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UAZ CARGO, Operation Manual

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Ulyanovsk Automobile Plant LLC

Motor Vehicles

UAZ PATRIOT,

UAZ PICKUP,

UAZ CARGO

Operation Manual

OM 05808600.132-2011

Seventh Edition

2016

Summary of Contents for CARGO

Page 1: ...Ulyanovsk Automobile Plant LLC Motor Vehicles UAZ PATRIOT UAZ PICKUP UAZ CARGO Operation Manual OM 05808600 132 2011 Seventh Edition 2016 ...

Page 2: ...cle and its assemblies and termination of the manu facturing plant s warranty liabilities Forsafetyandfault freemotorvehicleoperationpleaseobserve theoperationandmaintenanceinstructionsspecifiedintheManual Motorvehiclemaintenancemaybehandledbyoneoftheservice stations recommended by the company that sold the motor vehicle The service stations are provided with the necessary spare parts special tool...

Page 3: ...idity of up to 100 at plus 25 С air dust content of up to 1 0 g m3 and wind speed of up to 20 m s including in the regions located at altitudes of up to 3 000 m above sea level with a corresponding reduction of traction dynamic characteristics and fuel efficiency The motor vehicles manufactured in T are meant for opera tion under ambient operating temperatures of minus 10 up to plus 50 С air relat...

Page 4: ...cle nameplate I Full Transport Vehicle Type Approval number TVTA II Transport Vehicle identification number VIN code III Transport Vehicle maximum permissible weight IV Maximum permissible weight of a transport vehicle with a trailer V Maximum permissible load on the front axle VI Maximum permissible load on the front back axle VII Engine model identification VIII Package code IX Variant execution...

Page 5: ...on number and a bodyshell number Fig 1 3 Location of chassis identification number Engines ZMZ 40906 and ZMZ 51432 s identification number is stamped on the area located to the left of the crankcase above engine front support fastening lug bosses Fig 1 4 ...

Page 6: ...pace at the end of the identification A zero shall be entered in place of the sixth character II indicating part VIS consists of six characters The first character a letter or a digit represents the conditional code of the year of vehicle manufacture the second character digit is the conditional code of the engine manufacturing plant s division and the remaining characters digits are the order num...

Page 7: ...r vehicle type All terrain two axle 4WD axle configuration Vehicle dimensions Shown in Fig 1 5 1 11 Maximum bearing capacity including driver and passengers kg 600 800 800 665 575 Seating capacity including driver s seat 5 5 2 Maximum gross vehicle weight kg 2 650 2 670 2 860 2 775 Gross weight distribution by axles kg on the front axle on the rear axle 1 217 1 114 1 433 1 556 1 230 1 630 1 090 1 ...

Page 8: ...8 Fig 1 5 Main dimensions of UAZ PATRIOT motor vehicle with gross weight dimensions are shown for reference depending on package To the towing eye center To the towing eye center ...

Page 9: ...ig 1 6 Main dimensions of UAZ PICKUP motor vehicle with gross weight dimensions are given for reference dimensions with tonneau cover depending on package To the towing eye center To the towing eye center ...

Page 10: ...10 Fig 1 7 Main dimensions of UAZ PICKUP motor vehicle with a load box cover with gross weight dimensions are shown for reference depending on package To the towing eye center To the towing eye center ...

Page 11: ...11 Fig 1 8 Main dimensions of UAZ PICKUP motor vehicle with a load box top bow dimensions are shown for reference depending on package To the towing eye center To the towing eye center ...

Page 12: ...12 Fig 1 9 Main dimensions of UAZ PICKUP motor vehicle with a load box shelter with gross weight dimensions are shown for reference depending on package To the towing eye center To the towing eye center ...

Page 13: ...13 Fig 1 10 Main dimensions of UAZ CARGO motor vehicle with gross weight dimensions are shown for reference To the towing eye center To the towing eye center ...

Page 14: ... Main dimensions of UAZ CARGO motor vehicle with a food van or a general purpose van with gross weight dimensions are shown for reference dimension for a food van To the towing eye center To the towing eye center ...

Page 15: ... not be regarded as the operation standard Fuel consumption measuring accuracy is only ensured in special testing conditions and in strict compliance with the requirements of GOST 20306 90 when the motor vehicle total mileage reaches 9 000 10 000 km Gross weight of a towed trailer kg max equipped with brakes without brakes 1 500 750 Minimum turning radius on the centerline of the front outer as to...

Page 16: ...ber Four Cylinder arrangement In line vertical Ignition sequence 1 3 4 2 Cylinder diameter mm 95 5 Piston stroke mm 94 Engine displacement cm 3 2 693 Compression ratio 9 1 Minimum crankshaft rpm at idle min 1 800 900 Maximum torque N m kgf m as per Rules 85 UNECE GOST R 41 85 217 0 22 1 at 3 900 min 1 Maximum capacity kW h p as per Rules 85 UNECE GOST R 41 85 99 0 134 6 at 4 600 min 1 ...

Page 17: ...ype II AI 98 4 GOST R 51866 AI 95 K4 AI 98 K4 GOST32513 Cooling system Liquid closed with forced circulation Transmission Clutch clutch type drive type Dry single disk Hydraulic Gear box gear box type control type Mechanical five speed control type Mechanical Transfer case type of transfer case control type power take off With front axle drive decoupling Two stage by Dymos UAZ PJSC With electric c...

Page 18: ...an anti roll bar rear suspension on two longitudinal semielliptic leaf less springs with an anti roll bar Four hydro pneumatic telescopic bilateral Wheels and tires wheels Disc with a whole rim steel 6 Jх16H2 with a radial tubeless tire 225 75R16 or of light metal alloy 7Jx16H2 7Jx18H2 with radial tubeless tires 235 70R16 245 70R16 245 60R18 with hubcaps Wheel mounting by five nuts A spare wheel w...

Page 19: ...there is no mechanical pressure controller Circuit splitting is diagonal primary right hand front and left hand back wheel secondary left hand front and right hand back wheel parking brake type Wheeled combined with rear brakes or drum and transmission parking brake actuator type Mechanical Electric equipment Wiring system Single wire negative pole connected to the motor vehicle ground Grid voltag...

Page 20: ...tment in intermittent operation mode Tail gate window wiper Electrically driven with one brush Washer Electrically driven for windshield and rear window Power windows Remote controlled Electrical interlocking system Designed for simultaneous interlocking of all motor vehicle s door locks Safe parking system Designed to warn a driver of obstructions located out of driver s sight when motor vehicle ...

Page 21: ...osition corresponding to the beginning of steerable wheels turning in one direction to the steering wheel position corresponding to the beginning of steerable wheels turning in the opposite direction deg max 20 Wheel and tire in assembly unbalance g cm max 1000 Tire air pressure MPa kgf cm 2 in the front wheels 225 75R16 235 70R16 245 70R16 245 60R18 0 20 2 0 0 19 1 9 0 17 1 7 0 18 1 8 0 20 2 0 0 ...

Page 22: ... 8 Fuelling data litres Fuel tank 69 1 Engine cooling system 14 0 Engine lubrication system 6 5 Brake hydraulic drive system 0 6 Gearbox housing 2 5 Transfer housing Dymos UAZ PJSC 1 8 0 8 Final drive housing front axle back axle 1 5 1 4 Power hydraulic steering system 1 365 Clutch hydraulic drive system 0 18 Windshield washer reservoir 5 ...

Page 23: ...motor vehicle 4 When leaving the motor vehicle do not leave door keys and ignition keys inside 5 Before opening a door ensure that it will not be a hindrance for other road users Before closing a door make sure it will not catch someone or something It is prohibited to drive the motor vehicle with any door being opened 6 Do not adjust the tilt angle of the steering column when driving the motor ve...

Page 24: ...eaks from fuel lines 20 Thecatalyticconverteroperatingtemperatureis400 800 С The motor vehicle shall not be operated if no protective screen is installed on the catalytic converter During motor vehicle motion and in standstill keep an eye on the exhaust system ensuring that it has no contact with inflammable materials e g dry grass 21 When handling low freezing liquid or fuel or brake fluid please...

Page 25: ...gs must be unscrewed the battery must be charged in a well ventilated room Elec trolyte fume accumulation is dangerous to health and explosive 24 Do not wash the motor vehicle while the engine is running When washing the motor vehicle avoid spraying water directly onto electric equipment articles electronic devices sensors and detachable connections in the engine compartment Monitor the condition ...

Page 26: ...s the motor vehicle must be securely braked donotcarryoutmaintenanceoperationandrepairofthemotor vehicle with engine on except for specific works that require engine start according to the procedure with that take special care avoidbringinghands partsofclothingandtoolsdangerously close to operating drive belts pulleys etc the fuel supply system is under pressure when the engine is running after th...

Page 27: ...ne find out the cause of their occurrence the motor vehicle must not be operated until the malfunction is corrected 4 1 Afterstartingacoldengine thehydraulicvalvemayknock that should disappear in the course of engine warm up to the coolant temperature of 80 90 С but not more than in 30 minutes after reaching the specified temperature If knock persists it is necessary to check oil feed to the hydra...

Page 28: ...at facilitates motor vehicle driving but does not drive the motor vehicle itself therefore the manufacturing plant is not responsible for any pos sible damages when driving in reverse 15 It is prohibited to remove metal segments with the engine on or to check sparking charge to ground 16 Avoidspillingacids sodasolutions brakefluid antifreeze and fuel on the painted surface of the bodyshell wheels ...

