The Zavolzhsky Motor Plant (ZMZ) was among the first to produce car engines with an injection power system. The four-cylinder engine ZMZ 405 is a successful representative of this category; it is installed on the Gazelle car. Replacing the fuel pump on time allows the engine to operate efficiently and reliably for a long time.
More than 16 years have passed since this engine was first installed on a car. The manufacturer positions it as an engine for small trucks and buses, and it is installed on such vehicles as “Gazelle”, “Sobol”, etc. The engine operates unpretentiously and handles difficulties on the road with confidence. The unit is designed simply and replacing the fuel pump on a Gazelle 405 can be done independently by a driver with minimal experience in an ordinary garage. The same can be said about repairing the fuel system.
Vehicle 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;
- gasoline pump.
The fuel tank capacity is 64 liters. The filling hole is located on the left side and is connected to the tank using a rubber tube. At the entrance to the hole, there is a check valve inside that prevents fuel from leaking out. The tank is secured with clamps and brackets to the side members. When installing clamps, cardboard gaskets are made between them and the walls of the tank.
The neck is closed with a stopper. The space in the tank above the surface of the fuel is connected to the atmosphere by a two-way valve, which allows air to pass through as the liquid level decreases or releases pressure if the ambient temperature becomes higher. The valve is mounted on the neck of the tank and connected to the vent fitting using a plastic tube. The fitting is secured with a threaded connection at the top of the tank.
The car fuel system module is installed in the tank, the fuel pump can be easily replaced. The Gazelle minibus combines a module with a fuel level indicator. Fuel liquid comes from the fuel tank and is passed through a filter mesh that is installed on the fuel pump.
The fuel pipes are made of brass. The tubes interact with the tank, sediment filter, fuel pump, and fine filter. For connections, union nuts, clamps, conical couplings and fittings are used. A pipeline for draining residual fuel from the carburetor improves the functioning of the power system and allows you to start a hot engine in hot weather.
The aluminum fuel rail is needed to transfer fuel fluid to the injectors and is attached to the inlet pipe with two bolts. A brass fitting is connected to the fuel supply pipeline and is installed in the front part of the ramp.
How does a car behave with a faulty fuel pump?
Before we begin, it is necessary to make a small digression. No one can deny the fact that the fuel pump in a car’s design is one of the most important elements. Without which the car will not function, and malfunctions will lead to unstable engine operation.
It is worth noting that gasoline pumps can be divided into mechanical and electric. However, this article will not discuss mechanical fuel pumps due to the fact that they were used on older cars and cannot be found in modern cars.
How does an electric fuel pump work?
In the Photo: submersible fuel pump with a disassembled glass
Operating a car fuel pump
As we have already found out, a gas pump is a simple and unpretentious device. However, due to its compact size and high load, the pump requires special conditions for its operation. Firstly, its durability depends on the quality of the fuel, or more precisely on its cleanliness and the performance of the filtering system. Therefore, refueling with dirty, poor quality or contaminated fuel should not be allowed. Any specks of dust or particles can affect the integrity of the mechanisms.
To do this, it is necessary to regularly inspect fuel filters and screens that do not allow foreign elements to pass through. In addition, modern cars use submersible pumps, which are located directly inside the tank and are cooled by the fuel itself. Therefore, it is unacceptable to operate the car on an empty tank; overheating will certainly cause pump failure.
Symptoms of malfunction
Firstly, failure to comply with the rules for cleanliness, quality and availability of fuel in the tank will lead to pump failure, but other malfunctions associated with the fuel pump may also occur. But first, you need to understand the symptoms that will indicate a fuel pump failure.
First of all, you should pay attention to the unstable operation of the motor. The reason for this may be insufficient pressure in the fuel system due to the pump. At the same time, the car may gradually lose power or drive sharply, either normally or not at all.
Another sign of a malfunction or imminent breakdown of the fuel pump is the appearance of noise in the rear of the car. Strong buzzing sound from the fuel pump. Especially when you turn on the ignition, this is the first signal to replace it. Moreover, if you didn’t even pay attention to his work before.
In the Photo: The process of replacing a submersible fuel pump
Another sign of unstable operation is problems starting the engine. However, in such a situation there can be many reasons. From problems with the wiring of the entire car, to a malfunction of the motor itself or the electronic part of the control unit.
And the main sign of a malfunction is the complete inability to start the car, and complete silence in the fuel tank area when the ignition is turned on and attempts to start the engine.
