UAZ HUNTER 315148 Operating Manual Download Page 1

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Ulyanovsk Automobile Plant PJSC

Motor Vehicles

UAZ-315195 and UAZ-315148

and Versions Thereof

Operating Manual

RE 05808600.133-2012

3rd Edition

2016

Summary of Contents for HUNTER 315148

Page 1: ...Ulyanovsk Automobile Plant PJSC Motor Vehicles UAZ 315195 and UAZ 315148 and Versions Thereof Operating Manual RE 05808600 133 2012 3rd Edition 2016 ...

Page 2: ...it The maintenance of the motor vehicle can be performed by one of the service stations recommended by the Manufacturer or by the company from which you have purchased the motor vehicle Service stations have all the necessary spare parts sets of special accessories and tools All servicing of the motor vehicle is performed by experienced specialists Due to continuous work on the improvement of the ...

Page 3: ...atures of 10 up to 50 C air relative humidity of up to 80 at 27 C under conditions specified above for the U version motor vehicles The plus sign near the part assembly description means that this part assembly shall be installed into the motor vehicles depending on the configuration MOTOR VEHICLE MARKINGS The vehicle identification number Fig 1 2 is embossed on the name plate and on the horizonta...

Page 4: ...4 Fig 1 1 Basic dimensions of UAZ 315195 and UAZ 315148 hardtop motor vehicles dimensions are given for reference ...

Page 5: ...environmental class I the Vehicle Description Section VDS consists of six symbols with the first five symbols digits designating the engine model If the engine model designation includes less than five digits zeros shall take the place of blanks The sixth symbol zero or letter designates the engine configuration option II the Vehicle Identification Section VIS consists of eight symbols The first s...

Page 6: ...6 Fig 1 3 Location of the engine identification number ...

Page 7: ...at 5 5 Maximum load capacity incl driver and passengers kg for operation on roads with good pavement 750 735 for operation on other roads and terrain 550 535 Motor vehicle allowable gross weight kg for operation on roads with good pavement 2520 2550 for operation on other roads and terrain 2320 2350 Gross weight distribution by axles kg for operation on roads with good pavement front axle load 102...

Page 8: ...el 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 towed trailer kg max one equipped with brakes 1500 2 one without brakes 750 2 The least turning radius along the front external relative to the turning center wheel trace axis m m...

Page 9: ...Type 4 stroke with spark plug ignition diesel turbo engine with direct injection Number of cylinders four Cylinder arrangement row vertical Ignition sequence 1 3 4 2 Cylinder diameter mm 95 5 87 Piston stroke mm 94 94 Engine displacement L 2 693 2 235 Compression ratio 9 1 19 Minimum crankshaft rpm at idle min 1 800 900 850 900 Maximum torque N m kgf m as per UNECE Rules 85 GOST R 41 85 209 7 21 4...

Page 10: ...s A B C D E F AI 92 K4 GOST 32513 and AI 92V of classes 0 1 2 3 4 types II and II GOST RV 9130 001 in accordance with operating conditions Allowed Premium Euro 95 type II AI 95 4 and Super Euro 98 type II AI 98 4 GOST R 51866 AI 95 K4 and AI 98 K4 GOST 32513 Cooling system Liquid closed loop forced circulation TRANSMISSION Clutch clutch type Dry single disc drive type Hydraulic Transmission gear b...

Page 11: ... constant velocity joints CHASSIS Suspension suspension type Conventional front coil suspension with the stabilizer bar rear on two longitudinal semi elliptic leaf springs shock absorbers Four hydraulic dual action telescopic Wheels and tires wheels Undivided type disc wheels fastening five nuts Steel tire rim size is 6 1 2 Jx16 with projection of 40 mm or of light alloys tire rim size is 7Jx16 wi...

Page 12: ...71 14V 90A JSC BATE Rechargeable battery 6CT 66 6CT90A Spark plugs AU14DVRM GOST R 53842 DR17YC F by BRISK Company Heating plugs 0250 202 045 by BOSCH Company 0100 226 573 by BERU Company Starter 6012 3708 by ZIT CJSC AZE 2154 12V 1 9 kW by Iskra Company AZE 2203 12V 1 9 kW by JV Pramo Iskra LLC DW 12V 2 0 kW by BOSCH Company Ignition switch With anti theft system and starter re ignition lock Wind...

Page 13: ...al free play mm 5 8 Front wheel toe in 0 4 0 10 Front internal wheel maximum steering angle degrees 26 27 Steering system total clearance steering wheel s steering angle from the position corresponding to the steering wheels wedge in one direction to the steering wheel position corresponding to the steering wheels wedge in the opposite direction degrees max 20 Tire pressure MPa kgf cm2 Front wheel...

Page 14: ...rication system 6 5 Transmission gearbox case Dymos 2 5 made in China 1 7 Transfer gearbox case 0 8 Main drive case front rear 1 5 1 4 Steering mechanism hydraulic booster case 1 1 Clutch hydraulic drive system 0 18 0 20 Windshield washer reservoir 2 2 Rear window washer reservoir 2 2 Brakes hydraulic drive system 0 60 ...

Page 15: ...not leave the door and ignition keys inside 5 Prior to opening the door make sure that it will not cause hindrance for other road users Prior to closing the door make sure it will not pinch someone or something The motor vehicle shall not be driven if any door or tail board is open Prior to travel check good operating condition and the security of closing of locking mechanisms of the hood the body...

Page 16: ... that the exhaust system has no contact with flammable materials e g dry grass 17 When handling antifreeze fluids fuel or the brake fluid please observe the following rules avoid any operations resulting in the ingress of these fluids or their vapors into your mouth in case of skin contact immediately wash the fluid away with water and soap prevent the spillage of fluids in the motor vehicle or a ...

Page 17: ...c drive with steps disengaged in the gearbox and the transfer case shut off the engine due to loss of braking capacity 23 During the motor vehicle maintenance and routine repairs the following requirements shall be met prior to commencing work check the condition of tools and attachments arrange the work clothing button up cuffs tuck the clothing in such a way that no hanging ends are present tuck...