Page 29: ...ion installs rigid connection between the left and the right wheels excluding their separate slipping which in some cases improves the motor vehicleoff roadcapability butworsensitscontrollabilityandstabil ity as well as overloads the transmission parts For efficient and at the same time safe utilization of the differential lock consider and perform the following do not use the differential lock on...

Page 30: ...while moving at turns neither wheels slippage nor knocks in the transmission are detected and the controllability of the motor vehicle does not differ from usual The switching on of the differential lock does not necessarily increase the off road capability of the motor vehicle For instance while driving on soft waterlogged ground the switched on dif ferential lock can lead to turf disruption and ...

Page 31: ...tral position pings in the gear box synchronizer rings are possible These pings can increase with high gear actua tion and with the front wheels turned to the limit 30 The opened lift gate or the tailgate can block visibility of the back lighting system of your motor vehicle for other road users Before opening the lift gate of UAZ Patriot or the tailgate of UAZ Cargo motor vehicle install a breakd...

Page 32: ...ensor 6 head unit of multimedia system 7 device switches Set of switches depends on the motor vehicle package Windshield electrical heating switch Briefly press ing the switch key with ignition ON sends a signal to the heating time relay which actuates the heating element of the windscreen Windshield electrical heating will be switched off in 12 2 min automatically or when the switch key is presse...

Page 33: ...33 Fig 3 1 Control elements and driver s seat equipment for motor vehicles UAZ PATRIOT and UAZ PICKUP for item description see the relevant text ...

Page 34: ...34 Fig 3 2 Controls and passenger seat equipment for UAZ CARGO motor vehicle for item description see the relevant text ...

Page 35: ...dure for access to the unit 12 lighting control module Fig 3 4 13 clutch engagement pedal 14 brake pedal 15 accelerator pedal 16 cigarette lighter or cigarette lighter plug 17 parking brake lever To engage the parking brake posi tion the lever up to disengage press the button on the lever face and position the lever down against the stop 18 12V power socket 19 pre starting preheater timer Operatio...

Page 36: ...lights corrector regulator By turning the regula tor the headlights light beam inclination tilt angle is corrected depending on motor vehicle loading 0 one driver or a driver Fig 3 4 Lighting indicates control module see item description in the text Fig 3 3 Positions of the gearbox and transfer case levers 1 5 gears R reverse gear 2Н direct gear the front axle is disengaged 4Н direct gear the fron...

Page 37: ...external lights switch handle out to the first fixed position the handle should be in positions or Green signal device lights up in the cluster 5 rearfog lamps indicator Rear fog lamps are switched on by pulling the external lights switch handle out to the second fixed position If the fog lights are not installed on the motor vehicle the rear fog lamps are switched on at pulling the external light...

Page 38: ...h signal device yellow accumulator battery discharge signal device red If it is lit with engine on it indicates a lack of accumulator battery charge oil pressure warning signal device of the motor vehicle senginelubricationsystem red Signaldevicelightsup after starting up the ignition and goes out after starting the engine at increased crankshaft rpm Fig 3 5 Cluster see item description in the tex...

Page 39: ...s blinking with fre quency of 5 Hz in case of engine control unit malfunction and also in case of immobilizer malfunction and using of an unregistered code key see section Electronic anti theft device speed limiter signal device green off road mode turning on signal device green signal device of abnormal coolant overheating red 2 signal device box left direction indicator and hazard light ON signa...

Page 40: ...lights ON signal device green rear fog lamp ON signal device yellow door ajar signal device red security alarm system signal device yellow immobilizer ON signal device yellow 4 wheeldriveON forthetransfercasebyUAZ PJSC 3 speedometer with signal devices Signal devices on the speedometer cruise control signal device white green brakeABSmalfunctionsignaldevice ABS yellow park brake ON signal device r...

Page 41: ...e cluster switch over 2 s the setting mode is activated Hours minutes values can be set by turning the switch clockwise counter clockwise Switchingoverbetweenhours minutessettings is performed by short less than 1 s pressing the cluster switch ambient temperature depending on the package date in XXmonth format Tosetthedate the Datesetting mode should be switched on in the trip computer By long pre...

Page 42: ...h II right direction indicators are ON three blinks Unstable position III right direction indicators are ON stable position IV left direction indicators are ON three blinks Unstable position V left direction indicators are ON stable position VI pull headlights high beam flash Short time high beam switch regardless of vehicle light switch position Unstable position VII push distancelightisON ifforw...

Page 43: ...sitions Fig 3 8 I neutral position The windshield wiper and washer are OFF II windshield wiper intermittent mode is ON Stable position Spacing interval of the windshield wiper intermittent mode depends on the spacing interval regulator position 1 Fig 3 9 III windsсreen wiper constant mode low speed is ON stable position IV windshield wiper constant mode high speed is ON Stable position V Short tim...

Page 44: ...rter switch and the steering wheel rake and reach adjusting lever 1 horn switch The horn switch is built into the steering wheel lining press it avoiding extreme effort as the horn switch is combined with the driver s air bag module 2 ignition starter switch has three positions 0 parking stable position I ignition ON stable position II starter ON unstable position Fig 3 8 Understeering switch righ...

Page 45: ...without code pre reading from the transponder thus ensuring additional protection against unauthorized use The key is removed from the lock only in position 0 in which the locking device mechanism actuates and locks the steering system shaft To lock the steering system when parked set the key to posi tion 0 remove it and turn the steering wheel in any direction until it clicks which indicates that...

Page 46: ... Do not adjust steering column tilt angle when driving the motor vehicle After adjustment make sure that the steering column is securely fixed in a new position FLOOR STANDING BOX WITH BLOCKS AND CONTROL KEYS Floor standing box for motor vehicles UAZ PATRIOT and UAZ PICKUP Fig 3 11 1 transfer case mode switch Modes 2Н only back axle drive This mode is used to drive over dry hard surface roads 4Н a...

Page 47: ... performed only in a stationary motor vehicle There is no manual gearbox mode indication in the cluster in the initial position 2H only the back axle is driven Driving mode change 2Н 4Н To switch on all wheel drive 4H mode release accelerator pedal press and hold the clutch pedal set the handle from the 2Н position to the 4Н position If switching is successful the symbol is switched in the cluster...

Page 48: ...in the cluster With that only the back wheel drive remains active Inthiscase toswitchthe 4H mode itisnecessarytosettheswitch to the 2H position and the 4H mode should be switched on again Driving mode change 4Н 2Н To switch all wheel drive mode OFF engagement of back axle drive 2H it is necessary to release accelerator pedal press and hold the clutch pedal set the handle from the 4Н position to th...

Page 49: ...on in the cluster On motor vehicles UAZ PATRIOT and UAZ PICKUP with transfer box Dymos preliminary shift the transfer box in 4L mode on motor vehicles UAZ CARGO with transfer box UAZ in 4x4 mode After the lock is on ABS is automati cally turns off as a result ABS malfunction signal device lights up Fig 3 5 LED display of the cluster shows the following messages Wheel differential lock is off Hill ...

Page 50: ...remove the key 6 the front parktronic turn off button The ON signal device is in the cluster Turn on off the front parktronic by successive pushing of the button When the key is removed the control unit stores the latest position of the parktronic 7 auxiliary heater speed control switch Low speed of the auxiliary heater electric motor is switched on by short pressing the switch at which point the ...

Page 51: ...keys in whose bows the transponders are embedded The keys are equal in terms of their functional capabilities The system allows eight ignition keys to be registered The prerequisite for system operation is the registration of three ignition keys Thesystemcanbeinthe neutral taught and keyupgrading states with respect to ignition key registration Neutral state after replacing the engine control unit...

Page 52: ... cases if the engine is not started for 25 s after starting up the igni tion and successful key code recognition if after starting up the ignition the key code is not recognized thesystemwillstorethetroublecode whichcanbereadoutusing a diagnostic tester if the system is in the neutral state and key registration is not carried out if the system is in the taught state and an unregistered key is used...

Page 53: ...he test mode Then the signal device initiates the following state of the anti theft system until engine starts thesystemisinthe ON stateorthekeyregistrationprocedure is not completed the signal device is continuously ON the system is in OFF state or the key registration procedure is completed the signal device is OFF when performing the key registration procedure the signal device switches on 5 ti...

Page 54: ... on signal device starts blinking the system is ON For 20 s signal device blinking time start up the ignition using the key to be registered Registration is completed if in 5 s the signal device goes out If the signal device is lit continuously withoutblinking thekeyregistrationisconsidereduncompleted If a larger number of keys should be taught repeat the key registration procedure WARNING Switchi...

Page 55: ...registration is completed if in 2 s the signal device goes out If the signal device starts blinking the key registration is considered incomplete and the registration process is interrupted 10safterstartinguptheignition shutignitionandremovethe key from the ignition starter switch For registration of additional keys start the ignition up with the key to be registered within 20 s return to the prev...

Page 56: ...ce of obstruction it is possible to control the electrical interlocking system in the front from the left and right side of the motor vehicle at a distance of 10 m at rear at distance of about 6 m To prevent theft use remote control in close proximity to the motor vehicle The control unit records saves and displays the detected mal functions of the electrical interlocking system upon request of th...

