UAZ-31601 / UAZ-31602 / UAZ-31605 / UAZ-31622 / UAZ-31625 / UAZ-23602 / UAZ-23632, service e-manual (in Russian)

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

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UAZ-31601 / UAZ-31602 / UAZ-31605 / UAZ-31622 / UAZ-31625 / UAZ-23602 / UAZ-23632, service e-manual (in Russian)