How to find a breakdown
To start troubleshooting, you will have to know the entire structure of the fuel system. After all, a breakdown can occur not only in the fuel pump, but also in other elements of the fuel system. The entire fuel supply circuit consists of: a fuel tank with a fuel pump, fuel carrying pipes and hose, a fuel filter, injectors or other injection system and a return circuit of the fuel system.
If there is a suspicion of a drop in pressure in the fuel system, then the malfunction could occur in one of these elements. Next we will briefly go through each of them.
Fuel tank
In most modern cars, the fuel tank is a sealed container with a pressure release valve. However, the pressure in the tank is maintained and helps the entire system operate. But there are cases when the valve in the tank cap stops functioning normally and pressure disappears in the fuel tank or excess pressure accumulates. In this case, the entire system may not work correctly.
In addition, the tank may leak due to damage or corrosion. In this case, in addition to increased consumption and loss of pressure in the tank, there is a high probability of fire.
Fuel pump malfunction
The device itself can fail for a number of reasons:
• The gasoline pump has already exhausted its service life and the membrane with all its elements is not capable of pumping the required amount of fuel and maintaining the nominal pressure in the system.
• The valve responsible for maintaining constant pressure in the fuel system has failed and is constantly leaking fuel. Because of this, the engine does not receive enough gasoline and power decreases.
• The clogged mesh at the inlet to the fuel pump has become very dirty and has stopped passing a sufficient amount of fuel. In this case, in addition to reducing engine power, the fuel pump itself begins to work with increased load, which leads to rapid breakdown.
In the Photo: Filter mesh clogged with various dirt
• Also, the electrical wiring to the fuel pump may be damaged, or the contacts on the terminals of the device itself may be oxidized. But first of all, you should check the fuse in the cabin unit. If you successfully replaced the fuse with a new one, and it burned out again, you will have to carefully check the electrical wiring.
In this case, it is better to go to a service station and stop worrying about the problem, the specialists will do everything on their own, but while you are not able to move around in your own car, you can contact a car rental - https://avto-prokat.spb.ru/ with great choice of cars.
Also, it makes sense to pay attention to the injectors and fuel pipes. Remember that, first of all, fuel leaks should not be allowed; this fact can, and most likely will, cause a car fire. In other cases, these elements are checked for contamination, but the fuel pipes are extremely rarely contaminated.
How to check the fuel pump
We have already found out that problems with the fuel system can arise for many reasons. However, most often the cause is the fuel pump. But modern pumps cannot be repaired or are difficult to repair. Therefore, it is customary to replace them as an assembly, sometimes even complete with a glass in which the pump is installed.
The role of the fuel pump
The injection of fuel fluid and determination of the amount of gasoline entering the heating system depend on the normal operation of this small device. In modern Gazelle cars, replacing the fuel pump, which is an electrical device, occurs after removing the upper protective cover.
The gasoline pump serves to provide low pressure by pumping fuel with a manual lever. If the pump is of a diaphragm type, then gasoline is supplied to the carburetor (K-) through the fuel channels. The gasoline pump facilitates the uninterrupted supply of fuel to the carburetor in outdoor air conditions from + 50ºС to -40ºС, which allows its effective operation in different temperature zones. If the supply of gasoline is disrupted, the gasoline pump is replaced. The Gazelle 406, whose carburetor is suffering from a faulty device, is taken to the workshop for repairs.
The fuel pump is fastened with nuts through a gasket, tightening is done evenly on all sides. If gasoline leaks along the diaphragmatic perimeter, then the operation of the gasoline pump can be considered dangerous due to the possibility of pump failure and diaphragm delamination.
If it is not working properly, it 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. Next, gasoline under pressure enters through the fuel pipeline, passing through the filter into the ramp.
Design and features
The 406 engine (carburetor) runs on gasoline. It has 16 valves and 4 pistons. The injection is regulated by a built-in electronic system.
During the creation of this power unit, the manufacturer decided to highlight it and add features. This can be considered the location of the shafts at the top of the cylinder block. The spark plugs are located in the center. Through the use of a new injection system and combustion chamber, the compression was increased to 9.3. The carburetor-type power supply system was also replaced.
Due to some manipulations, fuel consumption was reduced. However, there were rumors that the power of one model of the Volga car (the 406 engine was also installed on it) was deliberately and artificially increased.
