Contents

For consumers' information

Technical data and characteristics of cars

• Vehicle labeling
• Technical characteristics

Safety requirements and warnings

Maintenance

• Scope of work by type of maintenance
• Lubrication of the car

Engine

• Maintenance
• Engine UMZ 4218 (UAZ 31519)
• Engine mount
• Cylinder head
• Gas distribution mechanism
• Lubrication system
• Crankcase ventilation system
• Cooling system
• Power system
• Gas exhaust system
• Possible engine malfunctions and methods of their elimination
• Engine ZMZ 409 (UAZ 315195)
• Engine mount
• Cylinder head
• Gas distribution mechanism
• Lubrication system
• Crankcase ventilation system
• Engine cooling system
• Power system
• Gas exhaust system
• Gasoline injection system with electronic fuel supply control and engine ignition ZMZ 409
• Possible malfunctions of the ZMZ 409 engine and methods for their elimination
• Possible malfunctions of power supply systems and engine management with petrol injection and methods of their elimination
• Engine ZMZ 5143 (UAZ 315148)
• Engine mount
• Cylinder head
• Gas distribution mechanism
• Lubrication system
• Crankcase ventilation system
• Cooling system
• Power system
• Air intake and exhaust system
• Generator with vacuum pump
• Engine management system
• Possible malfunctions of the ZMZ 5143 engine and methods for their elimination
• Checking the technical condition of engines
• Repair of the UMZ 4218 (UAZ 31519) engine
• Values ??of clearances and tightness in the engine
• Removal and engine installation
• Disassembly and assembly of the engine
• Cylinder block repair
• Cylinder block liner repair
• Replacing piston rings
• Replacing pistons
• Repair of connecting rods
• Replacement and repair of piston pins
• Assembling the connecting rod and piston group
• Crankshaft repair
• Replacing the crankshaft main and connecting rod bearings
• Camshaft repair and replacement of its bushings
• Replacing pushers
• Distributor drive repair
• Oil pump repair
• Cylinder head repair
• Cooling system pump repair
• Repair of fuel tanks
• Fuel pump repair
• Carburetor repair
• Engine break-in after repair
• Repair of the ZMZ 409 (UAZ 315195) engine
• Removal and engine installation
• Dismantling the engine
• Repair of the cylinder block, pistons, connecting rods, intermediate shaft
• Crankshaft repair
• Repair of cylinder head, valve train and camshafts
• Hydraulic tensioner repair
• Cooling system pump repair
• Oil pump repair
• Checking the technical condition of the thermal valve
• Checking the technical condition of the thermostat
• Assembling the engine
• Checking and adjusting valve timing
• Special tool
• Engine break-in after repair
• Tightening torques for engine screw connections
• Repair of the ZMZ 5143 (UAZ 315148) engine
• Removal and engine installation
• Dismantling the engine
• Parts cleaning
• Cylinder block repair
• Crankshaft repair
• Connecting rod and piston group
• Cylinder head, valves, springs, hydraulic bearings
• Hydraulic tensioner
• Coolant pump
• Thermostat
• Oil pump repair
• Fuel equipment
• Turbocharger
• Assembling the engine
• Installing the engine on a car
• Tightening torques for the main engine threads

Clutch

• Maintenance
• Repair
• Replacing the clutch with clutch release bearing for vehicles with four-speed gearbox
• Removal and installation of clutch discs for UMP engines with a four-speed gearbox
• Removal and installation of clutch discs of a ZMZ engine with a four-speed gearbox
• Replacing the clutch with clutch release bearing for vehicles with five-speed gearbox
• Removing and installing clutch discs for vehicles with a five-speed gearbox
• Assessment of the technical condition of the pressure plate
• Removing and disassembling the clutch hydraulic actuator
• Assessment of the technical condition of hydraulic drive parts
• Assembling the hydraulic clutch
• Bleeding hydraulic clutch

