steering

UAZ – 452

and its modifications

DV. ZMZ 409, DV UMP 421

WITH ZF PUMP

INSTALLATION INSTRUCTIONS

POWER STEERING

FOR A UAZ CAR – 3909 doors. ZMZ 409, UMP - 421

1. 
   PURPOSE

The power steering (power steering) is designed for installation on UAZ-2206, 3962, 3909, 3303 vehicles to improve vehicle handling.

2. Basic technical data

Steering gear ratio_________________________17.3

Angle of rotation of the output shaft-sector______________________________80

Maximum operating torque

On the sector shaft, the pressure of the working fluid is 12MPa________100kgf*m

Contents of delivery

1. 
   Cardan joint________________________________________________1 pc.
2. 
   Tank______________________________________________________________1 pcs.
3. 
   Pump bracket_______________________________________________________________1 pc.
4. 
   Pump shnkf 105-40 (dv. ZMZ 409) or shnkf 125 (dv. Umz 421)_____________1 pc.
5. 
   Belt 1190 (dv. ZMZ 409) or 1150 (dv. UMZ 421)________________________1 pc.
6. 
   Steering column_________________________________________________________ 1 pc.
7. 
   Steering mechanism______________________________________________________________1 pc.
8. 
   Steering gear casing_____________________________________________1 pc.
9. 
   Tank bracket________________________________________________________________1 pc.
10. 
    Tensioner_______________________________________________________________1 pc.
11. 
    Stretch corner (dv.umz 421)__________________________________________ 1 pc.
12. 
    Stretch (dv.umz 421)_____________________________________________ 1 pc.
13. 
    High pressure hose_______________________________________________1 pc.
14. 
    Suction hose_______________________________________________1 pcs.
15. 
    Drain hose__________________________________________________________ 1 pc.
16. 
    Fastening kit (hardware)__________________________________________ 1 set.
17. 
    Oil______________________________________________________________2 pcs.

19.Pulley______________________________________________________________1 pcs.

20.Fan spacer____ ________________________________________1 pc.

Certificate of Conformity No. DSAT RU.OS091.AS00039

INSTRUCTIONS

on installation of steering

with hydraulic booster for UAZ-3303, UAZ-3909 cars and their modifications

This instruction establishes the sequence of installation of power steering and the requirements for installation of the steering system of UAZ-3303, UAZ-3909 vehicles and their modifications equipped with UMZ and ZMZ engines.

1. 
   Dismantling of vehicle steering components and parts and preparatory work for installing a power steering system (power steering).
   1. 
      Remove the steering wheel from the car using a removable device designed for this purpose, to avoid mechanical damage.
   2. 
      Disconnect the steering column from the mounting brackets.
   3. 
      Disconnect the steering rod from the steering gear bipod.
   4. 
      Disconnect the steering column from the steering mechanism.
   5. 
      Remove the steering gear.
2. 
   Installing a power steering mechanism on a car.
   1. 
      Install the power steering mechanism in the standard location of the non-power steering mechanism. The tightening torque of the bolts should be from 55 to 78 N.m (from 5.6 to 7.9 kgf.m).

1. 
   Cut an opening in the floor as shown in the figure to avoid deformation of the amplifier fittings.
2. 
   Install the stock steering gear bipod onto the power steering mechanism. Tighten the bipod fastening nut from Mkr from 180 to 250 N.m (from 18 to 25 kgf.m).

1. 
   Install the protective cover supplied in the kit onto the cut opening.
2. 
   Install a steering column with a universal joint on the steering mechanism.
3. 
   Attach the steering column to the car body according to the standard pattern.
4. 
   Install the steering wheel onto the steering column.

3.1. Install the pump mounting bracket pos. 2 (Fig. 1) onto the engine. Secure the bracket with three bolts in position 7 to the engine. Install 2 flat washers, pos. 4, 3 mm thick, between the engine and the bracket. Tighten the bolts, pos. 2, with a force of 25 to 30 N/m (from 2.5 to 3.0 kgf/m)

3.2. Install the previously removed water pump pulley and water pump drive belt onto the engine. Tension the water pump belt according to the operating and repair manual for the UAZ vehicle.