Diaphragm fuel pump
Powered by camshaft eccentrics. Consists of separate prefabricated housing mechanisms with actuating lever and diaphragm. The pump valve contains a zinc holder, a rubber valve, and a brass plate, expanded by a bronze alloy spring. To filter the fuel, a brass mesh filter is installed above the pump valves.
If the engine is not running, you can fill the carburetor with fuel using the hand lever. To prevent the ingress of gasoline, the device is equipped with a mesh filter. If fuel stops being pumped, the fuel pump is replaced. "Gazelle" Business 4216 type with a carburetor allows for easy replacement, since the device is located outside the fuel tank.
The main causes of fuel pump failure
The coarse filter is clogged
Old and new fuel pump coarse filter
A clogged filter is brown in color because its cells are completely clogged with sediment.
The most common problem that causes the fuel pump to not pump is a clogged coarse filter. This filter is usually installed in the tank immediately before supply to the pump itself. This is where primary fuel filtration occurs. This malfunction can be determined visually. A clogged filter is brown in color; the cells in its mesh are almost completely clogged with sediment. Even a working pump cannot pump fuel through such a filter; as a result, the required pressure is not provided in the system. The coarse filter must be replaced. Its cost is low (about 50 rubles). However, replacing it takes time and a set of tools. First you need to remove the fuel pump itself, which is usually screwed to the tank. Before removing the fuel pump, you need to disconnect the terminal on the battery. Then the fuel pump is removed and the filter is removed from it. The filter itself is installed on the pump manually, without tools. It is recommended to change the coarse filter every 20 thousand. However, it can become clogged much faster. This depends on the quality of the fuel and the condition of the fuel tank. It only takes one refuel with low-quality fuel at an untested gas station to clog the filter. It can also easily become clogged with rust if the tank is already old and susceptible to corrosion.
Incorrect operation
An electronic fuel pump can be installed in the engine compartment.
If there is a small amount of gasoline in the tank, the electronic fuel pump quickly overheats.
Unlike a mechanical pump, which is installed on carburetor engines, an electronic one can fail due to improper use. The electronic pump becomes very hot during operation. It is cooled by the fuel in the tank. Therefore, with a small amount of fuel, the pump may overheat. At the same time, short-term operation with a practically empty tank is not critical for the pump. If you constantly operate the car with an almost empty tank, the fuel pump will overheat and quickly break down. It is recommended to keep the tank at least one third full at all times. Especially often, the fuel pump breaks down due to overheating on cars with gas equipment. Here, gasoline is used only to start the car, then gas is used for operation. As a rule, owners of such cars keep a small amount of gasoline in the tank. In this case, the fuel pump constantly works to maintain a certain pressure in the fuel rail. If there are only a few liters of gasoline in the tank, the fuel pump quickly overheats.
Wear
The fuel pump contains rotating parts that are subject to friction. Over time they wear out. Therefore, if the fuel pump is making a loud noise, it is advisable to replace it. The operation of the fuel pump should not be heard from inside the car when the engine is running. A pump that is too worn can jam over time and stop pumping fuel. To find out how to replace the fuel pump, you need to look at your car's manual. In mechanical gasoline pumps, the membranes wear out quickly, especially if they are of poor quality. As a result, traction is lost and the engine runs unstable due to a lean mixture. Mechanical pumps especially often break down in the summer due to overheating. Therefore, an electric low-pressure fuel pump is often installed for the carburetor, which is connected to the fuel line, instead of a conventional mechanical one. This avoids problems in the summer when the mechanical pump stops pumping. In addition, the car's dynamics are improved, since the electric pump allows fuel to be supplied to the carburetor at constant pressure.
No power to fuel pump
The reason for the lack of power to the fuel pump may be oxidized terminal contacts
Fine fuel filter
It is placed in front of the carburetor on the engine and contains a housing design made of a rubber sealing sleeve, a gasket, a ceramic or thick paper filter, a cup-shaped sump, a spring and fasteners.
To limit the release of toxic gases into the surrounding atmosphere, the vehicle is equipped with a system for recirculating gases obtained as a result of exhaust gases. Part of the exhaust gases is recycled by entering the engine from the outlet. Recirculation of exhaust gases occurs when the engine is heated to a temperature of up to 40ºC at partial overload.
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Gazelle EURO 3 won't start
Customers often have a question: why not with the ZMZ 40524 engine with EURO 3 toxicity standards.
