UAZ UAZ-31512 Instruction Manual Download Page 74

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Fig. 70. Front Wheel Brake:

1 -brake backing; 2 -bridge pipe; 3 -wheel cylinder; 4 -bleeder valve; 5 -coupling; 6 -shoe return spring; 7 -brake shoe lining; 8 -brake

shoe; 9 -boot; 10 -piston; 11-sealing ring; 12 -piston spring; 13 -adjusting eccentric; 14 -anchor pin; 15 -nut; 16 -coupling bolt;

17 -gaskets; 18 -support bushing; 19 -adjusting eccentric bolt; 20 -washer

Summary of Contents for UAZ-31512

Page 1: ...Open Joint Stock Company Ulyanovsky Avtomobilny Zavod AUTOMOBILES ÓÀÇ 31512 ÓÀÇ 31514 ÓÀÇ 31519 ÓÀÇ 3153 AND THEIR MODIFICATIONS Instruction Manual 2001 ...

Page 2: ...iption of the design and necessary operating and maintenance instructions Since efforts are continually made to improve the reliability and performance of the automobiles minor changes may be introduced without special notice We wish You a good trip ...

Page 3: ...netration of these fluids or their steams into the mouth cavity do not let to dry the liquid which is occured on the skin but wash it off right away with warm water and soap never spill liquids in the interior or indoors Should spillage occur wash off the spilled place with water and ventilate it take off the spilled clothes wash and dry it outdoors wet with kerosene the carbon of leaded gasoline ...

Page 4: ...ring booster pump 8 When using the gun with the unscrewed tip take out the spring and the ball in order to avoid their falling in the assemblies with liquid grease 9 Avoid falling acides soda solutions braking fluids antifreeze and fuel on the painted surfaces of the body and rubber parts 10 Do not allow impact loads on the chassis of the automobile When a strong impact of the front wheels is occu...

Page 5: ...The automobiles are designed for transportation of people and loads on roads of all types and intended for operating at ambient temperatures from 45 C to 40 C The automobiles ÓÀÇ 31519 ÓÀÇ 3153 are equipped with an engine of uprated power AUTOMOBILE MARKING The identity number of the automobile is indented on the nameplate on the level flange of the body front upper panel Fig 5 The nameplate Ident...

Page 6: ...all Dimensions of Automobiles ÓÀÇ 31512 and ÓÀÇ 31519 Dimensions are given for reference For automobiles with front spring suspension Note Dimensions of automo biles provided with axles with hub drive see in Fig 4 ...

Page 7: ...all Dimen sions of Automobile ÓÀÇ 31514 and ÓÀÇ 31519 Dimen sions are given for reference For automobiles with front spring suspension Note Dimensions of automobiles provided with axles with hub drive see in Fig 4 ...

Page 8: ...8 Fig 3 Overall Dimensions of Automobile ÓÀÇ 3153 Dimensions are given for reference ...

Page 9: ...9 Fig 4 Overall Dimensions of Automobiles ÓÀÇ 31512 ÓÀÇ 31514 ÓÀÇ 31519 pro vided with axles with hub drives dimensions are given for reference For automobiles with hard top ...

Page 10: ...rs 3 body number 4 chassis number 5 name plate Identification Data I international code of manufacturer II descriptive part automobile model make III indicating part year of automobile manufacture and ordinal number Fig 6 Location of Engine Number ...

Page 11: ...ibution kg front axle with soft top 965 965 with hard top 1000 1000 1080 rear axle with soft top 1385 1385 with hard top 1500 1500 1520 Vehicle total weight kg with soft top 1600 1600 wit hard top 1750 1750 1800 Vehicle total weight distribution front axle with soft top 880 880 with hard top 950 950 930 rear axle with soft top 720 720 with hard top 800 800 870 Maximum speed km h 110 110 120 120 Pe...

Page 12: ...der 1 2 4 3 Cylinder bore mm 92 100 Piston stroke mm 92 92 Displacement l 2 445 2 89 Compression ratio 7 0 7 0 Nominal power at crankshaft speed of 66 s 1 4000 min 1 kW hp to DIN 70020 57 4 78 63 2 86 gross to SAEj 816b 68 4 93 73 5 100 net to ÃÎÑÒ14846 55 9 76 61 8 84 Maximum gross torque at 36 42 s 1 2200 2500 min 1 N m kgf m to DIN 70020 164 8 16 8 193 19 7 gross to SAEj 816b 174 6 17 8 201 20 ...

Page 13: ...w range 1 94 or 1 47 Front and rear driving axles Final drive spiral bevel gearing gear ratio 4 625 front axle steering knuckle joints Constant velocity universal joints of ball type CHASSIS Suspension front type on four longitudinal semielliptic spring springs with transverse stabilizer rear on small leaf springs 1 2 3 4 5 The automobiles ÓÀÇ 31512 ÓÀÇ 31514 ÓÀÇ 31519 could be equipped with Ï sha...

Page 14: ...er mean gear ratio of steering mechanism 20 3 with hydraulic steering booster 17 3 without hydraulic steering booster 20 5 Brakes Service Shoe with two separate circuits actuated from two chamber master cylinder parking Drum with inner shoes acting on power train with mechanical drive ELECTRICAL EQUIPMENT Wiring Single wire with ground returned minus Rated voltage V 12 Overload breakers fuse Unit ...