Page 18: ...he motor vehicle until the fault is eliminated 3 1 Upon cold start knocking in hydraulic pushers of valves may arise caused by the suction of the air into the high pressure chambers of hydraulic pushers Typically these phenomena appear in the following cases cold start multiple starts after several unsuccessful starts engine start after a long time of standing still To remove the air the engine mu...

Page 19: ...t the sparking discharge is grounded 10 Prevent contact of acids soda solutions brake fluid anti freeze and lubricants with the body s painted surfaces and rubber parts 11 Prevent the motor vehicle suspension system from being subjected to impact loads In case of heavy impact with front wheels inspect thoroughly the wheels all the components of the front axle steering links steering system the eng...

Page 20: ...the units containing liquid lubricants 19 When the tail gate of your motor vehicle is opened other traffic participants cannot see the rear lighting devices Prior to opening the T gate place a warning triangle on the road as per GOST R 41 27 99 20 The long term and fail safe operation of the motor vehicle depends on how accurately you observe the requirements stipulated in this Manual 21 For tight...

Page 21: ... vehicle with a driver all seats occupied a motor vehicle with a driver and maximum allowed load in cargo compartment Adjust the headlights strictly by marks in accordance with the load For other loading options when gross weight is not exceeded select the position in the way that the road illumination by low beams is within the set standards without blinding oncoming transport drivers Fig 3 1 Con...

Page 22: ...n VII push high beam is on if headlights are switched on by the external illumination switch stable position The windshield wiper and washer lever see Fig 3 2b has the following positions I the windshield wiper and the washer are off II the windshield wiper intermittent mode is on unstable position III the windshield wiper intermittent mode is on stable position IV the windshield wiper constant mo...

Page 23: ...pressure warning lamp IV voltmeter indicating voltage in the motor vehicle s electrical system The instrument panel Fig 3 3b by the Takosan Company Turkey V tank fuel level indicator with fuel reserve warning lamp If there is no signal from the fuel level indicator the warning lamp flashes Each tank is equipped with its own indicator gauge VI cooling fluid temperature indicator with cooling fluid ...

Page 24: ...witched on with the engine running signals that the rechargeable battery is discharged The lamp can be on with engine running idle immediately after start To ensure delivery of current by the generator you must increase the engine crankshaft rpm and the lamp should then go off IV UAZ 315148 fuel filter water sensing lamp orange UAZ 315195 cooling fluid emergency overheat warning lamp red V UAZ 315...

Page 25: ...one or several lamps of the turn signal in the lights has failed IX high beam warning lamp blue It goes on when high beam is switched on X fault warning lamp of the engine control system OBD components affecting toxicity of exhaust gases orange It goes on when ignition is switched on and goes off after the engine starts The warning lamp turning on indicates faults of the engine components or exhau...

Page 26: ... the transfer case 1 5 gears R reverse gear 2H direct gear front axle disengaged 4H direct gear front axle engaged main position left N neutral position 4L front axle and speed reduction gear engaged Attention When the speed reduction gear of the transfer case is switched on the transfer case control lever in the end of stroke shall be independently driven by spring shift slightly to the left the ...

Page 27: ... standard wrenches At the Manufacturer s plant the bolt heads are not broken away to retain possibility to remove the lock from the steering post during the pre sale period A consumer must make his her own decision whether to break the heads away or not The ignition lock switch has four positions 0 everything is off stable position I ignition is on stable position II starter is on unstable positio...

Page 28: ...blowing pipes 31 air intake lever Interior and exterior equipment of the motor vehicle Doors Safe type door locks and handles The front door locks and the tail gate lock are locked with the key The door internal panels are equipped with handles 1 Fig 3 6 by means of which the door locks are locked from the interior handle bottom position Locks arrested with handles 1 cannot be unlocked from outsid...

Page 29: ...s Forming of a sleeping area extend the tilting seats into a working position if available turning handles 1 Fig 3 9 tilt the rear triple seat backward until it stops remove the headrests from the front seats move the seats into extreme front position and turning the seat back tilt adjustment knobs tilt them backwards Creation of cargo space unfasten the fastener of the rear triple seat safety bel...

Page 30: ... belts Infants up to 1 5 years old shall only be transported in the child restraint devices with face turned backwards ATTENTION The ISOFIX child restraining systems shall be mounted in accordance with Table 3 1 match of the ISOFIX child restraining systems to installation points in the motor vehicle Fig 3 9 Rear triple seat 1 seatbacktiltadjustingknob lever 2 lock handle Fig 3 8 Front seat 1 seat...

Page 31: ...r 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 facing seat ISO F2 IUF IUF B1 Front facing seat ISO F2X IUF IUF A Front facing seat ISO F3 IUF IUF IUF a place suitable for installation of a multi purpose for the given category front facing child seat with ISOFIX fasteners IL a place suitable for installation of a multi purpose child seat...

Page 32: ...s Fig 3 10 Fuel tank filler location 1 hatch cover 2 hatch cover lock Seats Weight Front Rear Rear group seat lateral central passenger s seat seat 0 up to 10 kg 0 9 months X U X 0 up to 13 kg 0 2 years X U X I 9 18 kg 9 months 4 years U U X II III 15 36 kg 4 12 years U U X Children seat category U multi purpose children seat to place a child either front facing or rear facing X place for a seat u...

Page 33: ...ats The front and the rear seatbelts are three point with retraction mechanisms To fasten the belt pull belt buckle 1 and without twisting of straps insert it into lock 2 until a click id heard To unfasten the belt push the button on the lock Rear seatbelts are equipped with a quick disconnect fastener attached to the floor of the interior see Fig 3 12 A When folding the seat unfasten the belts tu...

Page 34: ...d accidents or other damage if safety belt operating rules are violated or an unauthorized replacement of the safety belts was performed Safety belt warning lamp When ignition is turned on if the safety belt is unfastened the safety belt SB warning lamp goes on on the dashboard The warning lamp goes off when the SB buckle is inserted into the retractable SB lock or ignition is switched off If the ...