As soon as the car plant on the Volga began to equip its cars with EURO 3 engines, the first problems immediately arose:
won't start when cold ,
problems with hot starts, intermittent operation, variable speed, etc. Initially, MIKAS 11ET engine control units were equipped with software version 22, which did not justify itself at all. Then firmware version 32 came out, then version 52. Now most have firmware 32.
Doesn't start when cold
Let's start looking at the problems of EURO 3 with a “cold start” of a Gazelle car equipped with a ZMZ 40524 engine with an electronic gas pedal.
Trying to start a Gazelle in the morning turns into torture for the driver. It either starts the first time - just luck - or it catches on and immediately stalls, or it starts, but the revolutions jump from 400-500 to 1500-2500, and the last option - you can drain the battery, but not start
In most cases the reasons are:
At the initial moment of starting, the starting current of the starter is so high that the voltage on the battery drops to 5-6 Volts. This only lasts a few milliseconds, but this is enough for the engine control unit to reset. If a remote ground switch is installed, this increases the chances of it not starting. Resetting the ECU results in error 1602 being written to it (resetting terminal 30 or turning on the controller for the first time), all adaptation settings are reset, and the control unit begins to recheck all sensors, including the throttle valve assembly (the characteristic sound of the valve moving ), while turning off the fuel supply.
Replace the battery with a more powerful one (not less than 72-75 A/h);
Clean and tighten all power wires (terminals on the battery, body and engine ground, all connections on the remote ground switch, power wire on the starter)
If possible, replace the old-style starter with a more modern one, with a planetary gearbox (with the same torque it consumes less current)
The next problem is starting a hot engine.
Due to a faulty fuel pressure regulator located in the fuel pump module and due to the fact that the fuel rail is a dead end, a vapor lock may form in it. It pushes the fuel back into the gas tank. When you try to start, vapors enter the combustion chamber through the nozzles, which leads to instability of the engine. You have to repeat the start several times until the gasoline vapors are completely replaced by full-fledged fuel.
Fuel pump location
The gas pump of the Gazelle car with an injector engine is not installed separately, but as a side in the gas tank. This arrangement successfully combines the operation of the devices and increases the efficiency of individual elements of the unit. The fuel pump, remaining immediately behind the filter, draws fuel directly through the pump screen, increasing the degree of fuel purification. Installation and maintenance of the fuel level sensor becomes more comfortable, since the wires to the gas tank and to the pump pass in one place.
The key to high-quality operation of the fuel system is a flawlessly operating Gazelle fuel pump. Installation 402 of the system will allow fuel to be supplied in the required volume at a certain time.
Filter Features
The fuel entering the engine is purified through two elements. The first (cleaner-sump) is located next to the gas tank. It retains large debris, dirt and water, which collects in a special removable glass at the bottom. The fine filter is installed in the gap in the hose in front of the carburetor. It is designed to trap smaller dirt particles: the fuel passes through a special cardboard enclosed in a plastic cylinder.
On injection engines, fuel is purified through a filter located on the pump intake pipe. It is a thin flat metal mesh. It effectively traps dirt and debris that gets into the gas tank.
Troubleshooting and repair
Failure of the pump or its inadequate operation leads to malfunctions of the engine or other systems and components. The operational condition of the Gazelle vehicle depends on the prompt execution of repairs. Replacing the fuel pump is an effective way to restore your car.
To determine whether it is worth replacing the pump, or whether it is sufficient to repair it, the operation of the device is diagnosed and faults are identified. The most common symptom of improper operation is intermittent operation of the motor and jerky movement of the machine. Another sign is a long winding time, with the standard speed starting from a half turn. This sign indicates a deterioration in performance and 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 reason for the inoperative condition is a drop in pressure in the fuel system, and it is the faulty pump that affects this.
An instrumental check of the fuel pump is carried out using an indicator sold in a specialized store. To find out whether the fuel pump is to blame for the pressure drop or whether the pressure regulator, injectors or other devices are not working, install an indicator on the fuel pump. Mount the device in accordance with the attached instructions, turn off the engine and wait about 10 minutes. If after this a significant decrease in pressure is detected, then the fuel pump is working.
Characteristic
It is worth noting that this unit bypasses the previous engine of the 402 series in some respects. The 406 power plant runs on 4 pistons. Its power is 110 “horses”. It is difficult to say for sure whether this engine is overheating, because some drivers report a constant rise in temperature, while others say that the cooling system is superfluous - the unit does not heat up.