Page 15: ...oling fluid temperature in cooling system Ñ 80 90 Spark plug gap mm 0 85 0 15 Free travel of clutch pedal mm 35 55 Free travel of brake pedal mm 5 14 Front wheel toe in mm 1 5 3 0 Maximum turning angle of front inner wheel deg 27 Steering wheel play deg not more 10 Tyre Inflation Pressure kPA kgf cm2 Tyre Model ß 245 1 ßÈ 357A Ê 151 Ê 152 Ê 153 ß 435À Front wheel ÓÀÇ 31512 ÓÀÇ 31514 ÓÀÇ 31519 1 7 ...

Page 16: ...c actuated brake system 0 52 Clutch hydraulic system 0 18 Windshield washer reservoir 2 CONTROLS AND INSTRUMENTS Arrangement of the controls and instruments is illustrated in Fig 7 1 steering wheel 2 rear view mirror internal 3 instrument panel 4 sun visors 5 windshield wiper blades 6 windshield demisting nozzle 7 passenger grab handle 8 light mounted on automobile ÓÀÇ 31512 9 ground switch 10 fro...

Page 17: ...ections for moving the lever for shifting in the gears are indicated on the handle of the gearshift lever and in Fig 8 14 parking brake lever 15 heater and ventilator lid control handle Fig 8 Instruction Plate Positions of Transmission Transfer Case and Front Axle Shift Levers 1 positions of shift levers 2 transmission 3 transfer case 4 speed ranges 5 high range 6 neutral 7 low range 8 front axle ...

Page 18: ...er warning system button switch 2 speedometer with trip odometer indicating the automo bile speed in km h and trip odometer indicating the total run of automobile in km 3 fuel level gauge Each tank is provided with a fuel level gauge 4 brake emergency condition warning lamp red 5 parking brake warning lamp red 6 turn indicator warning lamp green 7 radiator cooling fluid emergency overheating warni...

Page 19: ...ent Panel of Automobile ÓÀÇ 31512 for Ref Nos refer to text Fig 10 Instrument Panel of Automobiles ÓÀÇ 31514 ÓÀÇ 31519 for Ref Nos refer to text Fig 11 Instrument Panel of Automobile ÓÀÇ 3153 for Ref Nos refer to text ...

Page 20: ...g wheel in any direction till click is heard this means that the lug of the interlock device is in register with the recess of the stop bush of the steering wheel shaft To unlock the steering gear insert the key into the ignition switch and by turning the steering wheel to the left and to the right turn the key clockwise to the position I Installed on some automobiles Fig 12 Position of Ignition K...

Page 21: ...ng it through 90o in any direction 23 windshield wiper and washer selector switch installed on the automobile ÓÀÇ 31512 The windshield wiper is switched on by rotating the switch knob and the windshield washer is switched on by depressing the knob axially 24 pushbutton of lighting circuit thermal cut out 25 heater fan electric motor selector switch has three posi tions OFF fan motor low speed ON f...

Page 22: ...ched on by means of the outer light switch II l h turn indicators are on non fixed position III l h turn indicators are on fixed position IV r h turn indicators are on non fixed position V r h turn indicators are on fixed position VI to himself upper beam is on independing upon the position of main light switch non fixed position VII from himself upper beam is on if headlamps are switched on by me...

Page 23: ...ulling the lever 9 on automobiles ÓÀÇ 3153 Such a position makes it possible to enlarge the cargo area of the body The rear single seats Fig 18 are provided with a separate back and cushion The back is secured unmovable to the body side panels the cushion may be hinged out upward and secured by straps In the service position the single seat cushion are fixed by pins in rubber sockets The automobil...

Page 24: ...3153 are fitted diagonal lap belts with an automatic retractor the middle safety belt of the rear seat is the lap belt provided with a length manual adjuster Fig 17 Triple Seat à seat of automobile ÓÀÇ 3153 1 seat back in service position 2 seat back in folded position 3 belt to fasten seat back to cushion 4 seat in reclined position 5 seat frame leg pivot 6 side lock bracket 7 buffer 8 lock handl...

Page 25: ...ld sitting on the knees of a passenger The belts could be washed with suds Do not iron the belts Replace the shabby and damaged belts and the belts after emergency loading as a result of an accident When folding the rear seat of the automobiles ÓÀÇ 31512 ÓÀÇ 31514 ÓÀÇ 31519 unfasten the locks 4 Fig 19 a and pull the belts The rear seat belts are provided with a body floor instant release attachmen...

Page 26: ...n hard surfaced roads deep mud sandy soils steep up grades etc 3 Do not exceed the following speed limits in direct gear 45 50 km h in the third gear 30 km h in the second gear 20 km h in the first gear 12 km h 4 Do not change oils filled in the engine and units at the manufacturing plant 5 Check the temperature of brake drums and in case of raising the temperature adjust them in compliance with t...

Page 27: ...ollowing operations 1 Close the radiator shutter and mount the radiator shell warmth keeping cover 2 Using the starting handle turn over the engine crankshaft for 3 5 times 3 Pull the choke control knob all the way out preliminary the throttle valve control pedal should be pressed Carry out the subsequent operations in the order specified for starting the engine at temperatures of 0 Ñ and above Af...

Page 28: ...to shift in the second gear for starting the automobile away from rest on level sections of roads or on down grades In other cases shift in the first gear for starting away from rest Disengage the clutch when shifting in gears Move the gearshift lever smoothly and without jerks If a required gear is not shifted before starting the automobile away from rest release the clutch pedal gently and then ...

Page 29: ...h riding surface by speeding up without engaging the transfer box to a low range and by shifting the gearbox in the second or third gears depending on an up hill gradient If for some reason it is impossible to overcome an up grade take all precautions and descend slowly by shifting in the reverse gear Descend little by little do not speed up the automobile and do not disengage the clutch When over...

