, but there are cases of short breaks until the excess air leaves the system.

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