3.3. Screw the adjusting bolt into the bracket until it stops.

3.4. Install the power steering pump assembly with the pulley and pump holder onto the pump mounting bracket. Secure with bolts, flat washer and spring washer. The bolts must be tightened in such a way that it is possible to move the pump and holder assembly along the groove of the bracket.

3.5. Put on the power steering pump drive belt (if it is impossible to put the belt on the pump pulley: unscrew the bolt, turn the pump with the holder, put on the belt, tighten the bolt). Tension the belt by unscrewing the adjusting bolt.

3.6. Adjust the belt tension so that the deflection from the force (39.2+2) N(4.0+0.2) kg.s applied perpendicular to the middle of the upper branch of the belt is 10-15 mm.

3.7. Tighten the bolts from 49 to 61 Nm (from 4.9 to 6.1 kgf.m). Note: It is allowed to touch the head of the bolt to the water pump pipe.

3.1. Installation of power steering pump for ZMZ 409

3.1.1. Install the pump mounting bracket pos. 1 (Fig. 2) onto the engine, secure the bracket with three bolts pos. 2. Use M8 bolts, pos. 2, spring washers, pos. 4, removed from the vehicle. The tightening torque of the bolts, position 2, should be made with a force of 25 to 30 N/m (from 2.5 to 3.0 kgf/m)

3.1.2. Install the previously removed water pump pulley, pos. 5, and the drive belt, pos. 6, onto the engine. Tension the water pump belt according to the vehicle’s operating manual.

3.1.3. Screw the adjusting bolt pos. 7 into the bracket pos. 1 until it stops.

3.1.4. Install the hydraulic booster pump assembly, pos. 8, 9, 10, onto the pump mounting bracket, pos. 1, and secure with bolts. The bolts must be pre-tightened so that it is possible to move the pump along the groove of the bracket, pos. 1.

3.1.5. Put on the power steering pump drive belt, pos. 14. Tension the belt by unscrewing the adjusting bolt, pos. 7. Adjust the belt tension so that the deflection from a force of 39.2 + 2 N (4.0 + 0.2 kgf) is 10-15 mm. Tighten the bolts pos. 11 with a force from 49 to 61 N/m (from 4.9 to 6.1 kgf/m)

4. Installing the power steering tank.

4.1. Install the tank on the partition (or the wall of the UAZ-3303 cab) behind the driver's seat on the tank mounting bracket so that the end of the shoulder on the tank rests on the end of the tank mounting bracket.

4.2. Install the tank so that its level is 100-150 mm higher than the level of the high pressure pump.

4.3. Secure the tank with the tank bracket with a clamp using a bolt, nut and washer. The tightening torque for the nut should be from Mkrot 14 to 18 N.m (from 1.4 to 1.8 kgf.m).

1. 
   Installation of hoses

1. 
   Install the high-pressure hose, attach one end with a clip to the steering gear distributor housing with a hollow bolt M 14 1.5. Install copper washers between the race and the bolt head, as well as between the race and the power steering distributor housing.
2. 
   Install the other end of the discharge hose under the M 16 1.5 bolt on the pump. Install copper washers between the pressure hose clip and the bolt head, and between the clip and the power steering pump housing.
3. 
   Install the hose without allowing any twisting, kinks or kinks in the hose. The hose must not touch other components, assemblies and parts.
4. 
   The tightening torque of the bolts should be from 49 to 61 N.m (from 5 to 6.2 kgf.m).
5. 
   Install the suction hose by securing one end of the hose with a clamp to the power steering tank nozzle, and the other with a clamp to the suction tube of the power steering pump.
6. 
   Install the drain hose with one end onto the connection pipe of the power steering tank and secure it with a clamp, and secure the other end to the fitting of the drain hose and secure it with a clamp. Secure the drain hose fitting to the power steering distributor housing. Install a copper washer between the distributor body and the end of the drain fitting.
7. 
   Tighten the clamp screws with a torque of 2 to 2.5 N.m (from 0.2 to 0.25 kgf.m).
8. 
   Fill the hydraulic system with oil according to the instructions.