Page 30: ...ar which would provide a required traction force of wheels Fording Overcome a ford with a great care The automobile could overcome a ford of a 500 m depth with a hard bottom at a low speed Before overcoming a ford check the bottom make sure that there are no deep pits big stones swampy grounds check the ground where the automobile would enter water and go out of water Cut the radiator shutter if i...

Page 31: ...This section indicates also operations which should be carried out in intervals between servicing terms according to the Coupons DAILY MAINTENANCE 1 Visually check the automobile for completeness of sets check the body glasses rear view mirrors licence plates body coating door locks frame springs shock absorbers wheels and tyres for proper condition Eliminate detected faults Inspect the automobile...

Page 32: ...ditions of the commutator and brushes wash and lubricate the bearings 4 Switch on the windshield wiper for 15 20 min the blades should be swung out of the way Before the Winter Season of Operation 1 Disconnect the air hose from the air cleaner union and set the manifold heat control valve in the winter position 2 Wash the fuel tanks and fuel filters 3 Check coolant specific gravity in the engine c...

Page 33: ...er head Tighten the nuts only on a cold engine Tighten the nuts in two steps in the sequence illustrated in Fig 23 the first step Fig 20 Engine l h view 1 fine fuel filter 2 oil filler cap 3 oil dip stick 4 rocker arm cover 5 cylinderhead 6 ignition distributor 7 starter 8 clutch housing 9 clutchhous ing lower part 10 fuel pump 11 engine mounting bracket Fig 21 Engine r h view 1 cylinder block dra...

Page 34: ... piston of No 1 cylinder at the TDC on the compression stroke and check the clearance between the rockers and valves of No 1 2 4 6 with the feeler gauge In the case of an incorrect clearance screw out lock nut Fig 25 of adjusting screw and rotating the letter with a screwdriver set a required clearance by means of the feeler gauge Then holding the adjusting screw with the screwdriver tighten the l...

Page 35: ...ystem For cooling oil in the engine lubrication system an oil cooler is provided It is recommended to cut in the cooler by opening the cock 7 Fig 26 at an ambient temperature above 20 C But when riding on heavy roads with heavy load and at a high engine crankshaft speed also cut in the cooler independing on an ambient temperature Fig 24 Timing Marks on Crankshaft Pulley 1 index pointer 2 mark for ...

Page 36: ...tact with the cylinder block surface then draw up tight the filter through 3 4 of turn Make sure that there is no leakage of oil Oil pressure in the lubrication system of a warmed up engine of a new automobile at a speed of 60 km h in direct gear and when the oil cooler cock is open should be at least 343 kPa 3 5 kgf cm2 Oil pressure in a cold engine can be increased to 588 kPa 6kgf cm2 and on a h...

Page 37: ...shaft speed Immediately stop running the engine if some faults in the engine lubrication system are detected Maintenance of the Crankcase Ventilation System For flushing and cleaning remove the vacuum regulator from the engine and disassemble it Clean the pipelines Fig 27 the calibrated orifice b Fig 28 and flush the parts of the vacuum regulator Check tightness between the case and cover plate wh...

Page 38: ... for leakage of fuel Leakage of fuel indicates that the diaphragm is faulty Periodically check the attachment of the pump to the engine and the connections of the pipelines for tightness Flush the gauze strainer and remove dirt from the upper casing Fine fuel filter 1 refer to Fig 20 Periodically disassemble the fine fuel filter for flushing the bowl and filter element Carburettor The carburettor ...

Page 39: ...hamber Adjust the fuel level by bending lip 3 Fig 31 The float should be in the horizontal position The valve 5 stroke is adjusted by means of the lip 2 and should be 1 5 2 0 mm Slow idling speed of the crankshaft at 700 750 min 1 is to be adjusted by means of the screw 1 Fig 32 when the engine is warmed up The screw 2 is used for adjusting the CO content Fig 30 Fuel Pumps of Á9Â type à inspection...

Page 40: ...proceed as follows loosen bolts 8 Fig 33 and yoke 2 shift clamps 9 take away cover 6 with filter element 5 take away yoke 10 and filter element from frame Assembly the air cleaner in the reverse sequence Never use the air cleaner with defective muff 1 Replace the filter element when bursting or burning the filter element every 100 000 km of run after maximum permissible procedures of cleaning Flus...

Page 41: ...rator pedal should be at a distance of 80 95 mm from the toeboard If the threaded portion length of the accelerator pedal rod is not sufficient for the adjustment change the length of rod screwing it out of the rod end As required lubricate the carburettor manual control linkage with lubricating grease Before lubrication remove it from the automobile and take off old grease Fig 33 Air Cleaner 1 mu...

Page 42: ...u may use other coolant recommended by the automobile dealer Bear in the mind that antifreeze is poisonous The coolant level should be 30 40 mm above the MIN level mark inscribed on the expansion tank Fig 35 Carburettor Control Linkage 1 accelerator pedal 2 lock nut 3 adjusting sleeve 4 return spring 5 bracket 6 shaft 7 compensating spring 8 lever 9 10 nuts 11 rod 12 intermediate lever 13 throttle...

Page 43: ...rry off steam from the radiator when parking drain coolant from the engine cooling system and heating system Keeping the coolant temperature in a range of 80 to 90 C during operation of the automobile considerably decreases wear of the engine and cuts down fuel consumption The recom mended temperature is maintained by means of an automati Fig 36 Cooling System Diagram 1 heater radiator 2 heater co...

