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UAZ UAZ-220695, Operation Manual

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UAZ UAZ-220695 Operation Manual Download Page 55

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4. Wash fuel tanks prior to the winter season of operation (or after 

30,000 km).

5. Check braking system efficiency and proportioning valve operability.

6. Switch the windshield wiper for 15 - 20 minutes with blades away 

from the glass.

7. Replace oils in units with winter sorts listed in Appendix 3.

Summary of Contents for UAZ-220695

Page 1: ...Ulyanovsk Automobile Plant PJSC Vehicles UAZ 374195 UAZ 396295 UAZ 220695 UAZ 390995 UAZ 330365 UAZ 390945 and Versions Thereof Operation Manual RE 05808600 106 2007 9th edition Ulyanovsk 2016 ...

Page 2: ...egettingstartedtooperateamotorvehicle pleasereadcarefully the Operation Manual and the vehicle log book Please pay special attention to the sections Safety Requirements and Warnings in the Operation Manual Improper operation can lead to injuries motor vehicle and its assembliesmalfunctionofthemotorvehicleanditsparts andtermination of the warranty by the manufacturing plant For safe and fault free ...

Page 3: ...e body separated into a two seat cab a three or five seat passenger cab and a cargo compartment It is designed for both passenger and cargo transportation UAZ 330365 motor vehicle Fig 1 8 is a freight vehicle with an increased wheelbase with a two seat cab and a metal or wooden cargo bed It is designed for cargo transportation UAZ 330395 motor vehicle Fig 1 9 is a freight vehicle with a two seat c...

Page 4: ...4 Fig 1 1 Overall dimensions averaged of UAZ 374195 motor vehicle with maximum gross weight dimensions are given for reference To center of tow eye To center of tow eye ...

Page 5: ...5 Fig 1 2 Overall dimensions averaged of UAZ 374195 05 motor vehicle with maximum gross weight dimensions are given for reference To center of tow eye To center of tow eye ...

Page 6: ...6 Fig 1 3 Overall dimensions averaged of UAZ 396295 motor vehicle with maximum gross weight dimensions are given for reference To center of tow eye To center of tow eye ...

Page 7: ...7 Fig 1 4 Overall dimensions averaged of UAZ 220695 motor vehicle with maximum gross weight dimensions are given for reference To center of tow eye To center of tow eye ...

Page 8: ...8 Fig 1 5 Overall dimensions averaged of UAZ 220695 04 motor vehicle with maximum gross weight dimensions are given for reference To center of tow eye To center of tow eye ...

Page 9: ...9 Fig 1 6 Overall dimensions averaged of UAZ 390995 motor vehicle with maximum gross weight dimensions are given for reference To center of tow eye To center of tow eye ...

Page 10: ...10 Fig 1 7 Overall dimensions averaged of UAZ 390995 04 motor vehicle with maximum gross weight dimensions are given for reference To center of tow eye To center of tow eye ...

Page 11: ...11 Fig 1 8 Overall dimensions averaged of UAZ 330365 motor vehicle with maximum gross weight dimensions are given for reference To center of tow eye To center of tow eye ...

Page 12: ...12 Fig 1 9 Overall dimensions averaged of UAZ 330395 motor vehicle with maximum gross weight dimensions are given for reference To center of tow eye ...

Page 13: ...13 Fig 1 10 Overall dimensions averaged of UAZ 390945 motor vehicle with maximum gross weight dimensions are given for reference To center of tow eye ...

Page 14: ...illed in blanks Thesixthsymbol zeroorletter referstotheengineconfiguration option II the Vehicle Identification Section VIS has of eight symbols The first symbol letter or digit means year of manufacture of the engine the rest of the symbols digits denote the engine serial number The engine identification number is stamped on the left side of the cylinder block Vehicle identification number Fig 1 ...

Page 15: ...20695 UAZ 220695 04 and UAZ 396295 only Fig 1 12 Vehicle marking 1 Vehicle identification number a b for UAZ 220695 UAZ 220695 04 and UAZ 396295 vehicles b for UAZ 374195 UAZ 374195 05 UAZ 330365 UAZ 330395 UAZ 390945 and UAZ 390995 vehicles 2 Chassis identification number 3 Body cab identification number 4 Name plate I Transport Vehicle Type Approval full number II Vehicle identification number V...

Page 16: ...t kg 475 Maximum weight of cargo transported on the cargo bed kg _ _ _ _ 1130 840 700 Number of seats including driver s seat barrow 2 5 5 2 10 9 5 7 2 5 Maximum allowable gross vehicle weight kg 2730 2845 2880 2880 2830 3070 2660 3070 Gross weight distribution by axles kg on the front axle 1300 1350 1440 1440 1360 1435 1230 1435 on the rear axle 1430 1495 1440 1440 1470 1635 1430 1635 1 Dimension...

Page 17: ...t more than 6 8 7 5 Maximum gradeability degrees 30 Maximum fording depth m 0 5 Maximum speed km h 127 115 Fuel consumption l 100 km when driven at a constant speed of 90 km hr 13 5 3 17 0 3 1 Including all liquids tools additional equipment a spare wheel and a driver 2 Trailer towing is allowed only in the presence of a ball type towing hitch properly certified as a part of the road train as per ...

Page 18: ...in 1 Maximum torque N m kgf m according to Regulations 85 EEC UN GOST R41 85 198 0 20 2 at 2500 min 1 Lubrication system Combined pressurized and by splashing Housing ventilation Closed system Fuel System With forced fuel supply Fuel Unleaded gasoline Regular 92 AI 92 4 GOST R 51105 AI 92 К4 GOST 32513 1 Allowable Premium Euro 95 type II AI 95 4 and Super Euro 98 type II AI 98 4 per GOST R 51866 A...