Page 35: ...ated on the left front wheel splash guard under the hood The rear window washer fluid pump is installed in the washer tank located in the niche of the left rear wheel arc The removable tanks shall be filled with pure water in the summer or with a dedicated windshield wiper anti freeze in winter Adjust the fluid stream direction by changing the position of spraying nozzle balls with a needle insert...

Page 36: ...ater you must turn on the tap of the fluid supply cut in to the heater radiator and on UAZ 315148 motor vehicle also turn on the heating system s additional pump pos 11 see Fig 3 1 and open the ventilation hatch Switch 22 see Fig 3 1 is used to switch the fan s electric motor on and to select its rpm When draining the fluid from the cooling system the heater tap must be kept open otherwise the flu...

Page 37: ...eration in winter season you might need to repeat the above procedure Chapter 4 MOTOR VEHICLE PREPARATION UPON RECEIPT FROM THE MANUFACTURER The dealer must only put up the motor vehicle for sale upon completion of pre delivery preparation as specified in the warranty and service book When motor vehicles are delivered to a dealership preliminary works shall be performed as specified in the sub sec...

Page 38: ...pter 6 ENGINE START AND SHUTDOWN Engine start General Prior to starting the engine check for the presence of cooling fluid in the cooling system presence of fuel and oil level in the crankcase Move the shift lever to neutral position Attention The ignition switch mechanism has an interlock allowing you to re start the engine only after the key is returned to position 0 Fig 3 5 Release the ignition...

Page 39: ... the warning lamp constantly on or flashing can result in converter failure 4 Press the clutch pedal as far as it can go Do not press the throttle control pedal when you start the engine 5 Switch the starter on by turning the key to position II 6 When the engine starts release the key turn the starter off 7 Retry starting the engine if necessary fater a pause of at least 15 20 seconds 8 Warm the e...

Page 40: ...n the start switch to position I Wait until the glow plugs cut in warning lamp goes off Disengage the clutch and engage the starter position II Keep the starter engaged until the engine starts but no longer than 15 seconds Retry starting after a puase of at least 1 minute If the engine fails to start or stalls return the key to position 0 Then turn the key to position I wait until the glow plugs c...

Page 41: ...rs with smooth pressing onto the lever and without jerks If it is not possible to engage the required gear prior to starting off slightly release the clutch pedal and then disengage the clutch again and engage the gear The speed synchronizers in the gear box allow changing gears without double disengagement of the clutch However to speed up the gear changing process and to extend the service life ...

Page 42: ...t climbs with convenient approach and comparatively even road surface shall be passed in acceleration without engagement of the speed reduction gear in the transfer case in the second or third gear in the gearbox depending on the uphill gradient If the climb cannot be passed for any reasons take all the precautions and go down slowly having engaged the reverse gear Go down gradually not allowing t...

Page 43: ...rades and deep ditches On such roads drive carefully on the crest and at a low speed Marshland shall be passed along a straight line without sharp turns and stops Start off smoothly and without jerks Move with the front axle and speed reduction gear in the transfer case engaged using the gear in the gearbox which would provide the required drive rim pull without slipping To prevent slipping of the...

Page 44: ...eral times partly disengage the clutch and partly apply the brakes in order to dry out the clutch facings and the brake shoe linings If the motor vehicle engine stops while fording try two three times to restart the engine using the starter If the engine fails to start the motor vehicle must be immediately removed from the water by any possible means If some water penetrated into the motor vehicle...

Page 45: ...ooks and lugs Fig 8 1 The motor vehicle must be towed smoothly without jerks A trailer may only be towed if the ball type tow unit is available Attention towing of the motor vehicle by the ball type tow unit is strictly forbidden Fig 8 1 Towing hooks and tow unit 1 towing hooks 2 rear lug ...

Page 46: ...enish to the standard the amount of cooling fluid oil in the crankcase braking fluid and fuel 2 Check functioning of steering system brake systems illumination devices light and sound alarm and window wiper Eliminate the revealed defects 3 Fill the windshield washer fluid tank Water is allowed for use in warm season 4 If the vehicle was operated in a very dusty environment or crossed fording sites...

Page 47: ...ater is poured into the windshield washer tank drain the water Pour in the low freezing point windshield washer fluid 3 Check the operation of the interior heating and ventilation system Eliminate the defects 4 Prior to winter operation or at 30 000 km flush the fuel tanks 5 Replace oils in the aggregates with winter grade oils specified in the lubrication schedule ZMZ 40905 ENGINE Engine suspensi...

Page 48: ...raulic pushers Where the hydraulic pushers are being used no clearance adjustment is required Engine lubrication system If there is a fault in the lubrication system the operation of teh engine must be stopped immediately For oil cooling the lubrication system comprises the oil radiator connecting into the cooling process automatically using the thermal valve Monitor the oil level in the crankcase...

Page 49: ...Z 40905 engine which must be replaced during the first maintenance whenthefirst2 500kmarecovered withoneofthefollowing Fig 9 2 ZMZ 40905 engine Left side elevation the fan and the fan drive coupling are removed for clarity 1 pipe of the cooling fluid supply from the radiator to the water pump 2 connecting hoses 3 temperature control valve housing 4 control system cooling fluid temperature sensor 5...

Page 50: ... the P mark is not allowed Use only the recommended oils The engine oils of different grades and different manufacturers may not be mixed If the engine oil of another grade or Fig 9 3 ZMZ 40905 engine Right side elevation the fan and the fan drive coupling are removed for clarity 1 pipe of cooling fluid removal to the heater 2 tube of cooling fluid intake from the heater 3 knock sensor 4 fuel line...

Page 51: ...ance of the engine crankcase ventilation system remove valve cap 4 Fig 9 4 ventilation hoses and tubes vacuum valve cap 3 the valve membrane and spring and clean the removed parts Clean the holes of valve cap ventilation necks holes 7 of separated oil drain calibration orifice 8 in the vacuum valve case and venting holes in the vacuum valve cap The oil baffle 5 shall be flushed while remaining mou...

Page 52: ...ing fluid avoid any operations resulting in ingress of the fluid into your mouth in case of skin contact do not let the fluid dry on the skin and immediately wash it away with warm water and soap wash away any spilled fluid with water and ventilate the room take off any clothing contaminated with the fluid dry it outdoors and then wash it Take care when opening the engine radiator plug to avoid sc...