Warning: It is strictly prohibited to start the vehicle engine if the steering hydraulic system is not filled with oil.

INSTRUCTIONS

for refueling the power steering system of a UAZ vehicle.

This instruction establishes the procedure for refueling the power steering system of UAZ vehicles.

General provisions.

Before refueling, the pipelines and hoses of the power steering system must be installed on the vehicle in accordance with the design documentation.

Oils of the HYDRO R TU 38.1011282-89 brand are used as the working fluid.

It is unacceptable to mix different brands of oils.

The volume of liquid (oil) to be filled is 2 liters.

The procedure for filling the power steering system of a car with oil:

1. 
   Remove the oil tank cap, pour oil into the tank up to the top mark of the dipstick located on the tank cap (the oil level should be approximately 38 mm from the top end of the tank).
2. 
   Without starting the engine, turn the steering wheel from lock to lock, at least 3 times in each direction, with the steered wheels hanging out, or with the bipod link disconnected from the bipod.
3. 
   
4. 
   Crank the engine with the starter without starting the engine for 5-10 seconds.
5. 
   Add oil to the tank to the level according to step 1.
6. 
   Start the engine and add oil to the tank at idle speed, preventing air from entering the suction line. With the engine running at idle for 20-30 seconds. Monitor foam formation in the tank (the tank lid is open). If the oil foams heavily in the tank, which indicates air has entered the system, turn off the engine and let it stand for 20 minutes. (until air bubbles leave the oil). Inspect the connection points of the hoses to the power steering units and, if necessary, eliminate leaks. After eliminating the leak, restart the engine.
7. 
   Bleed the power steering system (with the engine running) by turning the steering wheel from lock to lock, without holding it in the extreme positions, at least 3 times in each direction until the air bubbles are completely released. If necessary, add oil to the tank to the level specified in step 1.
8. 
   With the engine running at idle speed, unscrew the bleeder fitting on the side cover of the bipod shaft, bleed air from the mechanism until oil appears from the hole in the bleeder fitting. Tighten the bleeder fitting. The tightening torque of the bleeder fitting is from 4.5 to 5 N.m (from 0.45 to 0.5 kgf.m). Wipe off any remaining oil from the lid with a rag. If necessary, add oil to the tank to the level according to step 1. Close the tank lid with hand force.
9. 
   Start the engine and check for leaks from the connections when turning the steered wheels of the car from one extreme position to another with a delay of 2...3 seconds. in extreme positions.

OPERATING RULES

1. 
   It is not recommended to hold the steering wheel in the extreme position for more than 5 seconds to avoid overheating of the oil and failure of the power steering pump and high-pressure hose.
2. 
   If the power steering fails due to a broken pump, damage to the hose or pump drive belt, as well as when towing a car with the engine not running, you can only use the steering mechanism for a short time until the fault is eliminated.

LONG-TERM OPERATION WITH A NON-WORKING HYDRAULIC POWER POWER LEAD TO PREMATURE WEAR OF THE STEERING MECHANISM.

MAINTENANCE

Power steering maintenance consists of periodically checking the tightness of hoses and their connections, checking the condition of the steering wheel rotation limiters, topping up and changing oil. Instead of adding oil to the steering gear housing, oil is added to the power steering reservoir.