Page 19: ...led inside the body at that power takeoff mechanism shall be installed by the customer Permissible power takeoff is 40 Propeller shaft drive type Open type consists of two shafts Each shaft has two universal joints with spiders on needle bearings Front and rear driving axles axle type Single reduction driving Final drive gear ratio 4 625 axle differential Conical with 4 planet wheels front axle tu...

Page 20: ...helpers shock absorbers Four hydraulic telescopic double side action Four telescopic double side action front hydro pneumatic rear hydraulic Wheels and tires wheels Disk type with solid rim steel rim size 6 J 16H2 with offset ЕТ 40 mm tires radial tubeless 225 75R16 CONTROL SYSTEMS Steering gear type Screw ball nut rack sector with hydraulic power or concave worm with two ridged roll Screw ball nu...

Page 21: ... 12 Alternator ААК 5572 14V 80А by Iskra or ААК 5730 14V 80А by Pramo Electro or 5122 3771 14V 80А by Pramo Electro 3212 3771 10 14V 90А by BATE Battery 6ST 66A 6ST 66A w ventilation pipe Spark plugs AU14DVRM GOST Р53842 DR17YC f by BRISK Engine control module BOSCH Starter motor AZE 2154 12V l 9kW or AZE 2203 12V l 9kW by Iskra or 6012 3708 12V l 7kW by ZiT Ignition switch 31514 3704010 or 315196...

Page 22: ... temperature in the cooling system С 80 105 Brake pedal free play mm 5 14 Front wheels toe in 0 4 0 10 0 5 1 5 mm Inner front wheel maximum turning angle degree 26 27 Steering system total play steering wheel angle from the position corresponding to steerable wheel wedge in one direction to the steering wheel position corresponding to steerable wheels wedge in the opposite direction deg not more t...

Page 23: ... 2 4 0 21 2 1 0 24 2 4 Rear wheels 225 75R16 0 24 2 4 0 25 2 5 0 24 2 4 0 24 2 4 0 24 2 4 0 27 2 7 0 24 2 4 0 27 2 7 FUELING DATA liters Fuel tanks 1 main 50 50 50 50 50 50 additional 27 27 27 27 Engine cooling system including heater 12 7 13 7 13 7 13 7 13 7 13 7 13 6 Engine lubrication system excluding oil cooler volume 6 5 1 Amount of fuel fully consumed at the engine operation Table 1 1 contin...

Page 24: ...0 80 Steering mechanism housing concave worm type with two ridged roll 0 25 Hydraulic power steering system oil tank steering gear of screw ball nut rack sector with power steering type 1 3 Hydraulic clutch actuator 0 20 Hydraulic brake actuator 0 52 0 60 for UAZ 330365 and UAZ 390945 vehicles Windshield wiper tank 2 Table 1 1 end ...

Page 25: ...trollable 4 When getting off a motor vehicle do not leave door and ignition keys inside it 5 Before opening a door ensure that it will not be a hindrance for other road users Beforeclosingadoor makesureitwillnotcatchsomeoneorsomething It is prohibited to drive a motor vehicle with any door or tail board opened Check operability and reliability of bodyshell doors and tail board locking mechanisms b...

Page 26: ... them in ventilation if liquids spill on clothes dry it on the open air before washing moisten the gasoline soot with kerosene when scraping to avoid ingress of the soot toxic substances into your respiratory system observe fire safety rules when handling fuel 16 When a motor vehicle stops it shall be braked with the parking brake 17 Use extreme caution when handling electrolyte Follow these rules...

Page 27: ...hes in so that there will not be any hanging ends tuck hair under closed body hair cover foranyworks themotorvehiclemustbesecurelyarrestedwithbrakes do not perform any motor vehicle maintenance and repair with the engine running except for specific works that require engine start in such a case take particular care avoid dangerous approaching of hands clothes parts and tools to moving driving belt...

Page 28: ...eplace faulty hydraulic pushers 4 Engage the back run in the gear box and the underdrive in the transfer case only after the motor vehicle complete stop 5 Disengage front axle drive when driving on dry paved roads Avoid front axle engagement when driving the motor vehicle with small turning radii 6 In case of malfunction of any brake circuit brake pedal stroke increases and brake efficiency decrea...

Page 29: ...ltaneous haulage of passengers and cargo except for hand luggage in passenger and medical compartments of UAZ 220695 UAZ 390995 UAZ 396295 UAZ 390945 and in passenger and cargo compartment of UAZ 374195 05 is not allowed 20 Transportation of passengers on cargo beds of UAZ 330365 UAZ 330395 and UAZ 390945 is not allowed 21 UAZ 220695 and UAZ 220695 04 vehicles cannot be used as public or commercia...

Page 30: ...l Fig 3 3 2 ignition switch Fig 3 5 3 steering wheel 4 multifunctional understeering switches see Fig 3 5 5 sun visor 6 ceiling light A switch is installed next to the ceiling light 7 internal mirror for UAZ 220695 and UAZ 220695 04 8 front handle 9 glove box 10 door lock internal handle Fig 3 1 Controls see item description in the text ...

Page 31: ...or 22 ventilation and heating hatch cover actuator handle Fig 3 2 Diagram of gearbox and transfer case lever positions Instrument panel The following is installed on the instrument panel Fig 3 3 1 diagnostic socket 2 cover plug 3 cover plug 4 cover plug 5 manual headlights corrector Headlight beam inclination is adjusted by rotating this knob depending on vehicle loading 0 a vehicle with a driver ...