Page 53: ...rate travel up to 500 km check the cooling system hermetic tightness and after elimination of leaks add the same cooling fluid into the radiator or the expansion chamber Inexceptionalcases e g majorleakofcoolingfluid short time filling with pure fresh water into the cooling system is allowed Sea water may not be used nor alkali to soften the water since it corrodes the engine s aluminum parts Prio...

Page 54: ...pump 13 displacement for which the following must be done loosen bolts 11 adjust the belt tension using adjustment bolt 12 while moving the pump along the bracket and tighten bolts 11 The cooling system and engine generator drive belt 3 Fig 9 6 tension is ensured by the automatic belt tensioner No belt tension adjustment is required during operation To check the automatic tensioner condition check...

Page 55: ...e tightened see Appendix 2 with preliminary wetting of thread connections with special liquids or kerosene When the fuel system or the ignition system is faulty a great quantity of unburnt hydrocarbons ingress into the converter thus Fig 9 6 Drive belt tension of aggregates 1 timing sensor 2 automatic tensioner 3 generator and water pump drive belt 4 generator pulley 5 inlet pipe 6 receiver 7 thro...

Page 56: ...ngine control system automated external diagnostics and programming devices the data link connector is installed under the hood on the front body panel above the engine The main switch power circuit running from the battery is protected against ground short circuits with 10 A harness fuse At the same time IMECS ignition circuit is protected against Fig 9 7 Sensors layout on the engine 1 knock sens...

Page 57: ...g vapor cleaning do not direct the nozzle towards system components 8 The electronic components of the control systems are designed for very low voltage and are vulnerable to electrostatic discharges 9 The fuel system at the section from the fuel priming pump to the fuel pressure controller on the running engine is pressurized to 3 8 kgf cm2 To prevent leaking of fuel check thoroughly the hermetic...

Page 58: ...el tanks filling pipes necks are blind and ensure tight packing The following is recommended due to the specified features of the fuel system design when closing the tank filler necks make sure the plugs are in good condition the sealing gasket is present and undamaged and ensure tight closing of the plugs through application of for partial fuelling of the vehicle start from the right side tank mo...

Page 59: ...e strainer the jet pump the pressure controller and the fuel tank level gage From time to time check and clean the pins of the fuel pump connection to the vehicle s electrical network Fig 9 8 The engine fuel system pattern 1 fuel tank plug 2 tube from the fuel priming pump to the final fuel filter 3 fuel module 4 fuel rail 5 throttling device 6 absorber purge valve 7 8 11 12 26 vapor removal hoses...

Page 60: ...n the fuel drain the fuel and flush the fuel tanks with pure gasoline and replace the final fuel filter Leak in connections shall be eliminated by tightening worm drive clamps see Appendix 2 or replacing faulty components The fuel tubes shall be installed until a click of the quick coupler s locking spring Upon completion of any fuel system maintenance operations related to tightening of connectio...

Page 61: ...he vehicle has an air filter Fig 9 9 with a replaceable cardboard filtering cartridge Replace the filtering cartridge 5 Fig 9 9 every 30 000 km or in case of the engine power decrease During maintenance of the air filter inlet hoses must be carefully protected against ingress of foreign objects dirt and sand The filter cartridge shall be replaced as per the following order loosen the clamp and rem...

Page 62: ...epends on the conditions of the mechanical and hydro mechanical systems Several deviations leading to faults can be mistaken for electronic control system malfunctions such as low compression deviation of gas distribution phases caused by an incorrect assembly of engine components air ingress into the inlet and the outlet pipelines poor fuel quality failure to meet the maintenance schedule The con...

Page 63: ...ble Clearing fault codes The memory storing the fault codes can only be cleared using the scanning tester when the faults are eliminated If the rechargeable battery turns off the control unit self learning parameters are not lost and can be only cleared using the scanning tester When the fault codes are cleared the controller accumulated adaptive data the controller self learning parameters are cl...

Page 64: ...is still hot Prior to draining open the oil filler cap The oil drains for at least 10 minutes When fastening the drain hole plug check condition of the sealing gasket The damaged gasket shall be replaced with a new one Pour the fresh oil up to the upper mark on the oil level indicator and start the engine After the oil emergency pressure alarm is turned off stop the engine and in 15 minutes check ...

Page 65: ...r fastening neck nut and tighten if necessary When installing the filter onto the engine make sure the sealing gasket is in proper condition lubricate it with oil and turn the filter until the gasket touches the plane on the heat exchanger and then tighten another 3 4 of a turn Make sure there is no oil leak in the sealed joints Fig 9 11 ZMZ 51432 engine left side view 1 turbocharger 2 control sys...

Page 66: ...ng the water piezometer connected to the crankcase via the oil level indicator tube In the crankcase of an idle running engine with crankshaft rpm minimum to maximum there shall be negative pressure of 1 14 mbar 10 140 mm WG If oil traces appear on the joint between the turbocharger and the inlet pipe check the crankcase blow by gases pressure Fig 9 12 ZMZ 51432 engine right side view 1 starter 2 ...

Page 67: ...tor cap ventilation hose and the turbocharger inlet pipe Flush the removed parts with kerosene and dry out The oil baffle shall be flushed without disassembling it Cooling system Attention The cooling fluid is toxic Store the fluid in a tightly closed container The following rules must be observed during work with cooling fluid avoid any operations resulting in ingress of the fluid into your mouth...

Page 68: ...nsion chamber In exceptional cases e g major leakIn exceptional cases e g major leak of cooling fluid short time filling with pure fresh water into the cooling system is allowed Sea water may not be used nor alkali to soften the water since it corrodes the engine s aluminum parts Prior to use filter the water using the materials at hand As soon as possible drain the water completely flush the cool...

Page 69: ...nd 16 Fig 9 13 Attention The engine may not be operated without the temperature control valve without one the engine runs with the cooling fluid at decreased temperature which results in the engine components increased wear and increased fuel consumption Fig 9 13 The engine cooling system pattern 1 interior heater radiator 2 passenger compartment heater tap 3 engine 4 heating system additional pum...