1. 
   Pump belt tension. Normal belt tension corresponds to a deflection in the middle between the pulleys of 12-17 mm when pressed with a force of 39 N (4 kgf). If necessary, the belt is tensioned by moving the pump along the bracket. If the belt is found to be damaged or excessively stretched, the belt must be replaced.
2. 
   Checking the level and changing the oil. The oil must be replaced every 50,000 km or 6 months of operation. Fill the system according to paragraph 14. The oil tank filter must also be replaced.
3. 
   Free movement of the steering wheel. The free play of the steering wheel is checked when the engine is idling and the front wheels are in a straight position, swinging the steering wheel in both directions until the front wheels begin to turn. Free play should not exceed 10 degrees. If there is more than permissible free play, it is necessary to determine the unit due to which it is increased, for which check: the condition of the steering joints, the gaps in the hinges and splined connections of the steering joint, the tightening of the steering joint mounting wedge. If a gap appears in the spline joint of the steering joint, it is necessary to repair or replace the joint. If, as a result, it was not possible to eliminate excess free play, then the steering mechanism should be adjusted.

LUXURY PACKAGE

Equipping the power steering with the “LUX” set provides more convenient control of the headlight switching functions and windshield wiper modes. The headlights are also automatically turned off when the ignition is turned off and the steering shaft is locked when the key is removed from the ignition switch.

The package includes:

1 Ignition switch “Lux”__________________________________1 piece

2 Steering column switch________________________________1 pcs

3 Steering column switch housing____________________ 1 ct

4 Universal relay_______________________________________________3 pcs

5 Windshield wiper relay__________________________________________ 1 piece

6 Wiring harness__________________________________________________________1 ct

Option for location of light relay, windshield wiper relay

and steering column assembly

Location of components and parts for the LUX package

Steering column with ignition switch, multifunction

switch and housing.

The wiring harness is connected according to

attached diagram.

Warranty

The manufacturer guarantees that the power steering system meets the requirements.

The warranty period is 12 months from the date of installation. If the consumer discovers defects (malfunctions) of the product during the warranty period, it sends an application (complaint report) to the manufacturer (seller) with requirements for their elimination in accordance with current legislation.

Warranty obligations become invalid in the following cases:

- failure to comply with operating and maintenance rules,

- when interfering with the design of the product,

- in case of damage due to improper handling,

- in case of damage due to an accident, if it did not occur as a result of a technical malfunction of the product.

When using oils of other brands, the performance and tightness of the power steering system is NOT GUARANTEED.

Claims are accepted at:

RF, 432071 Ulyanovsk, st. Promyshlennaya 2e, IP Pyanov S.G. tel: 8 8422 65 55 90

mail : autogur73@ mail. ru

The product is certified. Certificate of conformity No. DSAT RU.091AC00086

Power steering mechanism number_________________

Power steering pump number ____________________

Date of assembly___________________________

So, I decided to install power steering. An installation kit was purchased from Avtodetalservice (ADS). At first glance, it lacks something, but we’ll buy something more.

The UAZ is in the garage, the only thing that stops it from working is the negative temperatures in the garage. At the same time, there are plans to install a wood stove in the garage, so as not to depend on electricity.

The weekend has arrived.

So what do we have? Auto and power steering kit.
We remove the steering wheel, the steering column switches, the old steering column, and disconnect the steering rod. We unscrew and knock down the steering bipod, unscrew and remove the steering gear.
Hurray, the place to install the new kit is ready.

I'm trying the steering gear in place, but it doesn't fit. Why?
Reading the manuals...
It turns out that the sets are different. It flashed through my head: “Your car! Why do they make different steering gearboxes?” Upon further study of this topic, it was found that my kit No. 004–40 is for installation on a 409 engine.
I had to spend the weekend installing a new steering column and a new luxury gazelle steering wheel, connecting the steering column switches. I spent the remaining time reading the UAZbook website.

Well, this one doesn't fit - we'll look for another one. For some reason they were not available in the stores “Everything on UAZ” and “Planet Zhelyazyaka”.

I had to order 4x4uaz from the online store.