Page 57: ...ink connector Operation procedure with the control system Door locks locking and armed mode switching on using the RCP To lock door locks and switch armed mode ON it is necessary to short press button 3 Fig 3 13 on the RCP All side door locks and the lock of the T gate are locked the system switches over to the armed mode that is indicated by a single blink of the T signals and a slow blinking of ...

Page 58: ... door locking is indicated by frequent blinking of the system s signal device in the cluster Unlocking the door locks from the RCP with side door window lowering Unlocking of all side doors locks and the T gate lock with automatic side door window opening is carried out by pressing the respective RCP button and holding it pressed till the window starts moving about 2 3 seconds The system carries o...

Page 59: ...on 2 on the RCP or button 2 Fig 3 14 of the DSDM again all other side doors and the T gate are unlocked Toswitchon offthefastunlockingmodeitisnecessarytopress button 2 of the DSDM max 1 second after starting up the ignition and hold it pressed for at least 3 seconds until the characteristic sound of the door locks triggered to open If subsequently the system should be switched over to the standard...

Page 60: ...rror right III mirror left IV mirror up Switching prompt alarm ON Switch prompt alarm ON is only possible with started up igni tion Switching ON is performed by pressing button 4 of the RCP and holding it for at least 2 s To switch prompt alarm OFF press any button of the RCP Locking and unlocking central door locks from the interior Locking all door locks including the T gate from the motor vehic...

Page 61: ... passenger door armrests to be disabled If disabling mode is activated thesymbolonbutton1hasyellowillumination Pressing the button again cancels disabling etc Ifadriverandapassengersimultaneouslycontrolanydoorwindow position the command from the DSDM switches has priority If passengers simultaneously control front and back windows of the right side doors a window control command from the right fro...

Page 62: ...conds and the mirror selection switches have not been pressed Exterior mirror position adjustment is possible only with the ignition started up or 30 seconds after shutting ignition if no side doors motor vehicle were opened MirrorcontrolisnotpossiblewhenarmedmodeisswitchedON System operation in armed mode When armed mode is switched ON the system monitors the states of the following security zone...

Page 63: ...tton the battery should be replaced For this purpose unscrew screw 1 Fig 3 15 from the hous ing side opposite to the control buttons using a flat screwdriver separate the housing halves pull the board out of the housing replace battery 2 observing connection polarity insert the board into the housing clip the housing s halves and tighten the screw RCP code re synchronization When the control panel...

Page 64: ...eave one of the doors open 3 Start up the ignition 4 Max 1 5safterstartingignition pressbutton4onthecontrol panel to be taught and hold it pressed 5 Wait until the system status signal device in the cluster starts blinking fast indicating the teaching process has started about 3 s after pressing button 4 6 Max 3 s after the indicator starts blinking holding button 4 pressed press button 2 one time...

Page 65: ...edifferencebetweenfastsystemteachingandfullteachingis that the already taught RCPs are not deleted New RCP codes are written in free memory cells the total number of the taught keys shall not exceed four For fast teaching it is necessary to deactivate the security system and close all doors and then perform items 3 13 described in section Full system teaching DEFENSIVE PARKING SYSTEM Rear parking ...

Page 66: ...trol unit performs integrated check in order to detect faulty sensors or other system malfunctions If a faulty sensor or other system malfunction is detected after the switching on signal a continuous low tone horn is given for 3 s then if sensor A left as viewed in the direction of motor vehicle motion Fig 3 11 or its circuit is faulty the system indicates the faulty sensor with one low tone horn...

Page 67: ...thorized modifications to the DPS circuit diagram and design are strictly prohibited When operating keep the parking system sensors PSS clean do not subject them to mechanical impacts PSS surface should be cleaned of contaminations using a soft cloth moistened with a mild soap solution When removing contaminations from the PSS surface avoid applying pressure to its central part in order to prevent...

Page 68: ...r sensors UAZ PATRIOT and four front sensors UAZ PICKUP gives horns if any object is detected at a distance of up to 120 cm in front of or behind the motor vehicle This system is auxiliary and it is not responsible for a damaged motor vehicle The range of detection of objects and the type of objects are limited During any maneuvering monitor the situation in front and behind the same way as in the...

Page 69: ...on or stop Red indication means that a hindrance is detected for driving at a distance less than 60 cm 30 cm for the front side sensors it is recommended to stop Numerical information about the actual distance to the nearest hindrance can be displayed on this screen see MMS settings This system is auxiliary and it does not allow to fully avoid the motor vehicle contact with hindrances Safe parking...

Page 70: ...oid the motor vehicle contact with hindrances Safe parking system is not responsible for the motor vehicle damages CAMERA REAR VIEW Rear view camera is embedded into the licence plate lamp lining and is intended to assist the driver when driving in reverse it displays the information about the situation on the road behind the motor vehicle on the screen Rear view camera displays on the screen of m...

Page 71: ...iving in reverse with a trailer the lines on the screen show the motor vehicle motion but not the trailer motion the screen displays only the area behind the motor vehicle That is why when rotating the steering wheel during the driving in reverse monitor the situation on both sides outside the vehicle if the lens of the camera is dirty the quality of the picture worsens hence the lens should be re...

Page 72: ...ne torque instrument cluster IC Shows the current of CC and OSL functions steering system keys unit Fig 3 17 It is intended for CC and OSL functions control Steering system keys unit CC and OSL functions are controlled with the following keys Fig 3 18 1 key Cruise control function selection 2 key Overspeed limiter function selection 3key Set activationoftheselectedfunction increaseof the set speed...

Page 73: ...ion For activation turn CC function on indicator lights up white push the accelerator pedal and reach the desired speed Then fix the target speed by pressing key Set or Set i e the system is activated indicator lights up green under the following conditions the motor vehicle speed should exceed or be equal to 40 km h and should be less or equal to 150 km h crankshaft rotation frequency should exce...

Page 74: ...ch to the overtaking mode which leads to the speed increase After the acceleratorpedalisreleasedCCfunctionwillautomaticallyreduce the speed to the target value At changing of the acceleration long pressing of Set or decelerationmode longpressingof Set toovertakingmodethe target speed will change to the current speed value at the moment the accelerator pedal is depressed 5 Gear shift mode Gear shif...

Page 75: ...on ResumptionofCCfunctionispossibleifkey RES ispressed The target speed value will be taken from the system memory at the moment of the previous deactivation of the function Resumption mode is possible only if the ECU memory keeps the target speed value different from zero The pressing of keys Set or Set during active resump tion mode will lead to setting of the current speed as the target Theresu...

Page 76: ...et eitherinthestationaryvehicle or while driving indicator lights up green The following condition must be implemented the motor vehicle speed should be less or equal to 150 km h If the motor vehicle speed is less than 40 km h then the speed threshold setting value at the moment of activation is 40 km h If the motor vehicle speed exceeds 40 km h or is equal to 150 km h then the setting speed thres...

Page 77: ... mode If the accelerator pedal is pressed to 95 of its stroke OSL function is deactivated and the vehicle speed increases without limit Subsequent activation of OSLfunction occurs automatically at pressing the accelerator pedal less than 95 of its stroke and decreasing the motor vehicle speed below the preset speed threshold 5 Deactivation FunctionOSLisdeactivatedbypressingkey CAN Thespeed thresho...

Page 78: ...mately 3 s after that ESP is activated When the system comes into operation the signal device of operation and malfunction of ESP on the instrument cluster starts flashing ESPoperationmaybeaccompaniedbylightpulsationand automatic operation of brake mechanisms This is not a deviaton from the norm For improvement of traction characteristics of the motor vehicle on dirty or slippery road the cranksha...

Page 79: ...eration and malfunction of ESP is on continuously In this case contact UAZ LLC service station the addresses of service stations are listed in the service book to eliminate the malfunction Traction control system TCS TCS controls the engine torque and the brake system brak ing torque electronic wheel differential lock and ensures driving without slippage of driving wheels If one of the driving whe...

Page 80: ...optionofrearaxledifferentiallockisavailable in the vehicle configuration and ESP system malfunction OffRoad Function When the ignition is turned on the off road signal device lights up in the cluster for approx 3 s then it goes off OffRoadincreasesthebrakingefficiencyonsoftsurfaces gravel sand deepsnow mud Optimizestractionofwheelswhendriving is started and the vehicle is accelerating on soft surf...

Page 81: ...yoverheat whichmay affect the efficiency of the brake system In this case apply more force to the brake pedal at braking until the brakes cool down The time needed for brakes to cool down depends on the environment ambient temperature motor vehicle speed etc ESP availability in various modes Mode ESP TCS ABS condition Signal device 2H ESP TCS ABS are available 2H OffRoad ESP is available TCS is av...

Page 82: ...ffRoad function is on the LED display of the cluster shows the following messages OffRoad mode and Electronic wheel differential lock is available when mode 4L is activated the LED display of the cluster shows the following message Electronic wheel differ ential lock is available when the rear axle differential lock is activated if such optionisavailableinthemotorvehicleconfiguration LED display o...

Page 83: ...40 km h above 40 km h ABS operates in its usual mode 4H ESP Off ESP TCS not available ABS available 4H OffRoad ESP Off ESP TCS not available ABS available in driving mode ABS OffRoad up to 40 km h above above 40 km h ABS operates in its usual mode when ESP is deactivated the LED display of the cluster shows the message Electronic wheel differential lock is off In4L rearaxledifferentiallockmode ifs...