Page 32: ...over plug 9 rear fog lights switch 10 cab heater switch 11 saloonheaterswitch exceptforUAZ 330395 UAZ 330365 and UAZ 374195 12 onboard power socket 13 instrument cluster 14 seats heating control module 15 box for small pieces 16 hazard switch 17 cover of clutch fluid reservoir hatch Instrument Cluster The instrument cluster is shown in Fig 3 4 Green and blue indicators inform a driver about normal...

Page 33: ...ngine Indicatorswitchingonindicatesmalfunctions of engine components or the exhaust system that affect exhaust gas toxicity When the indicator switches on if it is not accompanied by significant deterioration of riding qualities driving is permitted at low speed to the nearest authorized service station of UAZ PJSC to carry out diagnostic works Prolonged operation with the malfunction indicator sw...

Page 34: ... display mode current time daily mileage onboard electricsystemvoltage bybrief lessthan0 5s pressingoftheinstrument cluster button To reset the daily mileage counter to 0 0 km press the instrument cluster button for more than 2 seconds while in the Daily Mileage mode To switch to the Clock Correction mode press the button on the instrument cluster while in the Current Time mode To switch to the Ho...

Page 35: ...ition switch Fig 3 5 are as follows 1 turn indicators and beam switch lever with the following positions I direction indicators are OFF low beam is ON if headlights are switched on by the external light switch II left turn indicators are ON unstable position III left turn indicators are ON stable position IV right turn indicators are ON unstable position V right turn indicators are ON stable posit...

Page 36: ...he locking device mechanism actuates and locks the steering system shaft To lock the steering system in park set the key to position III remove it and turn the steering wheel in any direction until it clicks indicating that the locking device catch has matched the groove of the steering wheel shaft stop sleeve To unlock the steering system insert the key into the ignition starter switch and swayin...

Page 37: ...ed with three single seats for accompanying persons brackets and belts for barrow fixation and handle bars in the rear door aperture UAZ 220695 passenger cab is equipped with one dual and six single seats with safety belts UAZ 220695 04 passenger cab has a table on the front partition one dual and five single seats with safety belts UAZ 390995 passenger cab is equipped with a table and a triple se...

Page 38: ...re that the seat is securely fixed by moving it back and forth with the lever released Front seat dismounting unscrew thumb nut 1 and tilt the seat forward remove stud bolts on the seat from bushes 4 located on the wheel arch remove the seat To install the seat insert stud bolts into bushes tilt the seat back and tighten thumb nut 1 Some vehicles may be equipped with non adjustable seats ATTENTION...

Page 39: ...child restraint system in the direction of vehicle travel Weight group Seats Front passenger seat second row third row fourth row left center right left center right left right 0 up to 10 kg 0 9 months X X X X X X X X X 0 up to 13 kg 0 2 years X X X X UF UF UF UF UF I 9 10 kg 9 months 4 years X X X X UF UF UF UF UF II III 15 36 kg 4 12 years X X X X UF UF UF UF UF ...

Page 40: ...pe with retraction devices and on seats installed against travel direction of waist type with retraction devices Fig 3 8 3 9 Safety belts in UAZ 390995 and UAZ 390945 on seats installed towardsvehicletraveldirectionareofdiagonally waisttypewithretraction devices and on the middle seat of waist type with a retraction device Fig 3 10 To fasten safety belt take the belt buckle and without twisting th...

Page 41: ...y clean them it with an alkali free soap solution Protect the straps from contact with sharp edges Werecommendtoensureprotectionagainstexposuretodirectsunlight In order to clean buckles from dust blow it with compressed air at least once a year Fig 3 8 UAZ 220695 saloon safety belts 1 latch plate 2 lock 3 lock button ...

Page 42: ...42 Fig 3 9 UAZ 390995 04 saloon safety belts 1 latch plate 2 lock 3 lock button Fig 3 10 UAZ 390995 and UAZ 390945 saloon safety belts 1 latch plate 2 lock 3 lock button ...

Page 43: ...t ventilation a cab heater fan can be used turn it on by switch 10 Fig 3 3 with heating system valve 15 Fig 3 11 closed It is recommended to switch the cab saloon fan on when driving on dusty roads At that the front ventilation hatch cover shall be open and the rotating vent windows and down windows in cab doors closed Fresh air comes into passenger medical cab via rotating vent side windows as we...

Page 44: ... system via plug 17 Fig 3 11 with heating system valve 15 opened This plug is accessible from beneath the vehicle at the front Fig 3 11 Engine cooling and bodyshell heating system diagram 1 fitting for coolant supply into the heater 2 electric motor w pump 3 cab heater heat exchanger 4 cylinder block head 5 throttling device heating hoses 6 throttling device 7 two valve thermostat 8 radiator inlet...

Page 45: ...avel and one against the travel direction Guides allowing barrow movement along the bodyshell are installed on the floor to ease barrow handling Transporting of Patients UAZ 396295vehiclebodyshellallowstransportationof4to6persons not including the driver in the following arrangements Arrangement with barrows On seats for accompanying persons 1 or 3 persons In the driver s cab 1 person On barrows 2...

Page 46: ...onto belt loops dangling from the ceiling then lock the bracket and tighten belt loops using the pressing bar Fig 3 13 Be careful when transporting patients start smoothly and avoid hard braking Windshield Wiper and Washer The applied windshield wiper is two speed electrically driven To ease manual washing of the windshield wiper blades arms must be fixed away from the windshield To extend the scr...

Page 47: ...uring the running in period observe the following rules 1 Avoid high driving speeds and maximum crankshaft rpm engine crankshaft rpm shall not exceed 3 4 of the rated value change gears in due time depending on road and traffic conditions comparing the engine rpm with the driving speed 2 Vehicle loading shall not exceed 50 of the maximum value during the running in period 3 Do not drive along toug...