Page 44: ... and eliminate the cause of overheating The rise of the coolant temperature may be caused by the drop of coolant level in the radiator loose tension of the fan belt faulty fan drive coupling by movement of the automobile with the closed shutters and with the closed valve of warmth keeping boot Adjust deflection of the fan belt Fig 37 by turning the alternator Normal deflection of the belt equals 8...

Page 45: ...transistor switch and connect it to the terminal of the emergency vibrator Service life of the emergency vibrator is limited to 30 h therefore switch it into operation only in emergency cases and replace a faulty unit at the first opportunity Simultaneously when switching into emergency operation switch off the system of idling speed economizer for which purpose connect by means of one of the hose...

Page 46: ...40 Carburettor Mixing Chambers Housing 1 economizer union 2 sole noid valve vacuum supply union 3 union for vacuum supply to vacuum spark ad vance control For setting the ignition timing proceed as follows 1 Set the piston of No 1 cylinder at the TDC on the compression stroke until the timing hole on the crankshaft pulley gets in register with the timing pointer on the timing gear cover Fig 41 Che...

Page 47: ...selector plate to the distributor body 7 Reinstall the cap of the magnetic pickup and distributor unit and check to see that the ignition wires running to the spark plugs are set correctly in compliance with the engine firing order 1 2 4 3 counting counterclockwise Each time after setting the timing check for correct spark timing by listening to the running engine with the automobile in motion To ...

Page 48: ... cover plate 20 pressure springs 19 and release levers 11 in assy driven disk 3 with linings and torsional vibration damper in assy Some automobiles are equiped with a dry single plate clutch provided with the central pressure spring of the diaphragm type The clutch consists of the pressure plate with the cover plate and of the pressure disk diaphragm spring which tabs function as release levers d...

Page 49: ... central diaphragm spring needs no adjustment of free travel The free travel 5 30 mm is main tained by the clutch design Fig 43 Clutch 1 clutch housing lower part 2 flywheel 3 driven disk 4 pressure plate 5 front bearing 6 crankshaft 7 input shaft 8 needle bearing 9 clutch hous ing 10 release lever pin 11 release lever 12 release pin 13 release roller 14 release lever fork 15 adjusting screw 16 re...

Page 50: ...e with Pressure Springs and Release Levers 1 cover 2 filter gauze 3 reservoir 4 hydraulic pipe 5 master cylinder 6 bypass hole 7 compensating hole 8 washer 9 18 21 26 springs 10 cup 11 union 12 master cylinder piston 13 collar 14 boot 15 master cylinder pushrod 16 pedal shaft 17 fork 19 pedal 20 muff 22 ball support 23 clutch release fork 24 hydraulic hose 25 operating cylinder 27 cap 28 bleeder v...

Page 51: ...evelling of the oil levels is not obligatory Lubricate the shaft of the control levers through the grease fitting The access to it is from below Fig 46 Transfer Box Plugs 1 filler hole plug 2 drain hole plug Maintenance of the Propeller Shafts Periodically check tightening of the bolts attaching the propeller shaft flanges periodically lubricate them clean the propeller shafts of dirt Lubricate th...

Page 52: ...lly clean the safety valve 1 Fig 48 tighten up all fastening parts Apply grease according to the directions of Lubrication Table Check the oil level which should reach the edge of the filler hole Drain oil through the hole at the bottom of the housing by screwing out the filler plug Check also the level and change oil in the hub drive housings when the axles are provided with the hub drives Fig 48...

Page 53: ... IV 50 IV For disengaging the wheels turn the disk of the sleeve counter clockwise as far as it will go arranging in one plane the mark á with the figures 4õ2 For engaging the wheels turn the disk of the sleeve clockwise as far as it will go arranging in one plane the mark with the figures 4õ4 Never engage the front axle when the front wheels are disengaged CHASSIS Towing Hook The towing hook is i...

Page 54: ... 3 seal 4 20 gaskets 5 ball support 6 steering knuckle housing 7 thrust washer 8 cover plate 9 kingpin 10 grease fitting 11 lock pin 12 journal 13 wheel hub 14 driving flange 15 coupling 16 coupling bolt 17 lock bolt 18 protective cover 19 kingpin bushing 21 inner casing 22 ring baf fler 23 outer casing 24 rubber sealing ring 25 felt seal ing ring 26 thrust washers 27 steering stop bolt 28 steerin...

Page 55: ... journal 19 locking nut 20 23 thrust washers 21 hub drive pinion 22 lock pin 24 rubber sealing ring 25 thrust washer 26 axle shaft housing 27 steering locking angle adjusting bolt 28 steering stop 29 steering knuckle arm 30 coupling disk Fig 50 Axle Steering Knuckle with Hub Drive à indicating groove á indicator I right hand steering knuckle II left hand steering knuckle III wheels disengaging sle...

Page 56: ...he combined suspension are not interchangeable Maintenance of the Suspension Periodically check the condition and attachment of the springs and shock absorbers To prevent corrosion and eliminate squealing noise lubricate the spring leaves at least once a year To lubricate the springs remove them from the automobile disassemble wash in kerosene dry and lubricate each leaf with a grease according to...

Page 57: ...Ç 3152 ÓÀÇ 31514 ÓÀÇ 31519 1 front hanger 2 frame 3 buffer 4 cover plate 5 shock absorber hanger 6 shock absorber 7 rear hanger 8 rubber bushings 9 shackle outer cheek 10 shackle inner cheek 11 U bolt 12 gasket 13 spring 14 washer 15 spring axle ...