If you want to convert your 406 engine (carburetor or injection) to gas equipment, then you should note that it gets along well with propane and methane.
It is difficult to highlight the issue of fuel consumption - it directly depends on driving conditions and the time of year. According to the characteristics stated by the manufacturer, consumption is on average 13.5 liters per 100 km. Engine capacity – 2.28 liters.
In the external environment, it is necessary to note the compact arrangement of all elements. A special feature will be the location of the spark plug - in the center. The maximum rotational power of the crankshaft is 5200 rpm.
Detecting a fuel pump malfunction using a pressure gauge
Using this device, it is determined whether the fuel pump needs to be replaced. The Gazelle is checked for changes in pressure in the fuel network. The help of specialists is not required in this case either. The pressure gauge is connected to the injector frame and secured 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 shows the pressure created 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 changes in pressure. It is considered normal that if the pressure remains normal, the fuel pump does not need to be repaired.
In another case, the car stalls, the problem is electrical. The test involves connecting a test light to the relay with the ignition on. After this, it lights up for a few seconds. Leaks are detected at low pressure. If the reason for the machine's inoperability is fuel leakage, then the fuel pump is replaced. Farmer's Gazelle will have to be taken to the workshop for repairs.
Before determining whether the fuel pump needs to be replaced, the Gazelle 406 is checked for proper 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 we are talking about a submersible pump.
How to remove the fuel pump
We add that the fuel pump mount may differ on different cars, although the general principle remains almost the same.
Before removing the fuel pump, you must first relieve the pressure from the power system!
You can do this as follows:
- turn off the negative voltage on the battery;
- on the fuel rail under the hood, press the valve through which a certain amount of gasoline will flow out;
You can also go the other way. First, remove the terminal from the battery, then turn off the power to the fuel pump by removing the electrical connector from it. Then the terminal is put back on the battery and the engine is briefly turned with the starter. After a short period of time, the remaining fuel will leave the system. On some cars, the engine may even start and then stall.
So, the fuel pressure has dropped, now we proceed to remove the fuel pump. Remember, the terminal on the battery must be disconnected during work! The first thing to remove from the pump is the chip (electrical connector), if this has not been done previously
Then you need to pay attention to the fuel lines (1 fuel supply pipe and 1 return line to return fuel to the gas tank). On the indicated tubes, loosen the tightening of the clamps and clamps (if any), which are usually used to secure the electrical wiring sections to the lines to supply power to the pump
How to remove the tube from the fuel pump
Now you need to remove the lines themselves from the fuel pump. To figure out how to remove the hose from the fuel pump or disconnect the line, you need to accurately determine the method of attachment to the pump terminals. Often, the standard fastening of the fuel supply line is implemented in the form of a nut (fitting), which must be unscrewed with an open-end wrench. The so-called return line can be secured with a clamp.
If the vehicle has an unknown service history and the pump has previously been removed, then the mount may be non-standard or homemade.
Removing the fuel pump and replacing
After unscrewing the fuel lines, you will need to either unscrew the pressure ring of the fuel pump with a special puller, or use a tubular wrench to unscrew the nuts (which depends on the method of mounting the fuel pump on a specific car model).
- Before starting removal, it is worth noting that there are special arrow indicators on the pump and other fixing elements. We recommend remembering their position, which will facilitate subsequent reassembly.
- Then you need to remove the special o-ring. After removing the ring, you can remove the fuel pump from the tank. During removal, care must be taken, since devices for determining the fuel level in the gas tank (float sensor) may be attached to the fuel pump body.
- After removing the pump, there may be a rubber seal on its seat. For example, on cars of the VAZ family this seal is fixed on studs. This seal also needs to be removed by simply pulling it up.
The completion of the fuel pump replacement procedure is the installation of a new fuel pump, as well as the replacement of all rubber seals, which must be included in the kit or purchased separately.
We would like to add that during installation you should:
- Make sure that the pump is positioned correctly. To do this, there are special arrow-shaped markers on the pump itself, covers and pressure rings (depending on the make and model of the car). On some cars the arrows should line up, on others the arrow on the fuel pump should point towards the rear of the car. It is for this reason that it was recommended above to remember the position of the indicated arrows before removal.
- Also, in the process of placing the pump, you should carefully handle the float and other solutions to determine the fuel level in the gas tank. Often, during unprofessional installation, such elements are bent or broken, after which there is a need to replace them.