Page 84: ... may be released and suddenly move forwardorbackward whichcanleadtoinjuriesorpropertydamage MULTIMEDIA SYSTEM KEYS UNIT Function of multimedia system keys Fig 3 19 1 input key in the Phone mode Short pressing answering the incoming phone call or dialing the phone number from the calls list Long pressing shows the list of the calls 2 input key in the Phone mode Short pressing phone call finishing o...

Page 85: ... almost constant level at any speed of the vehicle Fig 3 20 shows the interior ventilation and heating system control unit 1 control unit side deflector 2 windshield blower heating nozzle 3 control unit central deflector 4 heating and ventilation control unit 5 floor tunnel deflectors 6 air flow control lever 7 flap control lever Climate control system has the control panel which is the mail contr...

Page 86: ...escreen Besidesthis theunitmaintains comfortable air conditioning in the interior by automatic control of air cooling speed and air volume The display shows the set value of the interior temperature The control unit detects faults and informs the driver about them and besides this it can shift to trouble free operation Fig 3 20 Interior ventilation and heating systems control elements for names of...

Page 87: ...current can be changed via small levers 6 Fig 3 20 on the deflectors 3 rotary switch of air fan control Position 0 air fan is off Position Auto Fig 3 21c to reach the target temperature the system will be controlled automatically Other positions steps 1 8 4 pushbuttonswitchofmode Supplyair recirculation Fig 3 21 with light indicator The button in the air fan control handle may switch the air suppl...

Page 88: ...r control panel a ventilation and heating control unit b interior ventilation and heating with air conditioning control block c Climate system control unit climate control for position names see the relevant text a b c ...

Page 89: ...ed at the rear panel of the floor container Direction of air currents is adjusted by two deflectors On the motor vehicles not equipped with an additional heater additional heating of the rear seat passengers is conducted through the feet air cooling air duct passing through floor tunnel Fig 3 22 Additional heater 1 heater tubes 2 hose for supplying the cooling fluid to the heater 3 fitting 4 lid o...

Page 90: ... 4 replace filtering element 5 lock filter cover 4 ATTENTION Using the operation modes of the heater fan from above average to maximum output rate in pouring rain con ditions can result in soaking of the air intake filter and ingression of moisture at the feet of the front passenger Interior ventilation Blowing ventilation of the interior is performed via the same channels when the handle 1 Fig 3 ...

Page 91: ...within points 1 and 8 the system switches to manual control and the air fan speed increases by 1 point up and down within the points range When this mode is switched on the control panel scans the condition of the control elements rotary switches 1 2 and 3 and depending on their positions works in accordance with the prescribed operation algorithm determines the condition of the recirculation flap...

Page 92: ...ap position of the windshield air cooling until the heater starts supplying warm air to avoid discomfort caused by cold air In hot weather AUTO mode ambient temperature is higher than 30 С the system first automatically selects constant low speed and the flap position of the windshield air cooling within 5 s and then it returns to the normal control to avoid discomfort caused by hot air Interior p...

Page 93: ...turned on If the ignition is turned on before the liquid pre start heater is turned off then the control panel automatically goes to Manual operation mode and the actuating elements of the climate control unit are adjusted in accordance with the control elements of the climate control unit Air conditioner Depending on the configuration the motor vehicle can be equipped with air conditioner To swit...

Page 94: ...en be shut off together with a loss of cooling efficiency In order to improve the airconditionerefficiencyinthegivenconditions itisrecommended that the rotation speed of the climate control unit fan be raised at the flick of switch 3 Fig 3 21 and a minimum air temperature be set at the flick of switch 1 additionally turn on the recirculation of air for a short time 5 10 minutes One of the features...

Page 95: ...ched on by pressing the cor responding left 1 Fig 3 26 or right 3 switch Operation mode of the interior ambient lighting depends on switch 2 position Fig 3 16 Lighting lamps interior rearview mirror sun visors and hand grip 1 5 sun visors 2 interior rearview mirror 3 pilot lamps unit 4 rear interior lighting lamp 6 hand grip 7 seatbelt height adjuster Fig 3 17 Interior space lighting unit 1 left s...

Page 96: ... turning on the ignition after all the doors are closed while the lamp is still in ON position 25 s after all the side doors are closed if during this period the ignition was not turned on any of the side doors were not open the Security mode was not switched on via a radio channel of the remote control panel in 10 minutes when one or more side doors are constantly open if during this period all t...

Page 97: ...ssary to fold in the exterior rearview mirrors to the side doors of the motor vehicle for UAZ PATRIOT UAZ PICKUP The mirror folds by applying force to the most remote from the base cover or body edge parallel to the coupling line of the body and the cover Fig 3 27 Sun visors Fig 3 25 In case of necessity it is recommended that the sun visors be positioned in either of the two positions flip the su...

Page 98: ... not be a hindrance for other road users Before closing a door make sure it will not catch someone or something Driver s door is locked with a key from outside If it is not locked the door opens when pulling moving part 2 Fig 3 28 3 19 of the door handle Fig 3 28 Front door view from outside 1 door lock switch 2 movable part of the door handle 3 door handle body ...

Page 99: ...w from the interior 1 locking button 2 door handle 3 armrest handle 4 pocket 5 place for loud speaker mounting 6 switch unit Fig 3 9 3 23 7 place for twitter mounting Fig 3 31 Rear door view from the interior 1 locking button 2 door handle 3 power window control switch 4 place for loud speaker mounting 5 pocket 6 lever for locking door interior handle 7 armrest handle ...

Page 100: ...can be locked when a door is opened The front doors can be locked only when a door is shut to pre vent accidental leaving key inside the cabin The windows of the side doors go up and down by turning the switches of the power windows 3 4 5 6 Fig 3 14 ATTENTION When closing the power windows fingers or other body parts may be caught which could lead to serious injury Therefore pay attention when usi...

Page 101: ...eats ATTENTION Do not adjust the driver s seat when the motor vehicle is moving The driver s seat and tilt angle of the steering column should be adjusted so as to provide the necessary position of the driver the driver should tightly bear against the back rest of the seat elbow joints of both arms should be slightly bent when holding the upper part of the steering wheel the legs should not be ext...

Page 102: ...ecommend that you turn on the heating for short periods of time Do not use additional pillows between the seat and the pas senger or the driver It is forbidden to place foreign objects under the driver s seat and in the area of his feet Changing of the headrest height or its removal is performed by moving the headrest in a vertical direction up by arm force to the uppermost position down when the ...

Page 103: ...rt for the lumbar part of the spine In order to raise the driver s seat pull up handle 2 several times until it is set to the desired height To lower the driver s seat pull down handle 2 several times until it is set to the desired height Foryourconvenience maketheadjustmentswiththedooropen Rear triple seat Fig 3 33 consists of pillows and backrests for one and two passengers Fig 3 32 Front seat 1...

Page 104: ... position raise the backrest until the headrest lock is activated to return the pillow to its initial position turn it back to the horizontal position only for UAZ PATRIOT the pillow should be fixed in the following sequence lift the seatbelt locks and lower the pillow up to the stop without flap ping pull the pillow strap retainer press the pillow release the pillow strap retainer check the fixat...

Page 105: ...fasten the seatbelt pull belt tongue 3 without twisting the straps and insert it into lock 4 until it clicks Press the red button of the lock to unfasten the belt The center seatbelt of the UAZ Pickup is a static lap belt The seatbelt height adjuster has four fixed positions The position of the upper mounting point of the seatbelt is adjusted by moving the belt adjuster support 1 Fig 3 35 up or do...

Page 106: ...lt guide support group 2 adjuster button Fig 3 34 Seatbelts 1 seatbelt height adjuster 2 seatbelt guide bracket 3 lock catch 4 lock 5 inertiareel 6 clip 7 adjusterforstaticmiddlebelt UAZPickup Strap extension Strap shortening pull pull ...

Page 107: ...n the backrest If the seat backrest is inclined too much the seatbelt may slip increasing the risk of getting injured in an accident ATTENTION Controltheconditionofplasticrestrictionclip 6 Fig 3 34 of the center seatbelt Unfastened seatbelt signal device If the seatbelt of the driver is not fastened when the ignition is turned on the seatbelt signal device on the instrument cluster turns on The si...

Page 108: ...e air bags are filled with gas and unfolding in front of the driver and the front passenger reduce the danger of head and upper body part injuring Airbags system actuates at frontal collision of motor vehicle when it is needed to increase the safety of the driver and the front passen ger The presence of airbags system is marked by the inscription AIRBAG on the steering wheel cover inscription AIRB...

Page 109: ...or instance with another motor vehicle airbag actuates only at high vehicle speed in case of a sufficient force of front impact on the vehicle some examples are shown on Fig 3 36 Airbags system does not actuate if the ignition is off minor frontal collisions vehicle rollover side or back blows to the vehicle i e in cases when the airbag is not able to increase the driver s safety Damage degree of ...

Page 110: ...well as seatbelts with pretensioner should be replaced by an authorized dealer ATTENTION Because of the impossibility of the front pas senger airbag unfolding do not install child seat against the direction of movement backrest forward on the front passenger seat If the airbag actuates a child can be seriously injured In motorvehiclesequippedwiththefrontpassengerairbag thereisa warning label on bo...

