Contents

Notice to consumers

Technical data and vehicle characteristics

• Vehicle marking
• Specification

Safety requirements and warnings

• Security requirements
• Warnings

Maintenance

• Scope of work by type of maintenance
• Vehicle lubrication

Engine

• Maintenance
• Engine UMZ-421 (UAZ-31601)
• Engine mount
• Cylinder head
• Gas distribution mechanism
• Lubrication system
• Engine ventilation system
• Cooling system
• Power system
• Exhaust system
• Possible engine malfunctions and methods for their elimination
• The UMZ-4213 engine (UAZ-31605, UAZ-31625) and the ZMZ-409 engine (UAZ-31602, UAZZ1622, UAZ-23602, UAZ-23632)
• Engine crankcase ventilation system UMZ-4213
• ZMZ-409 engine cylinder head
• The gas distribution mechanism of the ZMZ-409 engine
• Engine lubrication system ZMZ-409
• Engine crankcase ventilation system ZMZ-409
• Engine cooling system ZMZ-409
• Possible malfunctions of the ZMZ-409 engine and methods for their elimination
• Gasoline injection system with electronically controlled fuel supply and ignition of UMZ-4213, ZMZ-409 engines
• General Information
• Features of the engine power system
• Features of the engine exhaust system
• Features of the electronic fuel injection and ignition control system
• Diagnosis of the electronic engine management system
• Malfunctions of the engine management system and their corresponding codes
• Using parametric control for troubleshooting
• External diagnostic tools
• The main methodological techniques for monitoring and regulating the engine using external diagnostic tools
• Maintenance of the petrol injection system with electronic fuel and ignition control
• Idling
• Bleeding the fuel system
• Maintenance of anti-toxic systems
• Possible malfunctions of power supply and engine control systems with gasoline injection and methods for their elimination
• Checking the technical condition of engines
• Repair of engines UM 3-421, UMZ-4213 (UAZ-31601, UAZ-Z1605, UAZ-31625)
• The values ??of clearances and interference in the engine
• Maximum permissible wear of the main mating engine parts
• Removing and installing the engine
• Engine disassembly and assembly
• Parts and kits of nominal and repair dimensions of the engine
• Dimensions, tolerances and fits of mating engine parts
• Cylinder block repair
• Repair of cylinder liners
• Replacing piston rings
• Replacing pistons
• Connecting rod repair
• Replacement and repair of piston pins
• Assembling the connecting rod and piston group
• Crankshaft repair
• Replacing the shells of the main and connecting rod bearings of the crankshaft
• Camshaft repair and replacement of its bushings
• Replacing pushers
• Repair of the distributor drive of the UMZ-421 engine
• Oil pump repair
• Cylinder head repair
• Restoring valve tightness and replacing valve bushings
• Replacing valve springs
• Coolant pump repair
• Fuel tank repair
• Repair of the fuel pump of the UMZ-421 engine
• Carburetor repair
• Engine break-in after repair
• Repair of engine ZMZ-409 (UAZ-31602, UAZ-Z 1622, UAZ-23602, UAZ-23632)
• Dimensions, tolerances and fits of mating engine parts
• Parts and kits of nominal and repair dimensions of the engine
• Removing and installing the engine
• Engine disassembly
• Repair of cylinder block, pistons, connecting rods, intermediate shaft
• Subassembly of the connecting rod and piston group
• Controlled parameters during the repair of the cylinder block, pistons, connecting rods and intermediate shaft
• Crankshaft repair
• Controlled parameters during crankshaft repair
• Repair of the cylinder head, valve train and camshafts
• Parameters to be monitored during the repair of the cylinder head, valve train and camshafts
• Hydraulic tensioner repair
• coolant pump repair
• Oil pump repair
• Engine assembly
• Tightening torques for engine threaded connections
• Checking and adjusting the valve timing
• Special tool
• Engine break-in after repair

Clutch

• Maintenance
• Possible clutch malfunctions and methods for their elimination
• Repair
• Replacing the clutch with the clutch release bearing
• Removal and installation of clutch discs for UMP engines
• Removal and installation of clutch discs of the ZMZ engine
• Removal and disassembly of the hydraulic clutch
• Assessment of the technical condition of hydraulic drive parts
• Clutch assembly
• Bleeding the hydraulic clutch