Page 58: ...tie rod 3 9 rubber metal joints 5 longitudinal lever hinges 6 rubber joints 7 8 nuts 10 11 tie rod hinges 12 spring 13 14 spring hinges 15 vibration damping gasket 16 stabilizer 17 stabilizer bracket 18 19 rubber bushings 20 U bolt 21 buffer 22 shock absorber ...

Page 59: ...ngs 1 shock absorber hanger 2 spring 3 shock absorber 4 frame 5 cover plate 6 U bolt 7 pad 8 shackle bracket 9 shock absorber hanger 10 U bolt nut 11 axle 12 rubber bushing 13 buffer 14 shackle inner cheek 15 pin 16 shackle outer cheek 17 pin nut ...

Page 60: ...f the shock absorbers consists in periodically checking them for tightness and reliable fastening as well as in changing the fluid in compliance with the instructions laid down in Lubrication Table If leakage of fluid through the rod seal and the reservoir sealing rings is detected tighten nut 18 Fig 55 If the leakage fails to be eliminated repair the shock absorber in a workshop Fig 55 Shock Abso...

Page 61: ...wear of the front wheel tyres is detected check and adjust the toe in of the front wheels With the normal tyre inflation pressure the toe in of the front wheels should be such that the dimension A Fig 57 measured by the center line of side surface of the tyres ahead of the axle is 1 5 3 0 mm less than the dimension B measured back of the axle As required adjust the toe in of the front wheels by ch...

Page 62: ... its wear does not differ from wear of the other tyres Fig 59 When rotating the radial ply tyres rotate the front and rear wheel tyres separate for each side Do not introduce the spare wheel tyre Fig 57 Toe In of Wheels Fig 58 Steering Linkage Rod 1 locknut with l h thread 2 adjusting sleeve 3 locknut with r h thread 4 joint 5 grease fitting Fig 59 Tyre Rotation Diagram ...

Page 63: ...earings Do not apply too much grease to the hubs to avoid its ingressing in the wheel brakes Fig 60 Rear Wheel Hub 1 hub 2 bearing 3 gasket 4 journal 5 axle shaft 6 lock nut 7 lock washer 8 collar 9 wheel disk 10 brake drum Adjust the wheel hub bear ings in the following se quence 1 Jack up the wheel whose bearings are to be adjusted 2 Take out the rear axle axle shaft 5 Fig 60 remove the axle dri...

Page 64: ...arings after tightening the locking nut If the adjustment is correct the wheel should rotate freely without binding noticeable axial play and wobbling 9 Bend the one tab of the locking washer round the flat of the nut bend the second tab round the flat of the locking nut Fig 62 10 Reinstall the axle shaft of the rear axle driving flange and front axle wheel disengaging coupling install the spring ...

Page 65: ... the hydraulic steering booster Periodically check the steering wheel play The steering mechanism is considered to be in serviceable condition and needs no adjustment if the steering wheel play with the wheels set in a straight ahead position is not over 10 under a force of 7 35 N 0 75 kgf applied to a dynamometer which corresponds to 40 mm when measured on the steering wheel rim Check the steerin...

Page 66: ...olumn When knock in double coupling steering column Fig 65á is heard check the circlip 8 in the shaft groove for proper condition tighten up the nuts 15 28 and adjust bearings by tightening the nut 27 In the process of maintenance of automobiles pay attention to proper fastening of the bearings in the yokes of the steering arrangement universal joint Fig 64 Steering Column of Automobile ÓÀÇ 31512 ...

Page 67: ...lumn shaft 8 circlip 9 protective ring 10 distance sleeve 11 steering column shaft 12 steering column 13 steering column upper housing 14 switch under steering wheel 15 steering column shaft nut 16 steering wheel 17 screw to fasten steering wheel cover plate 18 screw 19 steering column lower housing 20 ignition switch 22 wedge 23 cotter 25 washer 26 steering gear cardan shaft 27 adjusting nut 28 s...

Page 68: ...ear of the steering mechanism Do not allow that the pump of the hydraulic steering booster functions without oil When leakage of oil from the hydraulic steering booster is detected the belt of the hydraulic steering booster drive is to be rmoved Belt tension of the hydraulic steering booster pump drive At a normal belt tension its deflection in the middle between the crankshaft pulleys and pump pu...

Page 69: ...minimum until air bubbles cease to escape from oil Check connections of hoses to the hydraulic steering booster units for tightness and eliminate untightness if required 5 Run the engine for 15 20 s and bleed the hydraulic steering booster by turning the steering wheel from lock to lock position without holding it in extreme positions three times in each direction 6 Top up oil if required 7 Place ...

Page 70: ...nd rear axle Do not operate the automobile when the pipes and hoses are faulty Fig 66 By pass and è Relief Valves of Pump 1 control valve of by pass valve 2 relief valve spring 3 guide of relief valve spring 4 relief valve ball 5 control valve spring 6 relief valve seat 7 filter 8 ring 9 plug stopper 10 sealing gasket 11 adjusting shims Fig 67 Master Cylinder Control Linkage 1 signalling device 2 ...

Page 71: ...rive is damaged When maintening the hydraulic steering system pay atten tion to the stopper 17 Fig 68 and check if there is no leakage of brake fluid from under it The plug in its service condition must be flushed with the opening of the regulator body against the stop If the stopper is extended above the opening and brake fluid leaks repair or replace the regulator In the service period when repl...