After installing the new fuel pump, reassemble it in the reverse order. All fastening elements should be tightened to the permissible torque.
If the fasteners are over-tightened, they may break. If the fuel pump fixing elements are not tightened enough, then the pump may dangle in the tank, which is unacceptable. After the pump is installed, all that remains is to attach the fuel lines back, connect the pump power connector and the terminal to the battery. This is what replacing a fuel pump with your own hands looks like.
Filter contamination detection
The mesh is removed after first removing the lid; if it is dirty, it is cleaned and washed. If the mesh is very worn, it is replaced. Electric pumps are structurally more complex; they are used in the Gazelle car. Replacing the fuel pump and filter in the tank is sometimes done at the same time. To do this, buy a special repair kit.
A dirty filter causes jerking when the car picks up speed and causes a decrease in engine power. The inability of the grid to pass fuel affects the operation of the electric motor, which operates under increased loads. As a result, plastic parts fail and moving parts wear out. Determine if the mesh is clogged by listening to the sounds of the fuel pump. Compared to the standard state, it produces additional sounds and noise. Before the fuel pump is replaced, the Gazelle is completely de-energized and the engine power supply system is turned off.
Why doesn't the gas pump pump pump?
Zavolzhsky Motor Plant is the main supplier of engines for Volga and Gazelle cars.
The engines of this enterprise have long been known to Russian car enthusiasts and engine technicians. Good maintainability, simplicity of design and reliability of the main systems deservedly place these engines among the best domestic engines. In addition, at the end of the 90s of the twentieth century, the plant designed and installed a distributed injection system on these engines. It is these engines, in particular the ZMZ-405, that are installed on light-duty Gazelle trucks, Sobol minibuses and their modifications. Of course, the injection system has complicated work and repairs, but engine maintenance does not raise any special issues. The same can be said about the repair of the fuel system of Gazelle and Sobol cars.
Selecting a filter element
The main problem is the lack of initial experience and basic knowledge to repair a Gazelle car. It is much more efficient to replace the fuel pump and filter yourself, since official dealers in specialized workshops sometimes change the filter element without paying due attention to cleaning the separator flask.
The problem with a damaged filter is wear in the center of the injector and fuel draining in the opposite direction. The nozzle is washed away by grains of contamination arriving under high pressure, a phenomenon reminiscent of the operation of a sandblaster. If you use filter elements of poor quality, then if they are poorly maintained, 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 hang loose, causing unclean fuel to be sucked in. Sometimes new meshes 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 low-quality one, look at the joint of the filter. A pink stripe should be visible on it. This may be an active substance for gluing or an element indicating the rate of hardening; in any case, such a sign indicates that the filter has been tested for quality in the factory.
When should you check your fuel pump?
It is necessary to check all potentially faulty components one by one, and the fuel pump first.
Problems when starting and running the engine are not always associated with the fuel pump. Sometimes the signs of a fuel pump breakdown are the same as those of a faulty fuel pressure regulator , injectors or jets, spark plugs and high-voltage wiring. Even experienced specialists who know by heart all the signs of a “dying” pump cannot unambiguously determine the type and cause of the breakdown the first time, and it is necessary to check all potentially faulty components one by one. In this case, the fuel pump is usually checked first. In this case, there are two types of malfunction - the fuel pump does not work at all or does not produce the required pressure. In the first case, the malfunction can be recognized by ear, since it should start when the ignition is turned on. In the second case, you need to know how to check the pressure of the fuel pump. Here you need to use a special pressure gauge. We list the main symptoms of a fuel pump malfunction:
Procedure for replacing the filter element
Before starting work, turn off the fuel heating using a wrench and disconnect the line fitting. By unscrewing the small valve at the bottom of the tank, the gasoline is drained from the separator flask. After this, disconnect the fuel heating connector in the separator of the Gazelle car. Replacing the fuel pump, a photo of which, like the filter, can be seen in the catalog, is done independently, without the involvement of a specialist.
After unscrewing the threaded 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 installed 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, the new rubber ring is treated with oil. This will help you easily insert the lid with a little pressure and screw it in until it stops.
Pump the fuel; the procedure involves pressing the button several times until it stops giving way. If diesel fuel was not previously poured into the flask, then press for several minutes to completely pump. Check the operation of the machine's factory. Sometimes the engine runs smoothly right away, but there are cases of short breaks until excess air leaves the system.
In conclusion, it should be noted that 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.