Page 48: ...il up using steam hot air etc 1 Turn on the ignition to activate the electric fuel pump which can be heard while the engine is off 2 Iftheengineistobestartedafteraprolongedstop itisrecommended to wait until the electric fuel pump is switched off about 5 seconds 3 The system functions correctly a malfunction indicator lamp on the instrument panel switches on and goes off after the engine starts If ...

Page 49: ...t the engine Engine Stop In order to stop the engine turn the ignition key to position 0 Before shutting down the engine let it run for 1 2 minutes at low rpm Chapter 7 Vehicle Driving in Different Road Weather and Climatic Conditions The manufacturer UAZ PJSC cares about its customers and hopes for thoughtful use of its products While supporting the all Russian program of road transport accident ...

Page 50: ...ightly release the clutch pedal and try to disengage the clutch and engage the gear Synchronizersinthegearboxallowgearshiftingwithoutdoubleclutch shift However to accelerate gear shifting and increase to synchronizers service life it is recommended to use double clutch shift with brief accelerator pressing when shifting gears down The reverse gear in the gearbox shall be engaged after complete veh...

Page 51: ...cle and do not disengage the clutch When overcoming the steep declines take measures to ensure safe descending Before overcoming a long decline more than 50 m determine its steepness shift the gearbox and transfer case into the required gears to overcome it Such declines are overcome by braking with the engine ATTENTION It is forbidden to overcome steep declines with disengaged gears of the gearbo...

Page 52: ...overcome a 500 mm deep ford with a hard bottom at low speed Before overcoming a ford check its bottom Make sure that there are no deep pits big stones swampy grounds choose and check the ground where the vehicle will enter the water and go out of the water switch off the fog lamps Overcomefordsslowly withoutmakingwavesinfrontofthevehicle in the first or second gear of the gearbox engaging the fron...

Page 53: ... certified as a part of the road train as per the established procedure Chapter 9 Vehicle Maintenance The motor vehicle maintenance extent and frequency are specified in the service book This section describes techniques of motor vehicle care and its units adjustment and also works to be performed on a regular basis in between maintenance operations stipulated by service book cards Tightening torq...

Page 54: ...es leaf spring U bolt nuts and wheel nuts of a new vehicle Seasonal Maintenance Seasonal maintenance shall be performed twice a year in spring and autumn and if possible combined with the next maintenance in accordance with cards of the service book Prior to summer operation 1 Drain sediments from fuel tanks 2 Switch the windshield wiper for 15 20 minutes with blades away from the glass 3 Checkbra...

Page 55: ...eason of operation or after 30 000 km 5 Checkbrakingsystemefficiencyandproportioningvalveoperability 6 Switch the windshield wiper for 15 20 minutes with blades away from the glass 7 Replace oils in units with winter sorts listed in Appendix 3 ...

Page 56: ...linder head and clean surface of the combustion chambers valve discs and piston tops off soot deposition Fig 9 1 Sequenceofthecylinderheadfastening bolts tightening Engine Gas Distribution Mechanism The camshafts have a chain double stage drive The chains are pulled by hydraulic tensioners ATTENTION Do not take the hydraulic tensioner out of the chain cover to prevent disengagement of the piston w...

Page 57: ...e sure you have flushed the lubrication system with flushing oil Flushing oil shall be selected as required by the engine oil manufacturer Replace the oil filter at each engine oil change Drain used oil from the engine housing immediately after a trip while it is still hot In this case the oil flows out quickly and completely Remove oil filter 11 see Fig 9 3 by turning it counter clockwise When in...

Page 58: ...creased escape of oil with crankcase gases and contamination of the environment To prevent the breather system depressurization you must close the oil filler captightasfarasitcango andinstalltheoillevelindicatoragainststop Fig 9 2 Engine ZMZ 40911 left side view 1 coolant from radiator to water pump supply pipe 2 connection hoses 3 control unit coolant temperature sensor 4 thermostat housing 5 coo...

Page 59: ...ed with the fluid dry it outside the room and wash Becarefulwhenopeningtheradiatorcapoftheenginecoolingsystem to avoid scalding with vapour Fig 9 3 Engine ZMZ 40911 right side view 1 coolant to heater branch pipe 2 heater coolant discharge tube 3 pinking sensor 4 proportioning valve 5 fuel rail with nozzles 6 absolute pressure sensor 7 upperhydraulictensionercap 8 engineelevationfrontbracket 9 low...

Page 60: ...sion tank varies significantly depending on the temperature checkthelevelwhenthesystemtemperatureisplus15 20 С In case of the cooling 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 cooler or the expansion tank Every three years or after eve...

Page 61: ...radiator plug 9 unscrew radiator draining plug 21 Fig 3 11 and heater draining plug 17 open cock plug 24 on the crankcase For draining set heater cock 15 control lever to position open The heater pump and alternator driving belt 5 Fig 9 5 is pulled up by tension roller 2 For this purpose release bolt 3 and tension the belt by turning adjusting bolt 4 Then tighten bolt 3 Fan and steering system hyd...

Page 62: ...ible limit and the converter will fail So special attention shall be paid to 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 5 Aggregates drive belt tension 1 crankshaft damping pulley 2 tensioning roll 3 tensioning roll fixing bolt 4 adjusting bolt 5 water pump and alternator driving belt 6 alter...