I picked up kit No. 004-20. Everything is in a box made of plywood. Upon inspection, the following was found:
Seller IP Pyanov (website - autogur73).
A detailed examination revealed positive and negative points:
Positive:
- there is a steering gear;
- there is a bipod for the steering gear;
- there is a cardan for installing a new type of steering column (a wedge is inserted on one side);
- there is a bracket for attaching the power steering pump to the engine;
- there is an L-shaped adjustment plate;
- there is a power steering pump;
- there is a power steering pump pulley;
- there is a tank with fasteners for the fender liner;
- all bolts and screws are present;
- there are fittings for connecting a high pressure hose;
- there are copper rings;
- there is a simpleton for the pump under the fan;
- there is a belt, a high pressure hose and a low pressure hose;
- there are normal hose clamps;
- there is a pulley for the second belt;
- there is a wedge for securing the cardan to the steering gearbox;

Negative:
- there is no mounting bracket for the power steering pump! (and without it there is no way to install the pump on the bracket securing it to the engine);
- no steering rod;
- with one copper ring the size was missed;
- the wedge for attaching the cardan to the steering gear does not fit (apparently they took it from the bicycle department).

I am writing a letter to the site, verbatim:
I received my order today. I arrived at the garage and checked the power steering kit. I realized what was missing:
- short tie rod;
- bracket for power steering pump
The answer is also verbatim:
Hello, this is not currently included in the kit, but many other things are included
not in the picture, but what you have in the box, there are instructions for
installation, install according to it and everything will work out for you

Well, what can you do, it’s good that there is somewhere to borrow (the old set, which did not fit, has not yet been sold).

Another weekend and back to the garage.
On the agenda is the installation of a power steering kit 004-20 old model range, spring or spring suspension.

Taking into account the experience of the previous weekend, I tried to install the steering gear straight away. So, with a little wisdom, it was established that he was in his regular place. However, a small ambush was discovered at the initial stage, namely the small distance from the injection hose bolt to the engine gear cover.

Everything was once again postponed until next weekend.

Installation of power steering kit 004-20.

Step 1: Install the second pulley

We take a pulley to install the second belt.

We twist and turn and look. There is a peculiarity, no matter how it doesn’t stand up right away, one of the holes is displaced. Therefore, we estimate the location or take a caliper and measure the distances.

Having figured out how to combine, install and tighten the bolts (the original ones won’t fit, we need longer ones). The pulley is pressed onto the original crankshaft pulley.

Step 2. Installing the bracket on the engine.

The one sold in the store is not suitable!

Take the power steering pump mounting bracket from the kit.
Here he is.

and put it in place of the factory gasoline filter. Tighten the nuts.

So we have room left for the third fastening. But alas, there is no hole in the head with threads. We'll drill it ourselves. We mark the middle with a core. Remove the bracket. Remove the valve cover.

We plug the holes where chips can get in. We take a drill or screwdriver, a drill and drill a hole, cut the thread with a tap.
I have a technological boss in the cylinder head, on the inside, so the hole is not through.

Well, it's ready

We put the valve cover back and install the bracket through the washers to the cylinder head (so that the bracket does not press the valve cover).
We take the power steering pump, attach a pulley and bracket to it and attach it to the bracket that we screwed to the cylinder head. Don't forget to put an "L" shaped plate to adjust the belt tension.

We put on a belt.

We tighten it with the help of an “L” shaped plate.

Part 3. Steering gear (RR) and grinder-file.

Having read UAZbuki. I decided to sharpen the PP and the cap of the discharge hose fitting.

So, carefully holding the PP in a vice, I took a caliper and roughly outlined the intended area for removal. We will shoot from the side of the plane that is applied to the frame.

We take a grinder (small), sharpen it, and use a large file to level the areas. There is a lot of metal dust, so it is better to provide a respirator.

Here is a photo of the intermediate work, to show how much I ground off and put a file on top. It can be seen that about 2-4 mm have been ground off on the right. So we cut down the entire site.

Using improvised means, we also grind off the head at the fitting. I placed a bolt nearby for clarity; the head was the same thickness.

Step 4. Installing the PP on the frame.