Page 111: ... can lead to injury The same danger exists if the driver or a passenger is smoking or talking on the phone while driving 3 Driving the vehicle do not place forearms palms of hands on the spot where the airbag is located 4 While moving the front passenger should not lean on the dashboard or handle any objects that can cause injury when an airbag actuates 5 Airbag system malfunction signal device sh...

Page 112: ... clear water During prolonged irritations consult your doctor At motor vehicle recy cling it is necessary to dismantle the airbag system units at the authorized dealership Child restraint system installation ATTENTION Mounting of the universal child restraint system in accordance with Table 3 2 is performed with the seatbelts of the vehicle Children under 1 5 years of age should sit in the child r...

Page 113: ...category Dimension class Clamping device Position of ISOFIX in vehicle Second row left right F Transverse cradle ISO L1 IL X 0 up to 10 kg G Transverse cradle ISO L2 X IL E Rear facing seat ISO R1 IL IL E Rear facing seat ISO R1 IL IL 0 up to 13 kg D Rear facing seat ISO R2 IL IL C Rear facing seat ISO R3 IL IL D Rear facing seat ISO R2 IL IL C Rear facing seat ISO R3 IL IL I 9 18 kg B Front facin...

Page 114: ...ing seat and a rear facing seat X child seats mounting is not permitted Fuel tank plug Toaccessthefueltankplug forUAZPATRIOT UAZPICKUP vehicles open the flap Fig 3 38 On UAZ CARGO vehicle the fuel tank plug is under the cargo bed right front in open access ATTENTION Fuel tank hatch cover has an opening angle restriction of 70 Opening the cover to a larger angle will cause a deformation of the hing...

Page 115: ...ending on the configuration the motor vehicle may be equipped with air springs for the hood which facilitate lifting of the hood and maintain it open The hood closing must be performed from a height not more than 200 mm above the radiator lining If the motor vehicle is equipped with air springs for the hood the latter should close by inertia after overcoming the force of the air springs Fig 3 26 F...

Page 116: ...vice keep the windshield wipers on for 15 20minutes Wiperbladesmustbeplacedinfixedpositionaway from the windshield The wiper bladearm of the rear window must be detached After 18 24 months of operation replace wiper blades or their rubber edges if necessary Replacement of wiper blades of windshield wipers To replace wiper blades of windshield wipers perform the fol lowing steps lift the arm of the...

Page 117: ...ep washer reservoirs turned ON for more than 10 s ATTENTION When switching on the washer of the tail gate door there may be water feed delay up to 2 5 s Luggage compartment Luggagecompartmenthasapulloutcovertoprotecttheluggage ATTENTION Avoid placing objects on the cover ATTENTION No passengers are allowed in the luggage compartment during driving ATTENTION Tail gate door only opens from the outsi...

Page 118: ...following rules 1 Crankshaft rpm of engine must not exceed the 3 4 of the nominal rotational speed 2 Do not exceed the motor vehicle nominal load 3 Do not drive along the tough roads deep mud sand steep inclines etc 4 Do not haul the trailer 5 Do not change the oils filled in the engine and units at the manufacturing plant 6 Check and adjust the tension of the auxiliary unit drive belts if necessa...

Page 119: ...g system fuel oil level in the engine crankcase and power steering tank Shift the gearshift lever in neutral position Remember that in order to prevent the starter from acciden tally switching on when the engine starts the ignition switch is equippedwiththeinterlock whichallowstheenginetoberestarted only when the key returns to 0 position Fig 3 10 Switchonthestarterforamaximumof5s Assoonastheengin...

Page 120: ...start the engine not earlier than 15 20 seconds after the first attempt When starting the engine it is not recommended to press the throttle pedal After starting the engine its system will automatically set the fast idle speed to warm up the engine and gradually reduce it as the engine warms up If the engine does not start after the third attempt stop the ignition detect and remove the malfunction...

Page 121: ...ng difficult road sections It is recommended to put in the second gear when driving away from rest on a level section of a hard surface road In all the other cases put in the first gear when driving away from rest Disengage the clutch when putting in the gears and engaging the front axle disengage the clutch fast by pressing the clutch pedal as far as it can go engage the clutch smoothly avoiding ...

Page 122: ...le in advance and use the reduction gearofthetransfercasewhendrivingthroughparticularlydifficult road sections Engage and disengage the front axle in motion and use the reduction gear of the transfer case only after bringing the motor vehicle to a complete stop Overcoming steep inclines and descents When driving on roads with steep inclines and descents the driver should be very careful and have q...

Page 123: ...n obstacle in a rush if an impact against the wheels is possible When overcoming ditches and trenches consider the possibil ity of getting stuck due to wheels slips and vehicle cross axling In such situations activate the rear axle wheel differential lock in advance Driving along muddy country roads and graded clay and gumbo roads When driving along clay and gumbo after heavy rain the motor vehicl...

Page 124: ...adius do not reduce the speed Do not drive along the track made by the motor vehicle moving ahead When overcoming sandy soils drive smoothly without jerks and stops Turn smoothly and with a great radius Switch on the highest possible gear and engage the front axle in order to overcome the sand drifts and short sand upgrades in a rush Avoid the slipping of the wheels Determine the road conditions p...

Page 125: ...surfaces of a 350 mm depth Steer the motor vehicle in the same manner as when moving on swampy grounds When driving on friable snow apply the same rules as when driving on sand surfaces CHAPTER 8 TOWING OF THE MOTOR VEHICLE The front and rear parts of the frame Fig 8 1 are equipped with towing eyes for flexible towing Before towing turn on the ignition positionI Fig 3 10 andlightalarm Whentowing c...

Page 126: ...nual DAILY MAINTENANCE 1 Visually check the motor vehicle configuration the condition ofthebody glasses rearviewmirrors trimpackages licenseplates painting doorlocks wheels andtires Eliminatethedetecteddefects Inspect the parking lot of the motor vehicle to make sure there are no fuel oil coolant or brake fluid leakages Eliminate the detected leakages Check and replenish to the standard the amount...

Page 127: ...tumn and if possible combines with the next maintenance in accordance to the warranty card of the service book Prior to the summer season operation 1 Remove the oil pump cover and check the condition of the oil pump drive gears 2 Check the operation of the window wiper and washer Elimi nate the defects 3 Replace oils in the units with summer all season grade oils specified in the lubrication sched...

Page 128: ...tightening in a sequence shown in Fig 9 1 in two steps Tighten the bolts evenly using a torque wrench refer to Appendix 2 Fig 9 1 Sequence of the cylinder head bolt tightening Engine gas distribution mechanism Camshaft drive is a two stage chain Chain tension is provided for by hydraulic tensioners WARNING Do not take the hydraulic tensioner out of the chain cover to prevent disengagement of the p...

Page 129: ...ers may not be mixed If the engine oil of another grade or manufac turer is to be poured you must flush the lubrication system with washing oil The washing oil shall be selected in accordance with the recommendations of the manufacturer of the newly poured oil Fig 9 2 Engine ZMZ 40906 left side view 1 coolant from radiator to water pump supply pipe 2 connection hoses 3 thermostat housing 4 control...

Page 130: ...system intact the emergency oil pressure warning lamp may be on at idle but it shall go out immediately after increasing the crankshaft rpm It is recommended to flush the engine lubrication system after each two oil changes For that purpose drain the used oil fill in special flushing oil VNIINP FD 3 5 mm over the MIN mark on the oil level indicator and let the engine run for 10 minutes Fig 9 3 Eng...

Page 131: ... cap Check the membrane for damage and breakage When re assembling ensure tightness of connections ATTENTION Theenginemaynotbeoperatedifthecrankcase ventilation system is not tightly sealed and with opened oil filler This results in an increased escape of oil with crankcase gases and contamination of the environment To prevent the crankcase ventilation system from de pressurization you must close ...

Page 132: ... the fluid dry it outside the room and wash it Take due care when opening the cap of the expansion tank of the engine cooling system to avoid a scald For cooling liquid use a low temperature freeze fluid TOSOL A40M OG 40 Lena or OG 40 TOSOL TC Fig 9 5 Engine cooling and heating system scheme 1 cabin heater radiator 2 heater radiator connection hoses 3 engine 4 thermostat 5 control unit coolant tem...

Page 133: ...fluid decreases in the expansion tank within a short period time or after moderate mileages up to 500 km check the cooling system tightness and after elimination of leaks add the same cooling fluid into the expansion tank Everythreeyearsorafterevery60 000km dependingonwhich happens first purge the cooling system and refill the coolant Purge the cooling system as follows fill the system with pure w...

Page 134: ...the drive belt tension by adjustment bolt 14 and move the pump along the rails Tighten bolts 13 Inmotorvehiclesequippedwithanairconditioner theaggregates driveisperformedbythesamebelt Itstensionisadjustedautomati cally Fig 9 7 It is necessary to check belt condition during the operation process Upon detection of its substantial looseness the GUR pump placement adjustment is possible by bolt 9 to c...

Page 135: ...ralizer will fail Therefore special attention shall be paid to the operation of the feed system and the ignition system Three cylinder based operation of the engine is prohibited even for a short period of time Fig 9 6 Aggregates drive belt tension 1 synchronization sensor 2 automatic tension mechanism 3 alternator and waterpumpdrivebelt 4 alternatorpulley 5 inletpipe 6 receiver 7 throttle assembl...