Page 63: ...nozzles 12 spark plugs 13 2nd and 3rd cylinders ignition coil 14 1st and 4th cylinders ignition coil 15 air filter 16 throttle valve actuator pedal 17 throttle valve position sensor 18 throttle unit 19 absolute pressure sensor 20 inlet pipe 21 receiver 22 pinking sensor 23 fuelrail 24 enginecontrolmodule 25 idlegovernor 26 coolanttemperature sensor 27 crankshaft position sensor 28 crankshaft synch...

Page 64: ...es above 80 С e g in an oven drier 6 Prior to arc welding operations disconnect the battery wire and the control unit connector 7 To prevent rusting of pins during vapour cleaning do not direct the nozzle to the system components 8 Electronic elements of the control systems use extremely low voltage and can be damaged by electrostatic charges ATTENTION For access to the fourth cylinder spark plug ...

Page 65: ...d unleaded gasoline lead from leaded gasoline causes failure of the exhaust gas oxygen sensors and the converter The fuel comes to the electric fuel pump from the left tank The left tank is replenished from the right one as the gasoline is consumed Plugs installed at necks of the fuel tanks filling pipes are blind and ensure tight packing The following is recommended due to the specified features ...

Page 66: ...lure The following works shall be done at the service station disconnect fuel supply and return pipes dismount the left fuel tank dismount the submersible module flush the fuel tank with clean gasoline and dry it out e g wipe with a lint free rag remove the electric fuel pump intake barrel and flush it flush the filter screen do not remove the filter screen from the electric fuel pump otherwise th...

Page 67: ...fuel is not pumped from the auxiliary tank into the main one disassemble the pump unscrew the nozzle flush it and purge with air The jet pump is fixed on the fuel hoses near the frame side member Leaksincouplingsshallberectifiedthroughtightening seeAppendix 2 or by replacing faulty components Upon completion of any fuel system maintenance operations related to tightening of connections removal or ...

Page 68: ... filter cartridge 4 out of the filter housing unscrew nut 5 and remove the filter element install a new filter element assemble the air filter installing the cover in relation to the body as shown in Fig 9 9 install the air filter to its place Evaporative Emission Control System In the course of the motor vehicle operation do pay attention to the following strongsmellofgasolineinthecab underthehoo...

Page 69: ...of the engine control system and the injection system depend on the mechanical and hydro mechanical systems proper functioning Several deviations leading to faults can be mistaken for the control system electronic part malfunctions these are low compression deviation of gas distribution phases caused by incorrectly assembled engine components air ingress in the inlet pipe line poor fuel quality di...

Page 70: ...s turned on and the engine is off the lamp is on continuously until the engine is on If the lamp does not go off after the engine start that means that the diagnosis subsystem has determined faults in electric circuits of the control system If the diagnostic lamp does not go off after the ignition is on or lit when the engine is running that means that the engine or the system needs servicing as s...

Page 71: ...ith tappet 6 Fig 9 12 of clutch master cylinder by changing its length Clutch pedal full travel shall be 200 20 mm Free travel 5 30 mm is a non adjustable clutch design feature Fig 9 11 Clutch Cylinder 1 fitting 2 piston spring 3 cylinder housing 4 piston 5 sealing cuff 6 safety cap 7 snap ring 8 piston tappet 9 bypass valve 10 cap Attention The length of tappet 8 is 112 mm Do not adjust its lengt...

Page 72: ...e to the lower edge of the inspection hole and the grease level in the transfer case can increase You do not have to even the grease levels Drive line The spline coupling is greased through lubrication nipple 1 Fig 9 15 which is screwed into the slip yoke and the needle bearings are greased through lubrication nipples 2 on the crosses Lubricate the needle bearings until the grease shows up from un...

Page 73: ...instruments that is why it is recommended to adjust it only at a service station Frontaxlesandreductiongearareswitchedusingthetransfercaselever While inspecting the steering knuckles check adjusting bolts 1 Fig 9 18 and steering stop bolts 3 The value of steering angle B of the right wheel to the right and of the left wheel to the left shall be within the limits of 26 27 The excessive steering ang...

Page 74: ...74 Fig 9 16 Front Axle with Vertically Split Housing 1 gauge plug 2 drain plug 3 safety valve Fig 9 17 Front Axle With Banjo Housing 1 filler orifice plug 2 drain orifice plug 3 safety valve ...

Page 75: ...ededtighteningtorquecanleadtothedecreased pre load and failure of the pin assembly The torque of ball strut 8 or housing 1 of the steering knuckle if the ball struts have not been disconnected from the axle shaft housing shall be within the limits of 10 25 N m 1 0 2 5 kgf m in any direction relatively to the common axle shaft of the pins considering removed O rings 5 6 and joint 7 of the steering ...

Page 76: ...e operation at malfunctioning and or missing shock absorbers and worn out suspension joints is strictly not allowed When servicing the vehicle check the tightening of the following units threaded couplings of leaf spring axle nuts 23 Fig 9 21 shackle pins nuts 14 Fig 9 21 for ABS equipped vehicles and U bolts nuts 15 Fig 9 20 19 Fig 9 21 for all vehicles see Appendix 2 Check rubber metal joints st...

Page 77: ...of the front propeller shaft and to breakdowns of the frame parts Shock absorber maintenance involves periodical checks of their tightness and fasteners The shock absorber can not be dismantled and it doesnotrequirespecificadjustmentduringvehicleoperation Attention Hydro pneumatic shock absorber disassembly is strictly forbidden to avoid accidents When driving on an uneven road the quick stop of b...

Page 78: ...ring bracket 2 frame 3 leaf spring 4 lining 5 buffer 6 buffer 7 shock absorber 8 shock absorber bracket 9 rear leaf spring bracket 10 rubber pad 11 bracket cap 12 shock absorber stud 13 rubber bushes 14 U bolt pad 15 U bolt nut 16 tightening bolt 17 U bolt 18 clamps ...