We paint over the open areas with paint or something else. First, we attach the high-pressure hose (remember to put copper washers on the bolt, then the hose and the washer again, and only then into the body of the RR. Next, we install the RR from the bottom - from the radiator side and fasten it with bolts from the old RR.

This is what happened.

For comparison, it was not turned

Step 5. Installing the tank, hoses, bleeding the system.

So, we install the reservoir in a convenient place, taking into account that the hoses do not bend, and the upper oil level in it is higher than the power steering pump.

We connect the hoses, fill in the oil, and bleed it with the front wheels hanging up. We check for leaks.

The topic was actively read on the UAZbuki website
forum.uazbuka.ru/showthread.php?t=67041&page=19

UAZ hydraulic booster: description, installation, operation, maintenance

• Power steering - softens shocks from the wheel to the steering wheel
• Power steering - increased safety in the event of a sharp drop in tire pressure when they are damaged
• Power steering - increases dynamic cross-country ability in extreme conditions
• Power steering - reduces steering effort by three times

Accepted notations

power steering- power steering
VZ - shaft with spool
R - steering wheel
RM- steering gear
RM with power steering - power steering
RK - steering column
RU - steering control
REA - UAZ-3151, 31512, 31514 cars and their modifications. Manual.

Brief description and device

The power steering RM consists of a pump driven by the crankshaft, a RM with a distributor, an oil tank and three hoses: discharge, drain and suction. The RM is made according to an integrated circuit: the hydraulic distributor and the power cylinder are made in the same housing with the RM.

Steering gear type: screw-ball nut with rack-and-pinion three-tooth sector. The PM screw is mounted on two angular contact bearings: one in the PM crankcase, and the second in the distributor housing. The ball nut, made integral with the gear rack, is also a power steering piston. The three-tooth sector rotates in the housing on two radial roller bearings with eccentric bushings.

The hydraulic distributor is rotary, tangential type, with a centering torsion. The distributor air intake is located in the axial hole of the screw and rests at one end on a radial roller bearing in the distributor housing. The air intake and the screw are interconnected by segmental, transversely located stops, which limit their mutual relative rotation and provide their mechanical connection in the event of power steering failure. The hydraulic neutral position of the air intake is set by the manufacturer during assembly and is fixed with a pin.

Delivery set (see. drawing)

Installation of nodes

Special tools will require a hacksaw and a drill with a drill bit d=8.5..9.

Procedure for installing PM

1. Remove the steering wheel by unscrewing the central nut, using a puller, a special washer (using the threaded holes in the steering wheel) or another available method. For example, using a Zhiguli jack mounted on a shaft and a strong cord that needs to be tied around the steering wheel.
2. Remove the CV assembly with the cardan joint. Fasteners for the universal joint and a stepladder with nuts will be used to install the power steering RM.
3. By unscrewing the nut with a wrench set to “22”, disconnect the steering rod from the bipod and by unscrewing the three bolts securing the PM with a wrench set to “17”. remove it. The mounting bolts will be used to install the RM power steering.
4. Place bipod 18 on the RM power steering shaft in accordance with the REA. Use a 27 wrench to tighten the nut. The tightening torque of the nut is 196..274 N*m (20..28 kgf*m).
5. Install the RM power steering with a bipod on the frame in place of the RM without power steering. Tighten the bolts with keys “17” and “19”.
6. Attach the steering rod to the bipod and secure it. Tighten the pin nut with a wrench to "22". The tightening torque of the nut is 58.8..78.4 N*m (6..8 kgf*m). Tighten the nut. You can perform this step after refueling the hydraulic system in step 4.2 so as not to hang the front wheels for this.
7. The RK from the kit is designed for installation in the UAZ-31519 car, therefore for models 31512, 31514 it is necessary to modify the RK 15 from the kit (For UAZ-31519, do not perform this step). Extend pipe RK 15 with plastic extension 8 from the kit. If the pressing force is significant or the fit of extension 8 is loose, straighten the pipe to d39. The extension 8 can also be secured with glue. Transfer the contact screw and bushing for the horn from the radio, removed from your car, to the extension. The procedure for installing the horn switch parts is specified in the REA. In addition, it is necessary to cut off the welded RC bracket, which will interfere with the stepladder securing the RC to the body, using a hacksaw or other accessible method.
8. (Do not do this for UAZ-31519) Use a key “10” to secure the aluminum support RK 11 to the car body using M6 bolts.
9. Place rubber ring 5, washer 21, special castle nut 3 on RK15 and insert everything together into the support. First secure RK 15 using a stepladder without tightening the nuts.
10. Insert cardan shaft 1 between the RM and RC and, aligning its hole under the wedge 4 and determining the inlet hole by the largest diameter, hammer the wedge pos. 4 with light blows of a hammer through a copper or aluminum drift. Place washer 38 and spring washer 41 on the threads of wedge 4 and secure it with nut 33 and cotter pin 43. Secure the slots of the opposite end in the same way as the cardan joint you removed, using the same parts.
11. Secure RK 15 with a stepladder finally so that the length between the joints of the cardan shaft is 300..310 mm. Tighten the castle nut by lightly tapping the bit.
12. Install the steering wheel on the steering wheel. Connect the ground wire to PK 15. Loosen the contact screw and adjust the position of the horn contact sleeve. tighten the screw.