Page 136: ...t be disconnected from the motor vehicle in vehicle network while the engine is running 4 While being charged from an external source the recharge able battery must be disconnected from the in vehicle network 5 The control unit may not be exposed to temperatures above 80 С e g in an oven dryer Fig 9 7 Accessory drive belt 1 automatic tensioning mechanism 2 auxiliary Idle pulleys guide rollers 3 co...

Page 137: ...not turn on the electric fuel pump on a dry when the right fuel tank is empty Feed System WARNING The motor gasoline and its vapours are toxic and flammable Observe the following rules observe fire safety rules avoid any operations as a result of which the liquid can enter into the mouth cavity do not let the fluid dry out on the skin immediately wash it off with soap and warm water cover the spil...

Page 138: ...lling pipe bolts in the flap frame Then unscrew coupling band pins turn collars down so as not to impede tank lowering and remove tank Install tank in reverse order Submersible module 5 Fig 9 8 includes electric fuel pump gauze filter intake camera with jet pump fuel supply union to the preheater the pressure controller and the fuel tank level gage At mounting of the tank check and clean fuel pump...

Page 139: ... fuel supply intake into preheater 7 tube from electric fuel pump to fine fuel filter 8 fuel drain tube from fine fuel filter to fuel module 9 16 18 20 vapor diversion hoses 10 fuel tank fill pipe 13 fine fuel filter 14 fuel supply tube 15 fuel supply hose 19 absorber 21 absorber blowing valve 22 vapor diversion tube 23 fuel rail 24 throttling device ...

Page 140: ...am hoses and tubes if this occurs check the hermetic tightness of joints con dition of the adsorption container absence of cracks and damage serviceability of the adsorption container s purge valve operability of the evaporative emission control system the absorber and the fuel tank valve Any failure of these elements leads tofuelsupplysystemfailures Damagedcomponentsshallbereplaced Accelerator pe...

Page 141: ...on the right hand side wall Diagnostics Serviceability of the engine control system and the injection system depends on the mechanical and hydromechanical systems Several deviations leading to faults can be mistaken for the control system electronic part malfunctions such as low compression deviation of gas distribution phases caused by an incorrect assembly of engine components Fig 9 9 Air filter...

Page 142: ...trol unit has reserve modes that allow the engine to go on in close to normal conditions Nonetheless when the fault is caused by ignition malfunction ing engine fault lamp starts to blink to avoid exhaust gas neutralizer failure the engine speed should be reduced to 2 500rpm motorvehiclespeedbelow50km h andyoushould head for a workshop WARNING Signal device switches on persistently when the neutra...

Page 143: ...formationaboutheateroperationandmaintenance is in the manufacturer s manual enclosed in the motor vehicle DRIVING SYSTEM At slow speed in gears 1 and 2 in acceleration deceleration regime an audible knock in the form of short clicks may occur in the driving system When moving at higher gears of the gearbox and the transfer case at speed higher than 60 km h in engine braking regime as well as durin...

Page 144: ...oir 2 Fig 9 11 Theclutchpedalpositionisadjustedbyclutchmastercylinderpush rod 5 length change Clutch pedal full travel should be 130 10 mm Free travel 5 30 mm is clutch design feature and is not adjusted Incomplete clutch release and pedal softness indicate air pres ence in the hydraulic system Perform system bleeding via clutch release cylinder valve 2 Figs 9 12 9 13 following the hydraulic brake...

Page 145: ...To check oil level screw out plug 9 Fig 9 12 or 8 Fig 9 13 The oil level should reach the filler orifice lower edge Upon oil replacement drain oil immediately following the motor vehicle shut down while the aggregate is hot For this it is necessary to wipe dry fill and drain plugs place a vessel under transfer case pull drain and fill plugs out let oil drain replace and tighten drain plug at 6 0 6...

Page 146: ...earbox housing drain plug 7 transfer case housing drain plug 8 motor drive 9 transfer case housing filler plug Fig 9 13 Dymos 5 step gearbox UAZ transfer case and clutch release cylinder 1 clutch release cylinder 2 transfer valve 3 gearbox 4 transfer case 5 gearbox housing filler plug 6 gearbox housing drain plug 7 transfer case housing drain plug 8 transfer case housing filler plug ...

Page 147: ...rosses Lubricate the needle bearings until the grease shows up from under the working edges of the cross oil seals Applying solid oil or its mixtures for lubrication of the needle bearings can lead to their premature failure Do not apply too much grease to the splined couplings as it would bleed through the spline coupling and that would provoke a premature failure of the oil seals and could eject...

Page 148: ...wear and that could result in an axle jam Check the axial clearance in the bearings by swinging the drive pinion by universal joint flange Axial clearance in the differential bearings of the final gear is not allowed Check the clearance by swinging of the drive pinion when the housing cap is removed If a gap is detected the axle should be adjusted The axle adjustment is a labor intensive operation...

Page 149: ...e steering knuckle pins At the wear of the interacting spherical surfaces of liners 3 or pins 2 the pre loaddisappearsandtheairgapappearsalongthecommonaxle shaft of the pins To remove the air gap tighten clamping bush 10 Operating the front driving axle with gaps in the pins units can lead to a premature failure of the liner of the upper pin It is easier to tighten clamping bush 10 of the lower pi...

Page 150: ...e not disconnected from the hous ing of the axle shaft in any direction relative to the common axle shaft of the pins should be within the limits of 10 25 N m 1 0 2 5 kgs m considering the removed O rings 5 6 and joint 7 of the steering knuckle Incasethecontrolparameterisnotreached tightentheclamp ing bush once again by turning the wrench by 10 20 and tighten the nut 13 with the specified torque I...

Page 151: ...er nuts front axle spring nut and spring shackle bolt nuts is performed at motor vehicle weight load Wheels and tires WARNING Worn out and damaged tyres excessive or insufficient air pressure in them deformed discs or weakening of fastening of wheels can cause an accident Regularly check tyres condition and air pressure discs condition and safe mounting Since tyres of different models tread patter...

Page 152: ...ed check and adjust the toe in of the front wheels and the air gaps in the pins units Checking and wheels toe in adjustment using on a process specialized stand Carry out wheels toe in adjustment at a normal tyre air pressure Adjust wheels toe in adjusting steering trapezoid rod length by nozzle 2 rotation Fig 9 18 after prior loosening of left handed thread counter nuts 1and right handed counter ...

Page 153: ...to avoid its contact with break mechanisms Thoroughly adjust the bearings If their tightening is loose the vehicle movement provokes shocks in them and as a result damages the bearings If the tightening is too tough the bearings overheat thegreaseleaksandthebearingsbreakdown Moreover big air gaps in the front wheel hubs increase brake pedal travel Adjust the wheel hub bearings in the following seq...

Page 154: ...cracks replace the washer 8 Check the adjustment of the bearings after tightening the lock nut Iftheadjustmentiscorrect thewheelshouldrotatefreely without binding noticeable axial play or wobbling 9 Bend one tab of the lock washer around the flat of the nut bend the second tab around the flat of the lock nut until full fit ting to the flats Unbend those tabs of the lock washer that are the closest...

Page 155: ...to tow it with a tow rope In this case use two wheel towing or tow truck service The steering mechanism can be used only for a short time when the hydraulic power steering is broken as a result of the pump damage the hose or the pump drive belt malfunction or when the motor vehicle is towed as a result of engine stop If the power steering system lacks oil the pump drive belt should be removed othe...

Page 156: ...mechanism at UAZ service station Tensionofpowersteeringpumpdrivebeltseesection Engine cooling system Replace the belt if damages or excessive stretch are detected Hydraulic power steering oil level check and change to avoid pump seizure as a result of under filling of the necessary oil volume this procedure should be caried out by two persons To check the oil level in the oil tank 1 Fig 9 20 the p...

Page 157: ... come out from the oil Inspect the connections between the hoses and the power steering units and eliminate the leakage as required 6 Bleed the hydraulic power steering system when the engine is running by turning the steering wheel lock to lock with no stops in the end positions to remove residual air bulbs from the oil Before the hydraulic power steering system bleeding open the bleeder valve th...

Page 158: ...h it off with soap and warm water flush the spilled fluid with water air the room take off the clothes contaminated with the fluid dry it outside the room and wash it The level of brake fluid in tank 3 see Fig 9 20 can be checked visually with the marks on the tank housing made of semitrans parent plastic When the cap is off and the brake linings are new fluid level should be on MAX mark If the br...

Page 159: ...igura tion motor vehicles can be equipped with the anti lock braking system ABS ABS prevents the wheels from locking up while braking which keeps the initial motion trajectory and minimum braking distance However the motor vehicle braking distance can be increased when breaking on roads with soft surface gravel sand unrolled snow compared to lock braking in the same conditions ABS braking starts f...

Page 160: ...ning light on Front disc brakes To inspect brake shoes 2 Fig 9 21 place the motor vehicle on level ground and raise the parking brake Inspect the shoes through the window in support 4 If the linings wear to a thickness of 1 5 2 0 mm replace the shoes on both front brakes Fig 9 21 Front disc brakes 1 spring 2 shoes 3 clip 4 support 5 safety cap 6 snap ring 7 O ring 8 protective boot 9 piston 10 bus...