Page 79: ...pad 8 leaf spring 9 shock absorber 10 shock absorber bracket 11 bracket of front leaf spring shackle 12 shackle web 13 bush of leaf spring eye 14 shackle pins nuts 15 clamp 16 shock absorber stud 17 rubber bushes 18 U bolt pad 19 U bolt nut 20 tightening bolt 21 U bolt 22 stabilizer 23 nut of leaf spring axle shaft 24 stabilizer eye View A ...

Page 80: ...he left and right hand thread and rotate fitting 2 Fig 9 23 Tighten the locknuts after adjustment Replace the wheels to wear the tires evenly Replace them only on one side the front instead of the rear one Do not use the spare wheel for replacement The attachment of the spare wheel is shown in Fig 9 24 The wheel shall be securely fixed on the holder with sector 2 Fig 9 24 A or with bracket 7 Fig 9...

Page 81: ...e cuff Fill the space between the bearings rollers with the grease Apply 10 15 mm of grease between the bearings Do not apply too much grease into the hub to avoid its contact with break mechanisms Swing the wheels to detect the gap in bearings 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 tighte...

Page 82: ... shoes against the brake disc or the drum 6 Tightenthehubbearingsadjustingnutsmoothlywiththetightening torque of 25 30 N m 2 5 3 0 kgf m When tightening the nut turn the steering wheel to adjust the rollers in the bearing properly 7 Install the lock washer screw and tighten the locknut with the torque of 20 25 N m 2 0 2 5 kgf m Fig 9 25 Rear Wheel Hub 1 wheel 2 hub bolt 3 wheel nut 4 adjusting nut...

Page 83: ... rotate freely without binding noticeable axial clearance or wobbling 9 Bend one tab of the lock washer round the nut flat and the other tab round the locknut flat until its full fitting to the flats Unbend the tabs which are the closest to centers of the nut flats 10 Install the rare axle shaft or the flange of the front axle hub clean the threaded part of the bolts from old sealant degrease them...

Page 84: ...t the steering mechanism periodically add oil into the tank of the hydraulic power steering system Periodically check the tightening of ends nuts and tie rods locknuts and do not let air gaps in the taper joints of levers and studs appear The vehicle is equipped with non repairable ends of tie rods They do not require adjustment and lubrication during the vehicle operation If non repairable ends h...

Page 85: ... the belt rip is possible Pay special attention to coolant temperature when the pump drive belt is removed to avoid engine overheating Long term vehicle operation with the disabled power steering can lead to the premature wear of the steering system Tighteningofthepowersteeringpumpdrivebelt Fig 9 5 consists inmovingthepumpalongthebracket mountedtotheengine Loosenthe pump bolts mounted to the brack...

Page 86: ...times with no stops in the end positions 6 Check oil level in the tank Heighten its level up to the filter screen When the engine is heated up or the power steering oil is heated up oil level can be up to 7 mm higher than the screen 7 Cover the tank and tighten the cap with a hand 8 Connect the drag link tighten see Appendix 2 and secure the ball stud nut with a cotter Maintenance of the control a...

Page 87: ...g gasket 11 adjusting shims Brake Systems ATTENTION Please remember that the stopped engine and the disabled vacuum booster considerably increase the effort necessary for pushing the brake pedal to stop the vehicle ATTENTION If one of the brake circuits is broken the pedal travel is increased and breaking efficiency is decreased In this case do not do short time multiple pedal pushes instead push ...

Page 88: ...dition with that there is no need to add fluid into the tank as installation of new linings heightens the fluid level up to the normal The brake fluid warning light comes on when the fluid level falls lower than the MIN mark which indicates that if the brake shoe linings are new or partially worn the system is non hermetic and the fluid leaks In this case add the fluid only after all leaks are eli...

Page 89: ...ribution EBD malfunction systemleakage etc Itisnot allowed to operate the vehicle with the brake system warning light on Front Disc Brakes To inspect the wear of brake shoes 2 Fig 9 28 you can use a mirror or remove the wheel For the second variant place the vehicle on a level ground and apply the parking brake Inspect the shoes through the window in caliper 4 If the linings wear to the thickness ...

Page 90: ...s Install spring 1 spring carrier 18 and screw bolts 16 ATTENTION Spring carrier 18 is asymmetric Its long side shall be mounted on crankcase 17 and its short side on clip 3 The necessary air gap between the brake shoes and the brake disc is maintained automatically during the vehicle operation In ABS equipped vehicles the calipers have recesses ATTENTION The brake disc bolts the tubing T connecto...

Page 91: ...ear through the orifices in the shields Unplug the orifices inspect the linings their thickness shall not be less than 2 5 mm plug the orifices Replace the linings in case of their excessive wear the rivets are sunk less than 0 5 mm When replacing the worn shoes or linings move the piston with the thrust ring deep into the cylinder for putting the drum on the shoes freely Fig 9 29 Rear Wheel Brake...

Page 92: ...raking forces between the axle shafts and prevents the rear wheels from blocking earlier than the front wheels When servicing the vehicle check the proportioning valve Clean it from dirt and check its attachment Make sure by visual inspection that the valve and its drive parts are not damaged the brake fluid does not leak and the coupling of the pillar with the flexible arm or the bracket on the r...

Page 93: ...t 4 Fig 9 31 until it touches piston tail 17 see Fig 9 30 of the valve 4 Tighten the locknut 5 Check the stroke of the valve piston see above 6 Check the adjustment correctness in motion of the vehicle While going on a straight level road with a dry surface brake the vehicle until wheels block If the valve operates properly and drive adjustment is done correctly the front wheels shall be blocked s...