Pump installation

1. Loosen the fan belt, remove the fan and, placing the fan spacer 13 from the kit under it on the pump hub, secure it with a key “12” to the hub. Instead of standard bolts, use 4 M8x40 bolts.
2. Unscrew 3 or 6 (depending on version) crankshaft pulley bolts with a key to “12” and install the pump drive pulley 14 on it with the ignition timing mark backwards in the direction of the vehicle. secure it with a key to “12”, using longer M8x40 bolts instead of the standard ones
3. Unscrew the nut securing the fine fuel filter, installed on the left side of the engine in the front part, with a wrench "13", and release the filter from the bracket. Having unscrewed the nuts to “13”, remove the bracket from the engine and install pump bracket 7 in its place as indicated in drawing
4. Unscrew the nearby upper nut on the “13” stud of the cooling system pump and, installing bracket 17 under it with the eye toward the back, screw it into place.
5. Using two M12x30 bolts with spring 42 and support 39 washers, secure pump 10 with strap 12 to bracket 7. Insert stop 19 with tip 9 and lock nut M8 between bracket 7 and bracket 17, and enclose bracket 7 with strap 12 with bolt 26 with nut 32 and washers. 37 and 40 in accordance with the figure.
6. Place belt 14 on the pulleys and use a M6x50 bolt with a “10” key to adjust its tension. By turning the stop out of the tip using keys “8” and “14”, limit the bending of bracket 7, achieve visual parallelism of the pulley rotation axes and check their perpendicularity to the plane of movement of the belt. The normal belt deflection is 12.17 mm when pressed with a force of 39 N (4 kgf). Using key “17”, tighten the pump mounting bolts, lock the stop 19 and tip 9 with locknut 33 on the 210” bar and “14”, 13, 8.
7. Install a fine fuel filter into the square hole d8. Use a 13 key to secure the filter. The purpose of the large oval hole is to remove the engine.

Tank installation

1. Using bracket 6, mark three holes d=8.5..9 on the left engine mudguard according to drawing Check that the hoses are long enough to reach this position of the tank.
2. Using a clamp 20 and an M8 bolt with nuts 33, washers 38 and 41, secure the tank to the bracket.
3. Drill a hole and secure the tank into the frame with bolts 27 with nuts 33, washers 38 and 41 with the nuts facing up.

Hose installation

Before installation, connecting fittings, ends and internal cavities of pipelines and hoses must be clean. The hoses are installed according to the figure. Sharp bends and local crushing of hoses are not allowed. The pressure hose must not touch the propeller shaft, the engine mount and the left wing mudguard. The tightening torque of the union bolts is 49..61 N*m (5.0..6.2 kgf*m).