Page 72: ...drums and for reducing the brake pedal travel adjust the brake drum to shoe in the following sequence Fig 68 Pressure Regulator 1 piston 2 piston sealing ring 3 6 piston spring bearing disk 4 piston spring 5 body 7 piston head seal 8 body liner 9 pusher sleeve bearing disk 10 pusher sleeve 11 pusher sealing ring 12 bearing plate 13 pusher sleeve spring 14 plug 15 plug gasket 16 by pass valve 17 st...

Page 73: ... to check the brakes for drum heating and for uniform application During the brake running adjustment do not touch the anchor pins as the Manufacturer s setting of the brake shoes will be disturbed If the rivets of the linings are flush mounted on a depth of less than 0 5 mm replace the shoes or linings Adjustthe brake pedal free travel by setting the stop of the stop light switch 14 Fig 67 in a p...

Page 74: ...cylinder 4 bleeder valve 5 coupling 6 shoe return spring 7 brake shoe lining 8 brake shoe 9 boot 10 piston 11 sealing ring 12 piston spring 13 adjusting eccentric 14 anchor pin 15 nut 16 coupling bolt 17 gaskets 18 support bushing 19 adjusting eccentric bolt 20 washer ...

Page 75: ...bleeding add brake fluid into the reservoirs of the brake master cylinder seeing to it that they are never empty in order to prevent penetra tion of air into the system again Fig 72 Bleeding Brake System During the whole operation keep the free end of the hose dipped in fluid If neither fluid nor air escape from the hose the hose is clogged or the valve is closed Fig 71 Rear Wheel Brake 1 marks on...

Page 76: ...y unscrewing the by pass valve of the front wheel screw in the by pass valve with the brake pedal depressed Switch on the signalling device brakes and their hydraulic system have been adjusted and bled correctly the full applica tion of the brakes should take place within 1 2 2 3 of the pedal travel Do not add into the brake master cylinder the brake fluid collected in the glass vessel during blee...

Page 77: ...nkage in which case adjust the length of the control rod To adjust the brake shoe to drum clearance turn in the screw 7 Fig 73 on the brake anchor plate and then turn out the screw against the stop through 4 6 clicks 1 3 1 2 of a turn until the drum is free to rotate Adjust the length of control rod in the following sequence 1 Shift the lever to the extreme forward position 2 Screw off lock nut of...

Page 78: ...rake shoe support 9 expander mechanism pushrod 10 cage of balls 11 expander mechanism housing 12 brake drum 13 18 brake shoes 14 brake shoe return spring 15 cap 16 expander mechanism ball 17 bolt 19 brake backing plate 20 adjusting mechanism housing 21 rod 22 spring 23 spring retainers a view with brake drum á view without brake drum ...

Page 79: ...the bracket under the hood The storage battery is connected parallel to the alternator If in the service period of the automobile the storage battery is gradually discharging or is excessivly charging by the alternator and the electrolyte begins to gas check the alternator for proper condition Keep the storage battery clean and in charged state protect its leads and terminals from oxides as indica...

Page 80: ...icing open the battery switch Periodically clean the starter of dirt visually check the starter for proper attachment to the clutch housing Check the condition of terminals working surfaces of contacts remove caking with a fine cut file then wipe them with waste and blow out Check the starter drive its pinion lever and spring Clean of dirt frictioning parts wash out and wipe them dry if required l...

Page 81: ...he following sequence 1 Place ready for road automobile with a driver s seat load of 75 kg on a level ground Errect the aiming screen in front of the automobile at a distance of 5 m Remove the rims 2 Switch on the headlamp and by operating the foot switch be sure that the lower and upper beams are lighting up simultaneously 3 Turn on the lower beam and cover one headlamp Adjust the beam by turning...

Page 82: ... the screw attaching the cover remove the cover and the lens Fig 74 Headlamp 1 5 screws 2 garnish molding 3 sealed beam unit 4 inner molding 6 adjusting screws Fig 75 Aiming Screen for Headlamp Adjust ment H distance from center of headlamps to ground level Fig 76 Aiming Screen for Fog Headlamp Adjust ment H distance from center of headlamps to ground level L distance between centers of fog head l...

Page 83: ...long the bracket Shift the switch lever from one into another position smoothly without jerks and blows Take care to prevent getting of lubricant and water on the switch rubber roller and keep the roller clean Overload Breakers The unit of overload breakers Fig 77 provided with three fuses 10A each is located under the automobile hood on the body front panel Fig 77 Fuse Unit 1 fuse unit body 2 fus...

Page 84: ...ms and units in the automobile They consists of speedometer voltme ter oil pressure gauge engine coolant gauge and fuel level gauge The gauges operate in conjunction with transmitters The automobile is provided with the automobile emergency condition warning flashers all the turn indicators flush simul taneously Maintenance of the devices comes to periodic checking the devices for proper attachmen...

Page 85: ...touches the piston 7 by rotating the handle insert the stud through slot of the piston and by rotating the handle lock the stud in the piston fit the head 1 over a nipple When rocking the lever 8 press the handle 12 Fill the gun with grease in the following sequence 1 Screw the cylinder 9 out of the body 4 2 Pull the piston 7 inside of the cylinder through 1 5 of strokes by means of the handle 12 ...

Page 86: ...imum height of lifting is 240 mm For jacking up the wheel proceed as follows 1 Install the jack on a level ground under the axle shaft sleeve 2 Turn out the jack internal screw 3 as high as the clearance between the axle shaft sleeve and the ground permits 3 Throw over the jack latch 5 to the l h side relative to the jack handle 6 so that the latch projection enters the tooth space of the ratchet ...