Page 94: ...ank with brake fluid up to the MAX mark 4 Press the brake pedal several times to eliminate the effect of depression in the brake booster 5 Bleed the brake system Bleed the system as follows ATTENTION While bleeding add the fluid to the master cylinder tank in time and do not let the fluid level decrease lower than the MIN mark Do not let air come into the system Fig 9 32 Drive of Master Brake Cyli...

Page 95: ...eeding is over screw the bypass valve and remove the hose Dry the valve head and put on the safety cap AddthebrakefluiduptotheMAXmarkintothemastercylindertank Cover the tank carefully to avoid breaking the cap While bleeding hold the hose end dropped into the fluid Check the brake system when driving the vehicle If the working brakes and their drives are adjusted correctly and the brake system is ...

Page 96: ... screw 8 shoe lining 9 release mechanism tappet 10 balls housing 11 release mechanism housing 12 brake drum 13 18 shoes 14 brake release spring 15 cap 16 release mechanism ball 17 bolt 19 brake shield 20 adjusting mechanism housing 21 bar 22 spring 23 spring cap a view with brake drum b view without brake drum a b ...

Page 97: ...um and the linings The brake shall be adjusted when the brake lever travel gets more than the half of its maximum travel and when the braking effect becomes insufficient Adjust air gaps between the shoes and the drums for worn linings as follows 1 Shift the transfer case lever into the neutral position and switch off the front axle 2 Moveparkingbrakelever1 Fig 9 34 intoitsextremefrontposition 3 Ja...

Page 98: ...s in the yoke and the lever coincide and choose the cable slack The lever must contact the housing of the release mechanism balls 4 Unscrew the adjusting yoke for 1 5 2 torques combine the orifices in the yoke and the lever install the stud secure with a cotter and tighten the locknuts If adjusted correctly the vehicle shall brake when the lever pawl is installed into the 2nd or 3rd sector slot fr...

Page 99: ...t to the bodyshell front rack Fig 9 35 The scheme of relays and fuses is shown on the inner side of the box cap Fig 9 36 To access the relay fuse box remove its cap Fig 9 35 Location of Relay Fuse Box 1 bracket 2 relay fuse box cover 3 relay fuse box 4 front panel racket Fig 9 36 Relay Fuse Box К1 К8 relays F1 F18 fuses see Table 9 1 ...

Page 100: ...cket cab lighting F6 15 Alarm signal F7 15 Stop signal rear fog lights F8 20 Starter motor F9 10 Integrated microprocessor controlled engine system 15 A F10 15 Gages alarm signal F11 20 Windshield wiper reverse F12 10 ABS F13 15 Seats heating F14 10 Low beam F15 10 High beam F16 10 Parking lamps gages illumination F17 80 90 Punch down block F18 40 ABS If available Alternator WARNING Even short tim...

Page 101: ...argebylargecurrent whenstarting a cold engine in winter time Thoroughly prepare the engine for starting and turn on the starter motor only for a short period of time no more than 10 sec Operate the battery in correspondence with the Battery Operating Manual When parking the vehicle for a long time switch the battery off by disconnecting the cable from the minus terminal Replace the battery on UAZ ...

Page 102: ...heck the ease of rotor rotation in bearings with the brushes lifted Warnings 1 The sleeve of the starter motor travel can be broken if the starter motor is on after the engine begins working 2 Do not wash the starter motor caps and the drive with gasoline or kerosene to avoid grease removal from bronze graphite cellular plain bearings ATTENTION It is forbidden to move the vehicle with the starter ...

Page 103: ...beam is switched to the high beam and vice versa simultaneously on both headlamps using the turn indicators and beam switch lever 3 Turn on the low beam and closing one headlamp adjust the other one with screws 6 see Fig 9 38 so that the light spot on the wall or on the screen is located as shown in Fig 9 39 Adjusting screws of the headlamps are located symmetrically to the headlamps center in a h...

Page 104: ... wire clamps clean the horn from dust and dirt and check the sound power adjusting it as required Adjust the horn in a workshop Gages and Alarms Periodically check the tightening of the gages the safety of their contact couplings Clean them of dirt and dust Fig 9 39 Screenmarkingfor headlamps adjustment H distance between headlampscenterandground level Fig 9 40 Screen marking for front fog lights ...

Page 105: ...water release to the cab is possible which is not a vehicle defect Wipe dry the washed bodyshell surfaces to avoid stains appearing after drying out in summer and to avoid cracks appearing after water drops freezing Do not use soda and alkaline solutions as it leads to paint fading When possible do not park the vehicle under direct sunlight to avoid deterioration of wheel tires and weather strips ...

Page 106: ...o avoid dirt coming into the vehicle mechanisms 3 Thoroughly remove escaped grease from all parts after lubrication 4 If the housings of the engine and the transmission units contain excessivelydirtyoil ortheoilcontainsmetalparticles washthehousings before filling fresh oil 5 It is not allowed to mix the engine oils of different brands or of different manufacturers When changing the oil brand or o...

Page 107: ...t of ratchet wheel 7 5 Lift the vehicle on a required height by swinging the tire lever inserted to the handle orifice 6 To lower the wheels move the jack pawl to the right and deepen the jack screws into housing 1 by swingings the tire lever At the end of work twist external screw 2 and internal screw 3 into the jack housing as far as it can go Jack Maintenance periodically clean threaded parts f...