Gearbox

• Maintenance
• Repair of a five-speed gearbox
• Removing the transmission from the vehicle
• Disconnecting the transmission from the transfer case
• Dismantling the gearbox
• Assessment of the technical condition of parts
• Gearbox assembly
• Repair of a four-speed gearbox
• Removing the transmission from the vehicle
• Disconnecting the transmission from the transfer case
• Dismantling the gearbox
• Assessment of the technical condition of parts
• Gearbox assembly

Transfer case

• Maintenance
• Repair
• Disassembling the transfer case
• Assessment of the technical condition of parts
• Transfer case assembly
• Assembling the transfer case with gearbox

Cardan drive

• Maintenance
• Length and applicability of rear propeller shafts
• Length and applicability of front propeller shafts
• Repair
• Dismantling the propeller shaft
• Assessment of the technical condition of propeller shaft parts
• Propeller shaft assembly

Drive axles

• Rear axle
• Maintenance
• Repair
• Removing the rear axle
• Dismantling the rear axle
• Assessment of the technical condition of parts
• Rear axle assembly and adjustment
• Front axle
• Maintenance
• Repair
• Removing the front axle
• Dismantling the front axle
• Front axle assembly

Frame and car suspension

• Frame
• Maintenance
• Repair
• Car suspension
• Maintenance
• Repair
• Dismantling the front spring suspension
• Removing, disassembling and assembling the rear suspension

Hubs, wheels & tires

• Maintenance
• Balancing wheels with complete tires
• Wheel bearing adjustment
• Repair
• Removing, disassembling and assembling hubs
• Removing wheels

Steering

• Maintenance
• Power steering pump drive belt tension
• Checking the level and changing the oil in the power steering system
• Servicing pump flow and relief valves
• Checking the steering wheel free play
• Adjusting the power steering
• Repair
• Removing the steering gear
• Removing the steering wheel
• Removing the steering propeller shaft
• Removing and disassembling the steering column
• Checking internal leaks
• Dismantling the steering gear
• Ball screw
• Disassembly of the hydraulic valve
• Installing PTFE sealing rings
• Steering gear assembly 315119 3400011 10
• Steering gear assembly 3162 3400011 (3159 3400011 20)
• Removal, disassembly and assembly of the tie rod

Braking system

• Service brake system
• Maintenance
• Adjustment
• Filling the brake system with fluid and checking the system performance
• Repair
• Removal, disassembly and assembly of service brakes
• Parking brake system
• Maintenance
• Adjustment
• Repair
• Removal, disassembly and assembly of the parking brake
• Removing and disassembling the parking brake actuator

Electrical equipment

• Wiring diagram
• Fuses
• Relays and breakers
• Battery
• Generator
• Starter
• Ignition system
• Contactless ignition system
• Control system for the economizer forced idle (EPHH) of the carburetor
• Lighting and signaling system
• Control devices

Body

• General data
• Interior heating and ventilation
• Doors
• Tailgate
• Seats
• Fuel tank cap
• Hood
• Windscreen wipers, water pumps for windshield, rear windows and headlights (washer)
• Seat belts
• Car awning
• Hard roof
• Body fixing
• Body maintenance
• Repair
• Removing the body
• Windshield wipers
• Mirrors, sun visors, ornaments, filler caps
• Handrails
• Front bumper
• Rear bumper
• Hood
• Front wing
• Radiator trim
• Wind window
• Windshield glass, tailgate and roof windows
• Doors
• Seat belts
• Instrument panel trim
• Heater
• Body panel repair

Applications

• Appendix 1 Cuffs and oil seals used in vehicle components and assemblies
• Appendix 2 Rolling bearings used in units and assemblies of cars
• Appendix 3 Wiring diagram of UAZ 31519 vehicles
• Wiring diagram of UAZ 315195 cars
• Wiring diagram of UAZ 315148 cars
• Appendix 4 Special tools and devices