Page 161: ...sure that the crankcase has no leakage Check safety caps 5 and boots 8 for damages and proper instal lation in seats replace them if necessary Check the outer surface of bushes 10 in the area of boots 8 for grease and lubricate them with UNIOL 2M 1 TU 38 5901243 92 grease as required Move clip 3 until pistons 9 rest the inner surface of crankcase 17 Bypass valve 14 can be opened to ease the fluid ...

Page 162: ...sealant if unscrewing these bolts and nuts Rear drum brakes Fig 9 31 Fig 9 32 depending on the configuration Remove brake drums periodically and clean the brake details from dust and dirt The frequency depends on vehicle operation conditions Clean the drums more often in summer and when driving dirty roads and less often in winter Fig 9 22 Rear wheel brake for wheel parking brake variation 1 a anc...

Page 163: ...ar of the friction linings and to the condition of the brake drum Safety caps must be tightly installed in piston and cylinder seats and not damaged If the drum working surface has deep notches and burrs or wear unevenly rebore the drums from the central orifice The maximum permissible diameter of the working rebored brake drum is 281 mm Fig 9 23 Rear wheel brake variation 2 a anchorstudmarks 1 an...

Page 164: ...the bar After the reassembly press the brake pedal 2 3 times to install the pistons to the working position Do not press the brake pedal when the brake drum or the leading shoes are removed as the compressed fluid will press the pistons out of the wheel cylinders and the fluid will escape During every drum removal grind the lip on the edge of the friction surface which appears from the drum wear t...

Page 165: ...eplaced The protective boot should be tightly installed in the seat of the piston and the housing should have no damages During the operation and during rear springs replacement adjust the force of flexible arm 4 Fig 9 25 to the valve piston For adjustment do the following 1 Install the motor vehicle on even level ground 2 Loosen the locknut of adjusting bolt 3 and unscrew the bolt for 2 3 turns F...

Page 166: ...r 1 2 edges of the bolt head and check the brakes in motion again Change the fluid regularly for proper work of the brakes drain old fluid via the bypass valves of wheel cylinders and proportion ing valve and then replace it with a new one Fill the brake system as follows WARNING Filling the brake system of ABS equipped motor vehiclesisnecessarilycarriedoutataservicestationasitrequires additional ...

Page 167: ... eliminated 1 Remove the cap from the bypass valve of the wheel cylinder from the crankcase or from the proportioning valve for non ABS motor vehicles and put a special rubber hose approx 400 mm long on the valve Drop the other end of the hose into a transparent vessel no less than 0 5 L which is half filled with brake fluid 2 Press the brake pedal 3 5 times abruptly hold it in the extreme positio...

Page 168: ...dd the brake fluid collected after bleeding to the master cylinder tank Brake pedal travel can be adjusted by turning adjusting screw 6 as required Fig 9 26 Free pedal travel should be 5 8 mm After adjusting tighten the screw nut with the torque of 14 18 N m 1 4 1 8 kgf m Adjust switches 4 with nuts 7 maintaining an air gap of no more than 0 5 mm which is indicated in the figure After adjust ing t...

Page 169: ...m to compensate their tightening and loosening during operation Adjust the parking brake drive when the travel of the brake lever is more than 6 clicks of the lever pawl and braking effect is insufficient WARNING Use a pit or a hoist for adjustment Adjust the parking brake drive as follows 1 Check the air gaps correctness between the brake shoes and the rear brakes drums press hard the brake pedal...

Page 170: ...170 Fig 9 27 Parking brake drive 1 front cable 2 parking brake signal switch 3 drive lever with sector 4 6 nuts 5 cables equalizer 7 rear left cable 8 rear right cable 9 idler lever unit ...

Page 171: ...ar therivetsare sunk less than 0 5 mm If the linings are glued replace worn brake shoes if the linings wear to a thickness of less than 1 5 mm Grind the linings on new shoes so that their diameter is 0 3 0 4 mm less than the brake drum diameter Despite labyrinth seal of the release and adjusting mecha nisms they gradually collect dirt therefore dismantle and clean the mechanisms especially the rel...

Page 172: ...tor 2 stud 3 13 snap pin 4 parking brake signal switch 5 6 nuts 7 drive cable 8 bolts 9 spring washers 10 adjusting screw 11 release spring 12 spring bracket 14 idler lever 15 drive rod 16 locknut 17 adjusting yoke 18 drive lever 19 housing of release mechanism balls ...

Page 173: ...djusted correctly the travel of lever 1 should correspond to 3 5 clicks of the lever pawl Adjust the length of the drive line brake drive rod as follows 1 Loosen adjusting screw 10 by 4 6 clicks 1 3 1 2 of the torque so that the drum revolves freely by hands 2 Unscrew locknut 16 of adjusting yoke 17 remove the snap pin and take out the stud which connects the yoke with drive lever 18 3 Match the o...

Page 174: ... the steering column Fig 9 29 The scheme of relays and fuses is located on the inner side of the box cap Fig 9 29 Relay and fuse box in motor vehicle cabin K1 fog lamps switch relay K2 high beam switch relay K3 additional interior heater relay K4 low beam switch relay K5 air conditioner compressor relay K6 tailgatewindowandmirrorsheaterswitchrelay K7 intermittentwiper K8 additional discharge relay...

Page 175: ...ver carefully without excessive effort The relay and fuse box under the hood is located on the left behind the battery Fig 9 31 The scheme of relays and fuses is shown on the inner side of the box cap To access the relay and fuse box remove its cap Before replacing a bad fuse find out the reason for its blowing and eliminate it Do not use metallic objects while removing a relay or a fuse Do not us...

Page 176: ...er switch box rear bodyshell heater F10 20 Heating of glass tailgate mirrors light control module F11 Not installed F12 20 Cigarette lighter luggage compartment socket F13 30 Dymos transfer case 30 A F14 10 Window lifters driver door module F15 5 Cluster 34 A reverse movement switch speed sensor 1 A alarm signal switch 2 A F16 15 Airbag F17 10 Multimedia system F18 15 Differential lock F19 10 Left...

Page 177: ...ic fan relay F1 F10 fuses see the table Designation Current A Protected chains F5 5 Instrumentation F6 20 Oil pump F7 20 Starter motor F8 30 Elecric fan 1 F9 10 Microprocessor based Engine Control System IMECS F10 10 ABS ESP F11 20 Heater F12 5 Heater F13 25 Heater F14 Not installed F15 Not installed F16 Not installed F17 60 Mounting block F18 40 ABS ESP F19 60 Mounting block End of Table 9 1 ...

Page 178: ...inse remained traces on the skin with 5 solution of ammonia or sodium carbonate collect spilled electrolyte with a special filler bulb or an areometer flush it with water and air the room to charge the battery remove it from the vehicle and unscrew filler plugs the battery must be charged in a well ventilated room Elec trolyte fume accumulation is dangerous to health and explosive Accumulatorbatte...

Page 179: ... Once the starter motor has been removed check the relay switch outputs and the working surface of electric terminals check the starter motor drive a gear a lever and a spring clean the rubbing details from dirt and lubricate them with Litol 24 grease as required Starter motor drive should move freely with no jamming at the shaftsplines anditshouldreturntothesourcepositionbythereturn spring The an...

Page 180: ... system light and audio alarm Lampmaintenanceconsistsinitsadjustmentandreplacement of bad ones Adjust the headlights as follows 1 Park the motor vehicle which should have a full fuel tank its curb weight normal tires pressure and loaded driver s seat 750 N 75 kgf on an even level ground 5 meters far from the screen with special markings Fig 9 32 2 Movecontrol3 seeFig 3 4 ofheadlightadjusterto0posi...

Page 181: ...emove the lamp Install halogen lamps wearing gloves do not touch the lamp bulb If the bulb has fat stains remove them with alcohol Front fog lamps Adjust the front fog lights with screw 1 Fig 9 34 using S 5 or Torx T20 keys Install the light into the position in which the cutoff line coincides with line 1 Fig 9 35 To replace front fog lights remove wiring harness connector 2 Fig 9 42 from the ligh...

Page 182: ...the lamp Replace T signal lamps only when lockers are removed Side T Signals are located at UAZ Patriot and UAZ Pickup in rearview mirrors Fig 9 37 If the lamps are broken they are replaced with a new rearview mirror Fig 9 35 Screen marking for front fog lights adjustment H distance between the headlights center and the ground level V V motor vehicle longitudinal axis projection A A B B axes of he...

Page 183: ...ull cap 3 and remove the holder from the upholstery orifice then turn the cap You can replace any lamp Fig 9 39 by taking out the sockets with lamps by rotating counter clockwise Replace the holder and the catch if necessary Fig 9 38 Hatch of tail lamp access 1 catch of holder cap 2 holder cap 3 cap Fig 9 36 Side T Signal 1 catches 2 socket Fig 9 37 Rearview mirror with side T Signal ...

Page 184: ... 9 41 The bad lamp should be replaced The center high mount stop lamp Fig 9 42 is located at UAZ Pickup on the tailgate depending on configuration and is fixed by catches 1 The bad lamp should be replaced Fig 9 40 License plate lamps 1 screen of license plate lamps 2 lamphousing 3 lamplens 4 lamp 5 slot 6 pawl 7 screws Fig 9 39 Tail lamps 1 socket of brake signal lamp 2 socket of T signals lamp 3 ...