Page 70: ...tension rollers 3 bring the belt tension to the required value for standard values see Table Specifications tighten bolt 4 If you cannot achieve the specified tension using one roller use the second roller The belt shall be replaced as per the following procedure loosen bolts 4 by turning the rollers 3 release the belt tension replace the belt and tension it as specified above Fig 9 14 Belt of the...

Page 71: ... belt tension hold the lever in this position and replace the belt Exhaust system ATTENTION The converter operating temperature shall be 400 600 C The vehicle may not be operated if no protective screen is installed on the converter When the vehicle is in motion and in standstill ensure that the exhaust system has no contact with flammable materials e g dry grass Fig 9 15 Belt of the generator coo...

Page 72: ...f part of the exhaust gases from the exhaust manifold to the engine cylinders The system operation is controlled by the microprocessor based control unit using the indications of the sensors of the Fig 9 16 Exhaust gases recirculation system pattern 1 turbine 2 compressor 3 recirculation valve 4 recirculating gases cooler 5 air supply pipe with throttle gate 6 inlet pipe 7 valve stem position sens...

Page 73: ...stallation of any components or wires of the control system disconnect the rechargeable battery ground wire 2 The engine may not be started if the rechargeable battery and the ground wire between the engine and the body are not connected reliably 3 The rechargeable battery may not be disconnected from the vehicle s electrical network while the engine is running 4 If being charged from an external ...

Page 74: ...e tank monitor the fuel consumption with due account for variation of the fuel amount in both tanks Fuel tanks 4 22 Fig 9 17 Maintenance of the fuel tanks includes periodic flushing of the fuel level indicator inlet tube filter right side and left side tanks and flushing of the tanks themselves From time to time drain the settling by unscrewing the plug in the tank bottom part Fig 9 17 The engine ...

Page 75: ...ere must be at least 20 liters of fuel in the right side tank Clogging of the final fuel filter presence of dirt and mechanical admixtures in the fuel tank appear first of all due to deterioration of the pumping of the fuel from the left side tank into the right side one unstable engine operation at high loads and degradation of vehicle performance Note At ambient air temperature of below 0 C the ...

Page 76: ... not be allowed For the final fuel filter use BOSCH 0 450 126 273 shown in Fig 9 18 Heating is controlled automatically using the fuel temperature sensor 6 Every 5 000 km remove the sediment from the filter unscrew plug 5 drain the settling until pure fuel flow appears and screw back the plug Every 15 000 km replace the filter cartridge Fig 9 18 Final fuel filter with priming pump and water in fue...

Page 77: ...tions must be done 1 Make sure the fuel plugs of tanks are tightened securely The fuel tank filler plugs are blind and ensure tight sealing 2 Loosen the air release plug 5 on the final fuel filter FFF Using a manual priming pump 1 on the FFF fill the main line until air bubbles disappear from the fuel going from beneath the air release plug 3 Tighten the air release plug 5 4 Start the engine with ...

Page 78: ...er To prevent turbocharger damage the engine may not be operated without the air filter or with the air filter damaged If the engine is operated with the recommended lubricating oils the TCR service life is the same as that of the engine Attention When the engine is stopped after long term operation at high rpm or high load you must let the engine run at idle minimum rpm for 3 5 minutes to prevent...

Page 79: ...ed control control of the operation of heating plugs to ensure engine start and warming control of recirculation of exhaust gases to reduce nitrogen oxides content in emitted exhaust gases control of the heating plugs turning on indication lamp on the vehicle dashboard control of the engine control system faults indication lamp on the vehicle dashboard diagnostics of the engine control system Engi...

Page 80: ...ION When the EDC fault warning lamp is turned on the engine must not be operated Stop the vehicle as soon as feasible and shut off the engine The vehicle may only be operated after the fault is eliminated When the OBD engine fault warning lamp is constantly on the engine components or the exhaust system components affecting the exhaust gas toxicity are faulty If the warning lamp is on and no signi...

Page 81: ...acceleration of the vehicle a slight knock of synchronizer rings of the gearbox may occur Clutch During abrupt release of the clutch pedal a single knock may occur because of the selection of the side gaps in tooth gear couplings spline couplings and in synchronizers of the gearbox The level of the fluid must be 15 20 mm lower than the upper edge of the reservoir 2 Fig 9 20 Incomplete clutch relea...

Page 82: ...a slight single knock in the transfer case may occur When driving at a lower gear the transmission noise is louder than when driving on the direct transfer of the transfer case Periodically check threaded couplings for proper fastening If a leak is detected find out the reason and replace the defective parts spacers collars To change the oil in aggregates drain it immediately after the vehicle sto...

Page 83: ... 2 gear box 3 gearbox housing filler plug 4 gearbox housing drain plug 5 transfer case housing drain plug 6 transfer case housing filler plug Fig 9 22 Clutch release slave cylinder five speed Dymos gearbox and transfer case 1 transfer case 2 gear box 3 transfer valve 4 clutch release cylinder 5 gearbox housing filler plug 6 gearbox housing drain plug 7 transfer case housing drain plug 8 transfer c...

Page 84: ... the transfer case see Appendix 3 mixing is not allowed Drive shaft The spline coupling is lubricated through grease pump 1 Fig 9 23 and the needle bearings are lubricated through grease pumps 2 on center crosses Lubricate the needle bearings until the grease shows up from under the working edges of the center cross collars Applying solid oil and mixtures or its contents for lubrication of the nee...

Page 85: ...the adjusting bolts 1 Fig 9 25 and steering stop bolts 3 The value of the steering angle B of the right wheel to the right and of the left wheel to the left should be within the limits of 26 27 A greater steering angle of the wheels results in the contact of the wheel with suspension parts It is not required to add grease into the spherical pins and into the ball struts during operation The grease...

Page 86: ...ping bushing 10 to remove gap preliminarily hitting the threaded end of the pin with a copper hammer by turning the wrench by 10 20 tighten this bushing to obtain a preliminary tension along the common axle shaft of the pins install shield 12 with spacer 11 tighten the nut of pin 13 with the torque force of 80 100 N m 8 10 kgf m see Appendix 2 Warning Exceeding of the tightening torque can lead to...