Page 87: ... key The internal door panels are provided with handles 2 Fig 80 by means of these handles the door locks are locked up from inside the lower handle position The locks locked up from inside by means of the handles 2 are not unlocked from outside The lock of the flap door is locked up by a key The body floor is provided with access hatches to the transmission transfer box parking brake as well as t...

Page 88: ... Unfasten the tarpaulin from the rear part of the body and from the body sides and thereafter remove the tarpaulin from the fasteners 2 Screw out the extreme bolts securing the metal holding down strips located on the windshield frame ease off the remaining bolts and remove the metal hold down strips Ðèñ 80 Automobile Door 1 door extension 2 door lock inner handle 3 door lock outer handle 4 gas ke...

Page 89: ...guard 5 hood lock hook 6 hood lock button 7 hood safety catch 8 hood safety catch lever Fig 83 Setting Hood in Open Position I hood in propped up position II hood latched to windshield frame 1 hood prop 2 hood 3 hood retainer clamp 4 hood retainer bracket 5 hood retainer latch ...

Page 90: ...al struts of the tarpaulin framework 9 Unscrew the bolts and remove the inclined props of the tarpaulin framework 10 Unscrew and remove the tarpaulin bows 11 Fold up the tarpaulin placing the inclined struts spring braces and straps inside Couple the tarpaulin bag by means of the belts Body Heating and Ventilation The body is heated with air admitted from the outside through the cowl ventilator lo...

Page 91: ... of dust At that time the door swivel glasses should be closed Windshield Wiper and Water Pump Windshield Washer Windshield wiper The automobile is equipped with the electric two speed windshield wiper It consists of the drive located under the instrument panel and two levers with blades For convenience when washing the windshield the blade and lever assemblies could be swung out of the way Do not...

Page 92: ...so if required replace blades and rubber tapes Washer Fig 86 The electric washer is intended for high speed cleaning the windshield Fill up the washer reservoir with clean water in summer or with special antifreezing fluid in winter Adjust the direction of fluid jet except for headlamp washer jets by changing the position of the jet balls by means of a needle inserted through the channel of the ba...

Page 93: ...und During service of the automobile periodically treat the body surfaces especially enclosed spaces with corrosion preventive compounds Treat the enclosed spaces of the body through the special holes in the panels and cross members of the floor which are closed by means of the rubber plugs If required recovery the body floor coated with bituminous cement by spreading it by means of a special spra...

Page 94: ... Ðîñà Äîò 4 is allowed in any proportions If metal particles are detected in oil open the unit check it and replace the worn parts PRESERVATION If the automobile is to be removed from operation for a prolonged period of time it should be subjected to preservation for which purpose do the following 1 Carry out the scheduled maintenance 2 Wash the automobile and wipe it dry Touch up the paintwork wh...

Page 95: ...e transfer box and housings of the front and rear axles for each purpose wrap the safety valves with the insulating tape 16 Clue the clearances between the brake drums and backing plates with oiled paper 17 Protect the tyres and other rubber parts from action of direct sunlight 18 Put under the axles the metal or wooden props that the wheels would be raised above the surface Unload the springs for...

Page 96: ...r rubber parts 10 Eliminate the troubles detected during inspection Depreservation 1 Remove the preservative lubricant from the parts for which purpose wash them with kerosene or clear gasoline Remove the lubricant from areas which may come in contact with rubber parts or painted surfaces 2 Carry out daily maintenance 3 Check the level of oil in the engine crankcase and drain an excess amount of o...

Page 97: ...water should be poured out from the cooling system and the sighboard Water is poured out should be hanged the storage battery should be cut off with the ground switch To protect the automobile from axial and side shiftings attach it with four tension wires of steel wire dia 6 mm with double thread each and also with wooden wedges 300x160x80 nailed to the floor under wheels Attach the tension wires...

Page 98: ... 10W 40 Transmission Oils ÒÑï 15Ê SAE 90 ÒÑï 10 SAE 75W Lubricant Grease Grease Ëèòîë 24 Lithium grease to NLGJ 3 Graphite powder Barbatia Grease 2 Fluids Shock absorber fluid ÀÆ 12Ò Shock absorber oil Spindle oil ÀÓ Shell Donax A Brake fluid Òîìü Ðîñà SAE 1703F DOT 4 Ðîñà 3 Ðîñà Äîò 4 Cooling fluids ÎÆ 40 Ëåíà Shell safe ÎÆ 65 Ëåíà ÒÎÑÎË À40Ì ÒÎÑÎË À65Ì ...

Page 99: ...99 Fig 88 Lubrication and Tank Chart of Automobile ...

Page 100: ... km of run If required top up Ì 8Â for ÌÎ the subsequent after Ì 6ç 12Ã1 or 16000 km of run or at Ñàì Îéë 4111 seasonal maintenance Ñàì Îéë 4112 Ñàì Îéë 4113 Ì 6ç 10Â Ì 4ç 6Â1 Ì 5ç 10Ã1 5 Engine oil 1 Every 8000 km of run Replace filter after running in filter 26 Distributor rotor bush 1 Motor oil Every 32000 km of run Lubricate with 4 or 5 drops before lubricating remove runner and filtz Ref Nos ...

Page 101: ...f run Lubricant Grease 18 Front and rear propeller 2 Every 8000 km of run Lubricate through grease fittings shaft splines 3 5 strokes of gun without forcing grease out 17 Front and rear propeller 4 Force grease through grease shaft joints fitting until it shows up from under all lips of cross seals ÒÑï 15Ê ÒÀÏ 15Â every 32000 km Add as required or of run ÒÑï 15Ê and ÒÀÏ 15Â ÒÀÄ 17È every 48000 km ...