Where is the fuel pump relay located on Gazelle 405
During operation of the submersible gas pump on the Gazelle, the following electronic relays, main relay, fuel pump relay, power control unit and fuses protect this electronic circuit. In addition, if the car is equipped with an anti-theft system, then another relay will be added to the circuit, which will cut off the supply to the fuel pump terminals.
And these Gazelle petrol cars still run on petrol and have an electronic circuit for the gas pump and an additional relay will be installed to turn off the gas pump when the engine switches to gas.
Therefore, the search for defects associated with a non-working gas pump on a Gazelle should begin with checking the integrity of the fuses. It is also necessary to check the condition of the contacts for oxidation. Next, we check the operation of all the relays used on this unit in the electronic circuit to supply voltage to the fuel pump terminals. If this doesn't help, you need to check the wiring harness and connectors from the electrical control unit to the main relay and the fuel pump relay.
Another common condition for fuel pump failure is the oxidation or burnout of the negative terminal located on the fuel pump inside the tank. There is a white block, but don't confuse it with the gas tank side. Typically, this malfunction initially manifests itself as the gas pump repeatedly turning on and off. If this problem occurs, you must periodically clean these pins by removing the module by other means, and reconnect them permanently, bypassing the terminal.
Sometimes the driver is often unable to find the faults associated with the malfunction when the submersible fuel pump is running on the gazelle, and a competent auto electrician is required to solve this problem.
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The fuel pump start relay is located in the relay block located in the right rear of the engine compartment. It is used to control the operation of the electronic fuel pump. For example, the relay breaks the pump power circuit if the engine stops when the ignition is turned on.
To start the fuel pump with the engine stopped, you need to remove the relay and close contacts 30 and 87 to a connector with a small wire 1.5 mm in diameter. On 520i / 525i / 524td models the fuel pump relay is brown, on 530i / 535i models it is orange.
Caution: The battery must be charged when testing the relay to activate the fuel pump.
Check fuse No. 23.
Connect a voltmeter to pins 30 () and 85 (-) on the relay connector. The voltage should be around 12 V.
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If not to that extent. connect a voltmeter to terminal 30 and ground. If the voltage here is around 12V, check for the presence of the brown-green wire according to the wiring diagram. If it is not damaged, check the reddish wire and replace if necessary.
Turn on the ignition. Connect a voltmeter to terminal 86 () and ground. The reading should be approximately 12 V. Otherwise, check that the circuit is not an electrical wire and replace it if necessary.
Check the output signal of the engine speed/angle sensor (to do this, contact a service station).
Cover terminals 30 and 87 using short jumpers. If the pump starts, replace the relay. Otherwise, check for the green or purple wire if necessary.
If the wire is OK, replace the fuel pump.
405 GAZelle Electric articulated motor
Zavolsky Motor Plant (ZMZ). one of the first Russian automobile engine manufacturers to begin producing engines with an injection system. One such high quality engine today is called the ZMZ 405, a four-cylinder engine that has been running for almost 15 years. This type of engine first appeared on the market back in 2000, installed on the GAZ-3111. The plant itself positions the engine as an engine for trucks and minibuses. It is set for them. Various vehicles in the GAZelle and Sable injector ranges have such engines.
The ZMZ 405 has proven itself to be a good, demanding engine in the past, ready for even the toughest highway testing. The 405 motor is capable of withstanding enormous loads without affecting its service life. Also, the extraordinary simplicity of the design of the device is inherent in the design of the engine. for repair and maintenance. This engine, installed on any car, can be used by anyone in a regular garage with minimal knowledge, which remains for our client according to the attached book, no questions asked. This also applies to the repair of the fuel metering software. Namely, the engine injector fuel pump is not difficult to repair without outside help.
The GAZelle gas pump with the 405 engine, as in the main part of the injection machines, is not made without outside help, since the unit is located in the gas tank. This includes:
This assembly saves space under the hood of the GAZelle 405 injector and increases the efficiency of each element of the block. For example, a filter cleans fuel even better because the gasoline pump is located immediately after the filter and supplies gasoline under pressure through the filter. The advantage of a fuel gauge is that the electronic wires going to the gas tank come with the wires for the pump, making it easier to connect. By the way, the fuel level indicator. it's just a float on a steel rod. A high-quality fuel pump is the key to good operation, allowing you to keep records (software) of fuel delivery to the car. GAZelle 405 Injector: Gas must be pumped out in the right volume and at the right time.