Page 87: ...If the critical parameter is not reached tighten the clamping bushing once again by turning the wrench by 10 20 and tighten nut 13 with the specified torque If the gap is not removed after the tightening of the threaded bushing the replacement of the liners of the pins units is needed You should contact the UAZ service station Fig 9 26 Steering knuckle and wheel hub 1 steering knuckle housing 2 pi...

Page 88: ...al rods trailing arms leaf springs The reduced tightening torque can lead to the premature wear of the pins and the mounting parts and to deterioration of vehicle handling Knocks and squeals in the joints increased backlashes in the couplings deterioration of vehicle handling indicate a wearing of the joints and the necessity to replace them Strains on the lateral rod of the suspension the tie rod...

Page 89: ...way or another When removing the suspension compression buffers and their re installation ensure the safety of their lock by using thread sealant compound or lock washers Wheels and tires Warning Tires of various models tread patterns may have different sizes and stiffness characteristics use identical tires on all wheels To provide uniform tightening of the nuts tighten them alternatively every s...

Page 90: ...rately for each side Do not introduce the spare wheel tire it can be used only in case of a excessively worn out tire Wheel hubs Rock the wheel to detect play in bearings Pay special attention to correct adjustment of the wheel hub bearing after running in For changing grease remove the hub from the pins remove old grease thoroughly wash the bearings and fill the space between the rollers with fre...

Page 91: ...otated with difficulty When tightening the nut apply the effort to the tommy bar smoothly without jerks and simultaneously rotate the wheel to Fig 9 30 Steering tie rod 1 left hand thread lock nut 2 adjusting connection 3 right hand thread lock nut 4 joint Fig 9 31 Rear wheel hub 1 wheel 2 wheel hub bolt 3 wheel fastening nut 4 ad justing nut 5 axle fastening bolt 6 lock washer 7 lock nut 8 thrust...

Page 92: ... 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 fitting to the flats Unbend those tabs of the lock washer that are the closest to the middle of the nut flats 10 Reinstall the axle shaft of the rear axle or the driving flange clear the threaded parts of the bolts from the residues of the thread sealant compound de...

Page 93: ...ft and gaps in the steering mechanism If radial gap in the joint of the steering shaft is detected axial displacement of the crosspiece in bearings punch the bearings in yoke eyes so that the bearing sleeve shall not become deformed If gaps in the spline couplings of the steering shaft are detected the shaft should be repaired or replaced The steering mechanism can be used only for a short time wh...

Page 94: ...minate the leakage as required 5 Let the engine run for 15 20 seconds and bleed the hydraulic power steering system to remove residual air from the steering mechanism by turning the steering wheel lock to lock with no stops in the end positions 3 times in each direction 6 Check the oil level in the tank The oil should be at the level of the filter screen in the tank 7 Cover the tank and tighten th...

Page 95: ...rake pedal WARNING Please remember that a stopped engine and disabled vacuum booster considerably increases the effort necessary for pushing the brake pedal to stop the vehicle WARNING If one of the brake system circuits is out of order brake pedal travel is increased and braking efficiency is decreased In this case do not make short time multiple pedal pushes instead push the pedal until maximum ...

Page 96: ...om air intake into the vacuum booster The level of brake fluid in tank 3 Fig 9 33 can be checked visually by the marks on the tank housing made of semitransparent plastic When cap 2 is off and brake linings are new the fluid level should be up to the MAX mark If the brake hydraulic drive is in good order reduced level of the tank fluid is connected Fig 9 33 Brake master cylinder 1 protective cap 2...

Page 97: ...ace the vehicle on a level ground and set the parking brake Inspect the shoes through the window in caliper 4 If the linings wear to the thickness of 1 5 2 0 mm replace the shoes on both front brakes If brake shoes with audio signals of the wear are installed on the motor vehicle change the shoes if clanking tinkling occurs which indicates the shoes are worn down Make sure you properly install suc...

Page 98: ...es against the disc press the brake pedal 2 3 times Install spring 1 spring carrier 18 and screw bolts 16 During further operation the necessary gap between the brake shoes and the brake disc is supported automatically Rear drum brakes Fig 9 35 Remove brake drums periodically and clean the brake parts from dust and dirt The frequency depends on vehicle operation conditions Clean the drums more fre...

Page 99: ...f the working re bored brake drum is 281 mm It is not recommended to change the brake drums between the hubs as the working surfaces of the drums will wobble more The gap between the shoes and the drum is restored automatically as the linings wear Check the wear of linings through the orifices in the shields Unplug the orifices inspect the linings the thickness of the linings should not be less th...

Page 100: ...ppears from drum wear to ease the next removals of the drum Tighten the bolts of brake shields when the hubs are removed Proportioning valve Fig 9 36 During maintenance check the function of the proportioning valve Clean it from the dirt and check the safety of its fastening Visually inspect that the proportioning valve and its parts have no damage there is no leakage of the brake fluid and no bac...

Page 101: ...le with its curb weight on an even level ground 2 Loosen the lock nut of adjusting bolt 4 and unscrew the bolt for 2 3 turns 3 Tighten bolt 4 see Fig 9 37 until it touches the regulator piston end 17 see Fig 9 36 by screwing the adjusting bolt for 1 11 3 turn 6 8 flats of the bolt head 4 Check the stroke of the valve piston see above 5 Check adjustment correctness during motion of the vehicle Whil...

Page 102: ... of the wheel cylinder or from the proportioning valve and place a special rubber hose approx 400 mm long on the valve Drop the other end of the hose into a transparent vessel with no less than 0 5 l capacity which is half filled with brake fluid 3 Press the brake pedal 3 5 times abruptly hold it in the extreme position and simultaneously unscrew the bypass valve for 1 2 3 4 of a turn in order to ...

Page 103: ...ntaining the gap of 0 5 mm which is indicated in the figure After adjusting tighten the nuts with the torque of 4 6 N m 0 4 0 6 kgf m Parking brake system Clean the brake pads from dust and dirt and sand them if they became greasy Replace greasy linings or keep them in petrol for 20 30 min and grind them with sand paper or wire brush Replace the linings in case of their excessive wear the rivets a...