Page 185: ...mps should be replaced Glove compartment lamp To replace the lamp remove the lampshade Fig 9 44 fromtheglovecompartment Releaseholder 2 and replace lamp 1 Fig 9 41 Center high mount stop lamp UAZ Patriot Fig 9 42 Center high mount stop lamp UAZ Pickup 1 catches 2 lens 3 lamp housing 4 connector 5 gasket Fig 9 43 Reading lamps Fig 9 44 Glove compartment lamp 1 lamp 2 lamp holder 3 catches ...

Page 186: ...2 Fig 9 45 Luggage compartment lamp 1 cap 2 lamp 3 lamp holder 4 catches Gages and alarms Whenremovingelectricsensors isolatethewirestoavoidshort circuiting Use a hex socket wrench or a box wrench to remove the coolanttemperaturesensorandthecoolantemergencytemperature sensor without damaging their housings Check the fluid level in the cooling system of the radiator If the fluid level is low the se...

Page 187: ...essure water jet using car shampoo and a soft cloth Do not use sponges Whenwashingthevehiclebodyusingsuchunitasthe Karcher choose regimes blade fan or similar It is not recommended to use the regime jet for washing doors and windows to avoid forcing out the rubber seals and ingressing water into the cabin Wipe dry the washed bodyshell surfaces to avoid stains appear ingafterdrying outinsummer andt...

Page 188: ...s and fluids table see Annex 3 It is not permitted to use oils and greases not indicated in the table and to break greasing intervals Methodsofassemblylubricationandgreasechangearedescribed in the corresponding manual sections Within 24 hours after fording check oil in all units If water is detected in the oil change the oil in this unit and grease all the lubricationnipplesofthechassisuntilthefre...

Page 189: ...pairing Carrying capacity of the jack in Fig 10 1 is 2 tons that of the jack in Fig 10 2 is 1 ton The highest lifting point of the jack in Fig 10 1 is 410 mm that of the jack in Fig 10 2 is 380 mm WARNING If defective or installed improperly the jack can cause injuries or motor vehicle damage It is strictly forbidden to carry out any work with the motor vehicle if it stands only on the jack For ja...

Page 190: ...190 Fig 10 1 Jack 1 housing 2 external screw 3 internal screw 4 head 5 pawl 6 handle 7 ratchet Fig 10 2 Jack 1 hexagon under 22 mm wrench 2 yoke 3 extension Variant 1 Variant 2 ...

Page 191: ...ed put wedges under the wheel which is opposite to the jacked up wheel 2 Install the jack on a level ground under the axle shaft sleeve 3 Lift the motor vehicle wheel to the necessary height by rotat ing hexagon 1 or yoke 2 clockwise with the 22 mm nut wrench or with extension 3 4 Tolowerthewheel rotatehexagon1counter clockwisewith the wheel wrench At the end of work fold the jack completely by ro...

Page 192: ...tle them as required Clean the wheel disks from dirt and corrosion straighten and paint them Clean the tires from dirt wash and dry them Talc the tubes and the inner side of tires Collect the wheels and tires put the normal pressure in them and install on the motor vehicle 10 As required flush out the fuel tanks and fill them with fuel 11 Prepare the accumulator battery for long preservation fol l...

Page 193: ...s in advance Once a year fill the engine cylinders with 30 50 g of the engine oil by turning the crankshaft 3 Clean the damaged areas from corrosion and grease and paint them 4 Turn the steering wheel to both sides 2 3 times 5 Check the parking brake and the pedal brake the clutch the throttle drive and lighting switches 6 Check the working fluid level in the reservoirs of the brake master cylinde...

Page 194: ... the motor vehicle The loading and unloading of the vehicles should be carried out by a crane with special grips During all transport motor vehicles should be arranged with the following distances between them 50 100 mm from the side of the engine cooling radiator 100 mm from all the other sides The motor vehicle parking brake is on the engine is off the lever of the gearbox is shifted into the fi...

Page 195: ...light fog and parking lights PY21W P21W P21W P21 5W 21 21 21 21 5 T signal side repeaters of UAZ 23602 WY5W 5 Side T signals of UAZ 3163 and of UAZ 23632 LED License plate lamps АС12 5 1 5 Dome lamps and reading lamps LED Glove compartment lamp АС12 5 1 5 Cigarette lighter illumination А12 3 1 3 Center high mount stop lamp for UAZ 3163 and UAZ 23632 LED Luggage compartment lamp АС12 5 1 5 ...

Page 196: ...Nuts of engine front struts to frame brackets 5 0 6 2 Bolt of engine rear strut to bracket 8 0 10 0 Nuts of rear strut to frame cross member 2 8 3 6 Inlet pipe nuts 2 9 3 6 Exhaust manifold nuts 2 0 2 5 Self locking nuts of neutralizer and engine 4 6 5 1 Oil housing bolts 1 2 1 8 Spark plugs 2 1 3 1 Filling pipe collar 0 25 0 35 Clamps of cooling system hoses 0 4 0 45 Bolts of cooling system radia...

Page 197: ...s 5 0 7 0 Tie rods locknuts 10 5 13 0 M10 bolt of steering system propeller shaft 4 8 5 6 Nut of steering system drag link 20 28 Front wheels journal bolts 3 6 4 4 Bolts of rear brake shields 4 4 5 6 Nuts of pipelines terminals brake units bypass valves 1 4 1 9 Bypass valves of the clutch release cylinder 1 0 1 4 For working cylinder switch with plastic housing 0 5 0 6 Bolts of front disc brakes 1...

Page 198: ...s 0 15 0 25 Nuts of Delphi power steering hoses 2 0 3 5 Nut of front spring joint 16 18 Steering wheel nut 3 2 3 6 Screws of external locks and door locks catches 3 0 4 0 Note Use the following tightening torque for other threaded couplings M6 0 45 1 0 kgf m M8 1 4 1 8 kgf m M10 3 0 3 5 kgf m M12 5 0 6 2 kgf m Appendix 2 end ...

Page 199: ... class 6 type II and K5 ZMZ 40906 engine lubrication system Engine oils SAE 0W 40 from minus 30 to plus 25 C SAE 5W 30 from minus 25 to plus 20 C SAE 5W 40 from minus 25 to plus 35 C SAE 10W 30 from minus 20 to plus 30 C SAE 10W 40 from minus 20 to plus 35 C SAE 15W 30 from minus 15 to plus 30 C SAE 15W 40 from minus 15 to plus 45 C SAE 20W 40 from minus 10 to plus 45 C SAE 20W 50 from minus 10 to...

Page 200: ...tem Mobil ATF 220 EZL 998 Shell Spirax S4 ATF HDX ТНК ATF IID Lukoil ATF G Box Expert ATF DX III Plastic lubricants Splines of front and rear propeller shafts with lubrication nipples joints of front and rear propeller shafts with lubrication nipples steering knuckle steering knuckles pins bearings of front and rear wheel hubs release and adjusting mechanisms of parking brake parking brake drive c...

Page 201: ... of front disc brakes UNIOL 2M 1 Rubber weatherstrips Graphite powder Barbatia Grease 2 Splines and joints of non repairable propeller shafts Kluberplex BEM 41 141 Fluids Hydraulic drives of clutch and brake system Brake fluid RosDot 4 Rosa Rosa 3 Tom For ABS equipped vehicles Rosa DOT 4 Rosa 3 SAE 1703F DOT 4 Engine cooling system Cooling fluid OZH 40 Lena OZH 65 Lena TOSOL A 40M TOSOL A 65M OZH ...

Page 202: ...202 Annex 4 INFORMATION about precious metals in motor vehicle electric equipment Item type Item name Precious metal Weight g 6002 3829 Emergency oil pressure sensor silver 0 0310 ...

Page 203: ... vehicle electronic anti theft system with the engine control unit МЕ 17 9 71 51 Power options control system 56 Defensive parking system 65 Rear parking system 65 Parking assistance system 68 Rear view camera 70 Autocruise and Overspeed limiter system Electronic stability program ESP 78 Multimedia system keys unit 84 Vehicle interior and body equipment 85 Interior heating ventilation and conditio...

Page 204: ...27 Before summer operation 127 Before winter operation 127 Engine 128 Engine suspension 128 Engine Cylinder Head 128 Engine gas distribution mechanism 128 Engine lubrication system 128 Engine housing ventilation system 131 Engine cooling system 132 Exhaust system 134 Gasoline injection system with microprocessor controlled fuel feed and ignition 59 Fuel supply system 137 Fuel supply and ignition c...

Page 205: ...Lubrication of the vehicle 188 Chapter 10 Tools and appliances 189 Chapter 11 Preservation 191 Maintenance of a stored vehicle 193 Depreservation 193 Chapter 12 Transportation 194 Chapter 13 Recycling 194 Annex 1 Motor vehicle lamps 195 Annex 2 Tightening torque of main threaded couplings 186 Annex 3 Lubricants and fluids 189 Annex 4 Information about precious metals in motor vehicle electric equi...

Page 206: ...For Notes ...

Page 207: ...For Notes ...

Page 208: ...32 2011 Seventh Edition Prepared for publishing by UAZ PJSC Chief Designer Department Editor in chief Chief Designer O A KRUPIN Editor I L NIKOLAEV Content by D A SHEMYREV Ulyanovsk Automobile Plant LLC Russia 432034 Ulyanovsk 92 Moskovskoye Highway http www uaz ru ...

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