Page 108: ...set of spare parts wrap everything in oiled paper or cloth 8 Cover the bodyshell glasses with lightproof paper cloth or with shields from the outside 9 Remove wheels from the vehicle clean the rims from dirt and paint any damaged areas Clean wash and dry tires bring their pressure to normal 10 As required wash the fuel tanks and fuel them up to the max level 11 Prepare the battery for long preserv...

Page 109: ... the crankshaft 3 Clean any damaged areas of corrosion grease and paint them 4 Turn the steering wheel to both sides 2 3 times 5 Checktheparkingbrakeandthe pedalbrake the clutch the throttle gate drive and lighting switches 6 Check fluid level in the tanks of the brake master cylinder Add the fluid as required 7 Check the electrical equipment instruments 8 Checktoolsandappliances wipeandgreasethem...

Page 110: ...owing distance between them 50 100 mm from the side of the engine cooling radiator 100mmfromallothersides Thevehicleparkingbrakeison the engine is off the gearbox lever is shifted into the first gear the battery is disconnected thecableisdisconnectedfromthebatteryminusterminal Before air transporting the fuel tanks shall be fueled to no more than 75 of their capacity Enter the aircraft in the firs...

Page 111: ...0х55 Headlamps Parking lamps А12 5 5 Turn indicators А12 21 3 21 Rear lamps Turn indicators А12 21 3 21 Parking lamps А 12 5 5 Brake indicators А 12 21 3 21 Turn repeaters А12 5 5 Reverse lamp А12 21 3 21 License plate lamp А12 5 5 Cab light А12 10 10 Rear fog light А12 21 3 21 Gages illumination LED ...

Page 112: ... 8 3 6 Bolt between engine front strut and crankcase bracket 9 0 11 0 Nuts between engine rear struts and brackets with cottering 3 2 Nuts between engine rear struts brackets and frame 2 8 3 6 Crankshaft coupling bolt 17 20 Screws of throttle heating hoses clamps 0 1 0 3 Inlet pipe nuts 2 9 3 6 Exhaust manifold nuts 2 0 2 5 Self locking nuts of inlet pipe 4 6 5 1 Oil housing bolts 1 2 1 8 Spark pl...

Page 113: ...d transfer case 4 0 5 6 Nut between flange and axle drive gear 17 21 Bolts between axle driven gear and differential case 10 14 Differential carrier bolts 3 6 5 0 Nuts of leaf spring U bolts 9 10 Nuts of shackle pins for vehicles w ABS 8 5 9 5 Nuts of leaf springs axle for vehicles w ABS 16 18 Wheels nuts 10 12 Bolts of front axle drive flanges and rear axle shafts 6 0 7 0 Nut between drag link an...

Page 114: ... 45 С as per operating properties API classification min SG or SG CD AAI Automotive Engineers Association classification min B4 or B4 D2 Transmission oils Final drive housings of front and rear axles For all seasons with min temperature of minus 25 С TSp 15K TAP 15V TAD 17I For cold season only from October 1 to April 1 TSp 10 For all seasons SAE 75W 90 API classification GL 5 Steering system hous...

Page 115: ...er shafts bearings of steering column shaft steering knuckles pins steering knuckle bearings of front and rear wheels hubs front bearing of gearbox driving shaft bearings of heater electric motor gearbox control drive release and adjusting mechanisms of parking brake parking brake drive cable battery terminals For all seasons Litol 24 Litol 24RK For all seasons Lithium grease of NLGJ 3 Steering kn...

Page 116: ...ating fluids Clutch and brake system hydraulic drives Brake fluid Rosa Dot 4 RosDot SAE 1703F DOT 4 Engine Cooling System Coolant OZH 40 OZH 65 Lena OZH 40 OZH 65 TOSOL TS TOSOL A 40M TOSOL A 65M Shell safe Windshield wiper tank Obzor Avtoochistitel stekol 2 Appendix 3 continued ...

Page 117: ...th two fuel tanks silver 0 013238 palladium 0 0046744 ruthenium 0 00064147 6002 3829 Oil emergency pressure sensor silver 0 0310 101 3839 Brake fluid emergency level sensor gold 0 01198 silver 0 029064 495 374701 Turn indicators contact breaker silver 0 0208 palladium 0 112 528 3747 04 Windshield wiper breaker silver 0 143 379 3710 07 1N Emergency alarm switch silver 0 107 ...

Page 118: ...After Buying 47 Chapter 5 New Vehicle Running in 47 Chapter 6 Engine Start and Stop 48 General Provisions 48 Engine Start 48 Engine Stop 49 Chapter 7 Vehicle Driving in Different Road Weather and Climatic Conditions 49 Chapter 8 Vehicle Towing 53 Chapter 9 Vehicle Maintenance 53 Daily Maintenance 53 Vehicle Maintenance Every 500 km 54 Seasonal Maintenance 54 Engine 56 Engine Suspension 56 Engine C...

Page 119: ...hting System Light and Audio Alarm 103 Gages and Alarms 104 Bodyshell 105 Vehicle Lubrication 106 Chapter 10 Tools and Appliances 106 Chapter 11 Preservation 108 Preserved Vehicle Maintenance 109 Depreservation 109 Chapter 12 Transportation 110 Chapter 13 Utilization 110 Appendix 1 Vehicle Lamps 111 Appendix 2 Tightening Torque of Main Threaded Couplings 112 Appendix 3 Lubricants and Special Fluid...

Page 120: ...AZ 220695 UAZ 330365 UAZ 390945 and Versions Thereof Operation Manual RE 05808600 106 2007 9th Edition Prepared for publishing by UAZ Chief Designer Department Editor in Chief Chief Designer O A KRUPIN Editor I L NIKOLAEV Content by D A SHEMYREV ...

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