Page 104: ...lever 1 into its extreme position 2 Tighten screw 10 so that the brake drum cannot be turned by hand 2 Unscrew lock nut 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 orifices in the yoke and lever 18 by rotating yoke 17 You should choose gaps in the release mechanism and in the drive by moving lever end 18 with the orifice...

Page 105: ...ud 3 13 snap pins 4 parking brake signal switch 5 nuts 6 washers 7 drive wire cable 8 bolts 9 spring washers 10 adjusting screw 11 release spring 12 spring bracket 14 idler lever 15 drive rod 16 lock nut 17 adjusting yoke 18 drive lever 19 housing of release mechanism balls ...

Page 106: ...hicle the battery is gradually discharged or overcharged by the alternator and the electrolyte starts boiling check the alternator operations Keep the battery clean and charged protect the battery clips and the cable terminals from oxidation Periodically clean vent orifices in the plugs check electrolyte level and add distilled water as required Before operation correct electrolyte density corresp...

Page 107: ...of reverse rotation the gear should revolve with the shaft In turning the shaft by hand check the ease of rotor rotation in bearings with lifted brushes Warning 1 The sleeve of starter travel can fail if the starter is on after the engine begins working 2 Do not wash the starter caps and the drive with gasoline or kerosene to avoid the removal of grease from bronze graphite cellular plain bearings...

Page 108: ...ectively The breaking points of the cutoff line should coincide with E and E points If it is not possible to adjust the headlamps check the function of the headlamp corrector The corrector is not repairable In case of damage replace the corrector Adjust the front fog lights so that the area of concentrated light on the wall or the aiming screen is located as indicated on Fig 9 42 To replace the fo...

Page 109: ... 43 with thirteen fusible links each are placed under the instrument panel to the left of the steering column The bracket with the relay is placed on the front left side panel from the driver s side Fig 9 44 Fig 9 42 Screen markings for front fog lights adjustment H distance from the front fog lights center to the ground level L distance between the front fog lights centers Fig 9 41 Screen marking...

Page 110: ...a fusible switch box with two fuses is installed Fig 9 46 The fusible switch box is places on the front shield under the hood Before replacing a burnt out fuse find out the reason for its failure and eliminate it Fig 9 44 Bracket with the relay K1 low beam relay K2 upper beam relay 1 turn signal interrupter 2 control unit of the seat belt alarm 3 rear fog lights relay 4 windshield wiper interrupte...

Page 111: ...mentation and warning alarms Periodically check the mounting of the devices safety of their contact couplings and clean them from dirt and dust When removing electric sensors isolate the wires to avoid a short circuit Use a hex socket wrench or a box wrench to remove the temperature sensor and the coolant emergency temperature sensor without damaging their housings Check the fluid level in the coo...

Page 112: ... left side upper beam warning lamp F18 7 5 Front fog light left side F19 5 Backing up lamp F20 7 5 Turn signals in the maneuver regime F21 10 Heater F22 20 Electromotor of windshield wiper windshield washer fluid F23 7 5 Cabin lighting lamps engine compartment dome lamp F24 15 Reserve F25 5 Instrumentation and alarms F26 10 Additional pump of heating system UAZ 315148 Relays and fuses box Fig 9 45...

Page 113: ...seals When washing the vehicle body using such unit as the 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 To take care of the vehicle body coatings use prophylactic polishing liquids auto emulsion polish spray wax AB 70 for vehicles etc To restore shine o...

Page 114: ...re to the following rules 1 Drain oil from the engine and the transmission aggregates immediately after the vehicle stops and the aggregates are hot 2 Thoroughly remove dirt from the grease pumps and plugs before lubricating to avoid an ingress of dirt into the vehicle mechanisms 3 Upon lubrication remove the squeezed out or leaked lubricant from all parts 4 Before filling the housings with fresh ...

Page 115: ...t applicable to the vehicle Jack Fig 10 1 or 10 2 is designed to jack up the vehicle wheels during its maintenance or repair The jack load lifting capacity is 2 tons The maximum height of lifting shown on Fig 10 1 240 mm on Fig 10 2 295 mm 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 for wrench 22 ...

Page 116: ...he jack screws into the housing 1 After work is over turn in the outer 2 and inner 3 jack screws into the housing up to the stop For jacking up the wheel with jack as shown on Fig 10 2 proceed as follows 1 Brake the vehicle with the parking brake shift into the first or reverse gear of the gearbox making sure that the transfer case gear lever is not in the neutral position As required put wedges u...

Page 117: ...s of hinged couplings hinges and door locks parking brake drive rods control rods of the carburetor towing gear and other units and also spark plugs 6 Lubricate the springs with a graphite lubricant 7 Check clean the tools accessories and spare parts set and wrap them with oiled paper or with cloth 8 Seal the windows from outside with light tight paper cloth or shut with shields 9 Remove the wheel...

Page 118: ... Carry out the maintenance of the vehicle every two months Proceed as follows 1 Carefully inspect the vehicle from the outside 2 Unscrew the spark plugs except for engine ZMZ 51432 and shift in the first gear of the gearbox and the low gear of the transfer case then turn the crankshaft of the engine by approximately 15 revolutions Once a year before turning the crankshaft lubricate the engine cyli...

Page 119: ... which would not damage the parts and the paint of the vehicle The loading and unloading of the vehicles should be carried out by a crane with special grips On all transports the vehicles should be located so that the distance between the vehicles extreme points on the engine cooling radiator side would equal to 50 100 mm and on the other sides not less than 100 mm When transporting the parking br...

Page 120: ...g lamp A12 21 3 21 Cabin lighting dome lamp A 12 10 10 Rear fog lamp A12 21 3 21 Front fog lights AKG 12 55 H1 55 Portable lamp A12 21 3 21 Instruments and reserve AMN12 3 1 3 fuel level lighting Upper beam warning lamp A12 1 2 1 2 Oil emergency pressure warning lamp A12 1 2 1 2 Coolant emergency overheating A12 1 2 1 2 warning lamp Turn signal warning lamp A12 1 2 1 2 Brake emergency condition A1...