Page 102: ...se cup to capacity 10 Transfer box shifting 1 Lubricate through grease fitting lever shaft 14 Towing gear 1 Lubricate through grease fitting Lubricate latch and pawl axles as required 15 Parking brake 2 Clean of dirt before lubricating expander and adjuster mechanism 23 Steering knuckle joints 2 Wash joints and pack 500 g of grease 25 Steering knuckle kingpins 2 Lubricate through grease fitting of...

Page 103: ... 2 Protect terminals against acid terminals Door hinges 8 As required Lubricate through grease fitting Door lock tongues sockets and latches hinges of 8 Lubricate door checks 19 Steering wheel shaft 2 As required when bearings squeaking bearing and when disassembling Door and hood locks 7 Grease Ëèòîë 24 As required Lubricate latch Applay grease ÖÈÀÒÈÌ 201 at temperature below 40 Ñ 1 2 3 4 5 6 Gre...

Page 104: ...ñà Ðîñà 3 Once in two years Add as required 21 Clutch release master 1 Òîìü Ðîñà Äîò 4 cylinder 22 Front and rear 4 Shock absorber fluid As required and when shock absorbers ÀÆ 12Ò spindle oil disassembling ÀÓ oil for hydraulic shock absorbers ÌÃÏ 10 3 Engine cooling system 1 Cooling fluids Change once in three years Wash cooling system before with expansion tank ÎÆ 40 Ëåíà or after 60000 km of ru...

Page 105: ...amp À12 21 3 21 Cab lamp À12 4 1 4 Interior dome lamp À12 10 10 Rear fog lamp À12 21 3 21 Fog lamps ÀÊÃ12 55 Í1 55 Hand lamp À12 21 3 21 Instrument illumination dome lamp ÀÌÍ12 3 1 3 Upper beam control light À12 1 2 1 2 À12 1 1 Emergency oil pressure control light ÀÌÍ12 3 1 3 À12 1 2 1 2 Coolant overheating control light ÀÌÍ12 3 1 3 À12 1 2 1 2 Turn indicator control light À12 1 2 1 2 À12 1 1 Brak...

Page 106: ...ng U bolt nuts 9 0 10 Wheel attaching nuts 10 5 12 Bolts attaching front axle driving flanges and rear axle axle shafts 6 0 7 0 Nut attaching pitman arm to shaft 20 28 Steering rod ball pin nuts 6 0 8 0 Steering rod lock nuts 10 5 13 0 Ball support attachment bolts 3 6 5 0 Wheel hub bearing lock nuts 5 0 7 0 Anchor plate bolts front 3 6 4 4 rear 4 4 5 6 Wheel reduction gear driving gear bearing re...

Page 107: ... 5 cm3 min emulsion tube 85 1 5 cm3 min Second idling air jet 330 4 5 cm3 min 175 2 5 cm3 min Idling emulsion jet 280 3 5 cm3 min 175 2 5 cm3 min Transfer fuel jet 150 2 0 cm3 min 200 2 5 cm3 min Transfer air jet 270 3 5 cm3 min Notes Some jets of the carburettors Ê 151Â and Ê 151Å differ in rated capacity A value in brackets is indicated for the carburettor Ê 151Å The data sheet rated capacities ...

Page 108: ...kcase ventilation system 37 Maintenance of the fuel system 38 Maintenance of the engine cooling system 42 Maintenance of the ignition system 45 Transmission 48 Maintenance of the clutch 48 Maintenance of the transfer box 51 Maintenance of the propeller shafts 51 Maintenance of the rear axle 52 Maintenance of the front axle 52 Chassis 53 Towing hook 53 Suspension 56 Maintenance of the suspension 56...

Page 109: ...aced in storage 95 Depreservation 96 Transportation 96 Lubricating materials and special fluids 98 Lubrication table 100 Appendix 1 105 Lamps employed on automobiles 105 Appendix 2 Torques for main threaded connections 106 Appendix 3 Main metering jets of carburettors K 151B and K 151E 107 Appendix 4 Wiring diagram of automobiles UAZ 31512 in Insert Wiring diagram of automobiles UAZ 31514 UAZ 3151...

Page 110: ...FORNOTES ...

Page 111: ...mp switch 46 interior dome light 47 dome light switch 48 high beam control light 49 turn indicator control light 50 parking brake control light 51 brake failure warning light 52 turn indicators and emergency warning light relay 53 socket 54 fog lamp switch 55 fuel level gauge switch 56 main light switch 57 heater switch 58 heater motor fuse 59 foot dimmer switch 60 thermal fuse 61 backing lamp swi...

Page 112: ...witch 47 interior dome light 48 dome light switch 49 high beam warning light 50 turn indicator warning light 51 parking brake warning light 52 brake failure warning light 53 turn indicators and emergency warning light relay 54 socket 55 fog lamp switch 56 fuel level gauge switch 57 main light switch 58 heater switch 59 heater motor fuse 60 thermal fuse 61 backing lamp switch 62 parking brake warni...

Page 113: ...ht 50 turn indicator warning light 51 parking brake warning light 52 brake failure warning light 53 oil emergency pressure warning light 54 coolant overheating temperature warning light 55 thermal fuse 56 interior dome light switch 57 ignition switch 58 ignition switch relay 59 instrument lighting rheostat 60 light signal switch 61 horn button 62 windshield wiper switch 63 backing lamp switch 64 f...

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UAZ UAZ-31512, Instruction Manual

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