Gearbox

• Maintenance
• Possible malfunctions of the gearbox and methods for their elimination
• Repair
• Removing the gearbox from the vehicle
• Disconnecting the gearbox from the transfer case
• Dismantling the five-speed gearbox
• Dismantling the four-speed gearbox
• Assessment of the technical condition of parts
• Assembly of five-speed gearboxes
• Assembling a four-speed gearbox
• Dimensions, tolerances and fits of mating gearbox parts

Transfer case

• Maintenance
• Possible malfunctions of the transfer case and methods for their elimination
• Repair of a spur transfer case
• Transfer case disassembly
• Assessment of the technical condition of parts
• Transfer case assembly
• Helical transfer case repair
• Transfer case disassembly
• Assessment of the technical condition of parts
• Transfer case assembly
• Assembling the transfer case with gearbox
• Dimensions, tolerances and fits of mating parts of the transfer case

Cardan transmission

• Maintenance
• Length and applicability of rear driveshafts
• Length and applicability of front driveshafts
• Possible malfunctions of cardan shafts and methods for their elimination
• Repair
• Dismantling the cardan shaft
• Assessment of the technical condition of cardan shaft parts
• Cardan shaft assembly
• Dimensions, tolerances and fits of cardan gear mating parts

Drive axles

• Rear axle
• Maintenance
• Possible malfunctions of the rear axle and methods for their elimination
• Repair
• Removing the rear axle
• Rear axle disassembly
• Assessment of the technical condition of parts
• Assembling and adjusting the rear axle units
• Dimensions, tolerances and fits of the mating parts of the rear and front axles
• Front axle
• Maintenance
• Possible malfunctions of the front axle and methods for their elimination
• Repair
• Removing the front axle
• Front axle disassembly
• Disassembly and assembly of constant velocity joints
• Dimensions, tolerances and fits of front axle mating parts
• Front axle assembly

Vehicle frame and suspension

• Frame
• Maintenance
• Repair
• Vehicle suspension
• Maintenance
• Possible suspension malfunctions and methods for their elimination
• Repair
• Dismantling the front spring suspension
• Removal, disassembly and assembly of the rear suspension

Hubs, wheels and tires

• Maintenance
• Wheel balancing with complete tires
• Wheel bearing adjustment
• Possible malfunctions of wheels and tires and methods for their elimination
• Repair
• Removal, disassembly and assembly of hubs
• Dimensions, tolerances and fits of wheel hub mating parts
• Removing wheels, disassembling and assembling tires

Steering

• Maintenance
• Power steering pump belt tension
• Checking the level and changing the oil in the power steering system
• Servicing the flow and relief valves of the pump
• Checking steering wheel play
• Power steering adjustment
• Possible malfunctions of a steering and methods of their elimination
• Repair
• Removing the steering gear
• Removing the propeller shaft
• Removing the steering wheel
• Removing the tilt steering column
• Disassembly of the Column Angle Adjustment
• Steering gear disassembly
• Checking for internal leaks
• Steering gear disassembly
• Ball Screw
• Disassembly of the valve
• Installation of PTFE O-rings
• Steering gear assembly 31601-3400011-01
• Steering gear assembly 31601-3400011-20
• Removal, disassembly and assembly of the tie rod

Brake system

• Service brake system
• Maintenance
• Adjustment
• Filling the brake system with fluid and checking the operation of the system
• Possible malfunctions of the service brake system and methods for their elimination
• Repair
• Removal, disassembly and assembly of service brakes
• Dimensions, tolerances and fits of mating parts of brake systems
• Removal, disassembly and assembly of the vacuum booster
• Parking brake system
• Maintenance
• Adjustment
• Repair
• Removal, disassembly and assembly of the parking brake
• Removal and disassembly of the parking brake drive