Page 121: ...atchet 17 22 Camshaft caps bolts 1 9 2 3 Camshaft sprocket bolt 5 6 6 2 Bolts for fastening sprockets of intermediate shaft 2 5 2 7 Upper and middle chain stabilizers bolts 2 0 2 5 Lower stabilizer bolts 2 7 3 0 Tightener rod strut bolts 2 7 3 0 Tightener rod bolts 2 7 3 0 Cylinder head front cap bolt 1 2 1 8 Bolts and nuts for fastening crankcase to cylinder block and crankcase amplifier 4 2 5 1 ...

Page 122: ...nary tightening 4 5 exposure not less than 1 minute 15 seconds final tightening additional turn to angle 90 Bolts for fastening cylinder head to chain cap 2 0 2 5 Screw for fastening water pump drive belt of automatic tensioner 4 0 5 0 Screws for fastening throttle module 0 6 0 9 Nuts for fastening ignition coil 0 3 0 5 ZMZ 51432 ENGINE Main bearing caps bolts 10 11 Connecting rods bolts 6 8 7 5 B...

Page 123: ... injection pipe rear strut to cylinder head 3 5 4 0 Bolt for fastening alternator to fuel pump bracket and alternator 3 5 4 0 Bolts for fastening engine rear bracket to gearbox crankcase 5 0 6 2 Oil filter union nut 4 1 6 1 Oil filter union 4 1 6 1 Oil crankcase drain plug 2 5 3 0 Nuts of bolts for fastening propeller shaft flanges 4 4 5 6 Bolts and nuts for fastening gearbox and transfer case 4 0...

Page 124: ...0 3 0 during bearings replacement 3 0 4 0 Union bolt for fastening hydraulic power steering hose 5 0 6 2 Bolts for fastening steering mechanism 5 5 8 0 Nut for fastening steering wheel 6 5 8 0 Steering knuckle lever stud nuts 8 0 10 0 Self locking nut for fastening inlet nozzle 4 6 5 1 Note Use the following tightening torque for other threaded couplings kgf m M6 0 45 1 0 M8 1 4 1 8 M10 3 00 3 5 A...

Page 125: ...5 to 45 C SAE 20W 40 from 10 to 45 C SAE 20W 50 from 10 to 45 C SAE 30 from 5 to plus 40 C SAE 40 from 0 to 45 C SAE 50 from 0 to 45 C by operating properties Gasoline engines STO AAI 003 05 B4 B4 D2 B5 API SG SH SJ SL Diesel engines STO AAI 003 98 D3 B4 or D3 API CF 4 SG or CF 4 Places of lubrication filling Name of lubricant or fluid Basic Foreign Appendix 3 LUBRICANTS MATERIALS AND SPECIAL FLUI...

Page 126: ...75W 90 not lower than 25 C acc to API GL 3 TSp 15K TAP 15V TAD 17I Only in winter time 01 10 01 04 TSp 10 Main drive housings of front and rear axles For all seasons SAE 75W 90 acc to GL 5 of API classification Oil tank of hydraulic power steering system Brand P THK ATF IID Mobil ATF220 Lukoil ATF G Box Exper ATF DX III Tatneft r oil Plastic lubricants Front and rear drive shaft splines front and ...

Page 127: ... front seats adjustment rear seat folding and CIATIM 201 Centuri 1180 attachment mechanism front wheels switching off clutch Disc brake mechanisms guiding bushes UNIOL 2M1 Rear springs Graphite grease USSa Lithium lubricant according to NLGJ 3 Rubber weatherstrips Graphite powder Barbatia Grease 2 Fluids Clutch and brake system hydraulic drives Brake fluid SAE 1703F DOT 4 ROSDOT ROSDOT 4 Rosa Dot ...

Page 128: ...0 0048156 Ruthenium 0 0008236 1 2 TM111 03 Coolant emergency Silver 0 1485 overheating sensor 1 1 23 3829 Oil pressure sensor Silver 0 017848 Palladium 0 0018377 Ruthenium 0 00049569 1 3902 3829 Oil pressure sensor Silver 0 02412 Palladium 0 0029 Ruthenium 0 00224 1 6002 3829 Oil emergency pressure sensor Silver 0 0310 1 1 101 3839 Brake fluid emergency level sensor Gold 0 01198 1 1 Silver 0 02906...

Page 129: ...ld wiper flasher Silver 0 00053 1 1 245 3710 Emergency Hazard switch Silver 0 107 1 1 82 3710 05 09 Heater switch Silver 0 34551 1 1 82 3710 06 10 Fuel tanks switch Silver 0 46068 1 1 3832 3710 Fog lights switch Silver 0 2033 1 1 10 03 3832 3710 Rear fog lights switch Silver 0 2033 1 1 11 04 3832 3710 Cabin dome lighting switch Silver 0 0565 1 1 02 09 ...

Page 130: ...art 38 General 38 ZMZ 40905 engine start 39 ZMZ 51432 engine starting 40 Engine shutdown 40 Chapter 7 Vehicle Driving in Different Road Weather and Climatic Conditions 41 Chapter 8 Vehicle Towing 45 Chapter 9 Vehicle maintenance 46 Daily maintenance 46 Vehicle maintenance every 500 km 46 Seasonal maintenance 47 Prior to summer operation 47 Prior to winter operation 47 ZMZ 40905 engine 47 Engine su...

Page 131: ...pension 88 Wheels and tires 89 Wheel hubs 90 Control systems 93 Steering system 93 Brake systems 95 Electric equipment 106 Alternator 106 Battery 106 Starter 107 Lighting System Light and Audio Alarm 107 Relays and fuses 109 Instrumentation and warning alarms 111 Vehicle body 113 Lubrication of the vehicle 114 Chapter 10 Special tools and appliances 115 Chapter 11 Preservation 117 Maintenance of a...

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Page 136: ...15148 and their modifications Operating Manual RE 05808600 133 2012 3rd Edition Prepared for publishing by Chief Design Department of UAZ PJSC Editor in chief Chief and Designer O A KRUPIN Editor I L NIKOLAEV Content by D A SHEMYREV ...

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