Removing the cab GAZelle Next

Removal and installation of the cab of the GAZelle NEXT vehicle

The vehicle cab is secured by four mountings.

The front cab mountings are attached to the subframe.

Rear rubber cab cushions in the brackets — **Fig. 2.** Rear rubber cushions in the brackets.

The rear rubber cushions are installed in brackets that are bolted to the frame side members.

Access to the rear mounting bolts is through openings in the cab floor that are closed with plugs.

Important: the following tools are required to remove the cab: 8, 10 and 13 mm sockets, 19 mm spanners and TORX T25, a 6 mm hex key, a set of screwdrivers, pliers, and a lifting mechanism with a lifting capacity of at least 500 kg.

We place the vehicle over the inspection pit.

We disconnect the negative battery terminal.

We remove the air filter.

We remove the battery.

**Fig. 5.** Draining of the coolant from the cooling system.

We drain the coolant from the engine cooling system.

**Fig. 6.** Disconnection of the hoses from the expansion tank.

We slacken the clamps and disconnect the hoses from the expansion tank.

**Fig. 7.** Disconnection of the wiring connector from the coolant level sensor.

We disconnect the wiring connector from the coolant level sensor.

**Fig. 8.** Extraction of the brake fluid from the reservoir.

We extract the brake fluid from the reservoir.

We push out the spring retainer of the clutch hydraulic line end fitting and disconnect the line from the slave cylinder.

**Fig. 9.** Disconnection of the clutch hydraulic line.

We drain the brake fluid from the brake hydraulic system (article — Brake fluid replacement and brake bleeding).

**Fig. 10.** Disconnection of the wiring connector from the brake fluid level sensor.

We disconnect the wiring connector from the brake fluid level sensor.

**Fig. 11.** Disconnection of the vacuum hose from the brake servo non-return valve.

We disconnect the vacuum hose from the brake servo non-return valve.

**Fig. 12.** Disconnection of the brake pipes from the brake hoses.

We disconnect the brake pipes from the brake hoses and withdraw the hoses from the brackets.

**Fig. 13.** Marking the position of the bonnet hinge brackets.

We mark the position of the bonnet hinge brackets.

**Fig. 14.** Slackening of the bonnet mounting bolts.

We unscrew two bonnet-to-hinge bolts on each side. We remove the bonnet.

We remove the bumper (article — Removal and installation of the wheel arch liners and bumper).

**Fig. 15.** Removal of the bumper reinforcement.

We unscrew four bumper reinforcement mounting bolts and remove the reinforcement.

**Fig. 16.** Disconnection of the hoses from the heater valve.

Having slackened the clamps, we disconnect the hoses from the heater valve.

**Fig. 17.** Disconnection of the earth cable from the cab side member.

We unscrew the bolt and disconnect the earth cable from the cab side member.

**Fig. 18.** Removal of the cooling system radiator.

We remove the cooling system radiator.

**Fig. 19.** Removal of the charge air cooler (intercooler).

We remove the charge air cooler (intercooler).

**Fig. 20.** Extraction of the power steering reservoir.

We extract the power steering reservoir.

**Fig. 21.** Slackening of the alternator field winding supply wire nut.

We unscrew the alternator field winding supply wire nut.

**Fig. 22.** Removal of the wire terminal from the «L» terminal of the voltage regulator.

We remove the wire terminal from the «L» terminal of the voltage regulator.

**Fig. 23.** Slackening of the power wire nut.

We unscrew the power wire nut.

**Fig. 24.** Removal of the wire terminal from the «B+» terminal of the alternator.

We remove the wire terminal from the «B+» terminal of the alternator.

**Fig. 25.** Disconnection of the wiring connectors from the horns.

We disconnect the wiring connectors from the horns.

Slackening of the power steering heat exchanger bolts on the left — **Fig. 26.** Slackening of the power steering heat exchanger bolts (left).

We unscrew two bolts on the left of the power steering heat exchanger mounting.

Slackening of two bolts on the right and removal of the power steering heat exchanger — **Fig. 27.** Slackening of two bolts on the right and removal of the heat exchanger.

We unscrew two bolts on the right and remove the power steering heat exchanger.

**Fig. 28.** Slackening of the screws securing the plastic base of the radiator frame.

On the left-hand side of the front end we unscrew the screws securing the plastic base of the radiator frame to the cab side members.

**Fig. 29.** Slackening of the screws at the front wing holder.

We unscrew the screws at the front wing holder.

**Fig. 30.** Slackening of the screws securing to the upper front panel reinforcement.

We unscrew the screws securing to the upper front panel reinforcement.

We disconnect the wiring harness connectors from the engine management system sensor sockets.

**Fig. 31.** Disconnection of the wiring harness connectors from the sensor sockets.

We remove the fuel filter (article — Removal and installation of the fuel filter).

We lead the engine wiring harness out of the cab mountings.

**Fig. 32.** Disconnection of the intermediate shaft from the steering gear.

We unscrew the clamping bolt of the clamp joint of the upper and lower steering intermediate shafts.

We disconnect the intermediate shaft from the steering gear.

**Fig. 33.** Slackening of the screw securing the parking brake lever cover.

We unscrew the screw securing the parking brake lever cover. We remove the cover and disconnect the cable from the lever.

**Fig. 34.** Disconnection of the cable from the parking brake lever.

**Fig. 35.** Removal of the driver's seat.

We remove the driver's seat.

**Fig. 36.** Removal of the passenger seat and gear lever.

We remove the passenger seat. We remove the gear lever.

**Fig. 37.** Slackening of the front cab mounting nuts.

We unscrew two front cab mounting nuts.

**Fig. 38.** Slackening of the rear cab mounting nuts.

We unscrew two nuts from below the rear cab mounting while holding the bolts through the openings in the cab floor. We withdraw the bolts with washers from the openings.

Important: we check once more that all wires and hoses are disconnected from the cab.

We hook the cab or body by the door apertures (the doors must be open) with the lifting mechanism and lift it off the frame.

Important: we install the cab or body in the reverse order.