Electrical equipment

• Wiring diagram, fuses
• Mounting block
• Circuits protected by fuses
• Repair
• Battery
• Maintenance
• Generator
• Maintenance
• Repair
• Possible malfunctions of the generator and methods for their elimination
• Starter
• Maintenance
• Possible starter malfunctions and methods for their elimination
• Repair
• Auxiliary starter relay
• Ignition system
• Contactless ignition system
• Maintenance
• How to set the ignition timing
• List of possible malfunctions of the ignition system and methods for their elimination
• Forced idle economizer control system (EPKhK) of the K-151L carburetor (UAZ-31601)
• Checking the EPHX control unit
• Checking the solenoid valve
• Lighting and signaling system
• Maintenance
• List of possible malfunctions of lighting and signaling devices
• List of lighting and light signaling devices
• List of lamps used
• Closing contacts for various stalk lever positions
• Headlight cleaner
• Electric door lock system
• List of possible malfunctions of the electric door lock system
• Windshield wiper motor
• Dismantling, assembling and checking the technical condition of the cleaner gearmotor
• Possible malfunctions of the windshield wiper motor and methods for their elimination
• Heater fan motor
• Possible malfunctions of the heater fan motor and methods for their elimination
• Control devices
• Possible malfunctions of control devices and methods for their elimination
• Repair
• Removal and installation, disassembly and assembly of instrument clusters
• Instrument troubleshooting technique
• Checking sensors of control devices

Body

• General data
• Interior heating and ventilation
• Doors
• The cargo compartment of the car UAZ-23632
• Seats
• Fuel cap
• Hood
• Windshield wipers, water pumps for windshield, rear windows and headlights (washer)
• Seat belts
• Body mount
• Body maintenance
• Repair
• Body removal
• Wipers
• Removal and installation of a screen wiper of a wind window
• Removal and installation of the windscreen wiper of the tailgate
• Removal and installation of the tank and washer nozzles
• Mirrors, sun visors, handrails, roof mouldings, filler caps
• Removal and installation of an external rear-view mirror
• Removal and installation of an internal rear-view mirror
• Removing and installing sun visors
• Removing and installing the filler manhole cover
• Removing and installing the handrail
• Removing and installing roof molding
• Footboards
• Take off and installation of the folding footboard of the tailgate
• Side stand
• Front bumper
• Removing the front bumper
• Dismantling the front bumper
• Rear bumper
• Removing and disassembling the rear bumper
• Hood
• Removing the hood
• Hood lock drive
• Radiator cover
• Removing the grille panel
• Removing headlight trim and grille
• Front fender
• Removing the front fender
• Removing and installing wheel aprons
• Windscreen glass, tailgate windows and sidewalls
• Removing and installing door seal
• Removal and installation of front and rear window opening seals
• Sunroof
• Doors
• Removing and installing front door trim
• Removal and installation of the sliding glass and the mechanism for moving the glass of the front and rear doors
• Removing and installing the front door lock
• Removing and installing rear door lock
• Removal and installation of the lock and handles of the tailgate
• Removal and installation of the door opening limiter
• Door hinge
• Tailgate and roof cover of the cargo compartment of the car UAZ-23632
• Seat belts
• Dashboard
• Heater

Application

• Appendix 1 Cups and seals used in vehicle components and assemblies
• Appendix 2 Rolling bearings used in vehicle components and assemblies
• Appendix 3 Wiring diagram of the UAZ-31601 vehicle (with instrument cluster 157.3801-10)
• Wiring diagram of the UAZ-31601 car (with instrument cluster АР110.3801)
• Scheme of electrical equipment of cars UAZ-31602, UAZ-31622 (with anti-toxic systems, with instrument cluster АР 110.3801)
• Scheme of electrical equipment of cars UAZ-31602, UAZ-31622 (with anti-toxic systems, with instrument cluster 432.3801-10)
• Wiring diagram for UAZ-31602, UAZ-31622, UAZ-31625 vehicles (without anti-toxic systems, with instrument cluster 432.3801-10)
• Wiring diagram for UAZ-31605, UAZ-31625 vehicles (without anti-toxic systems, with instrument cluster 152.3801-10)
• Wiring diagram of the UAZ-23602 car (with anti-toxic systems, with instrument cluster AR 110.3801)
• Wiring diagram of the UAZ-23632 car (with anti-toxic systems, with instrument cluster 432.3801-10)
• Appendix 4 Mounting block
• Appendix 5Special tools and accessories