Refilling the hydraulic system

All-season oil grade "R" TU 38.1011282-89 is used as a working fluid. Cleanliness class no rougher than 13 according to GOST 17216-71. The volume of liquid to be filled is 1.1 l. Duplicate oil brands: MGT, Shell tellis 22. In exceptional cases, as a temporary measure, it is allowed to use motor oil with a temperature range of use corresponding to the ambient temperature with a complete replacement of the hydraulic system volume.

1. Remove the oil tank cap and add oil until it appears above the filter mesh (no more than 5 mm).
2. Without starting the engine, turn the steering wheel from lock to lock until air bubbles leave the oil in the tank. add oil to the tank. When pumping, hang the front wheels or disconnect the steering rod from the bipod.
3. Start the car engine while adding oil to the tank. The oil supply to the tank must be at least 5.5 l/min to prevent air from entering the suction line. If there is excessive foaming of the oil in the tank, which indicates air has entered the system, turn off the engine and let the oil sit for at least 20 minutes (until the air bubbles stop leaving the oil). Inspect the connections of the hoses to the units and, if necessary, eliminate leaks.
4. Let the engine run for 15-20 seconds and bleed the power steering system to remove residual air from the PM by turning the steering wheel from lock to lock, without holding it in the extreme positions, three times in each direction.
5. If necessary, add oil to the tank. The oil level should be no lower than the tank mesh and no higher than it by 5 mm.
6. Close the tank with the lid and tighten the lid nut by hand. if necessary, attach the steering rod to the bipod, tighten and cotter the steering pin nut.

Operating rules

1. It is not recommended to hold the steering wheel in the extreme position for more than 5 seconds to avoid overheating of the oil and failure of the power steering pump.
2. If the power steering fails due to a broken pump, damage to the pump drive hose or belt, as well as when towing a car with the engine not running, the power steering can only be used for a short time until the fault is eliminated.
3. Long-term operation with inoperative power steering leads to premature wear of the steering mechanism.

Maintenance

In addition to the information specified in the REA, maintenance consists of periodically checking the tightness of hoses and their connections, checking the condition of the steering wheel rotation limiters, adding and changing oil. Instead of adding oil to the PM crankcase, oil is added to the power steering reservoir.

Pump belt tension

Normal belt tension corresponds to a deflection in the middle between the pulleys of 12..17 mm when pressed with a force of 39 N (4 kgf). If necessary, the belt is tensioned by moving the pump along the bracket as indicated in paragraph 4.2. If the belt is found to be damaged or excessively stretched, the belt must be replaced.

Checking the oil level and changing the oil

The oil must be replaced every 100,000 km or 2 years of operation. Refill the system in accordance with clause 6.

Free play of the steering wheel

The free play of the steering wheel is checked when the engine is idling and when the front wheels are stopped in a straight line position, the steering wheel is rocked in both directions until the front wheels begin to turn. Free play should not exceed 10 degrees. If there is more than permissible free play, it is necessary to determine the unit due to which it is increased - why check: the condition of the steering rod joints, the gaps in the joints and splined joints of the propeller shaft, the tightening of the drive shaft mounting wedge. The procedure for troubleshooting is specified in the REA. If a gap appears in the spline joint of the propeller shaft, it is necessary to repair or replace the shaft. If, as a result, it was not possible to eliminate excess free play, then the PM should be adjusted.

Adjusting PM power steering

To adjust the PM, it must be removed from the vehicle.
a) Disconnect the discharge and drain hoses from the PM and secure them so as to prevent complete leakage of oil from the hydraulic system.
b) Undo the cotter pin, unscrew the nut to “13” until the first thread appears and hit the nut to knock out wedge 4 through a soft metal drift.
c) Disconnect the steering rod from the bipod.
d) Unscrew the bolts securing the PM and remove it.
e) Fix the RM in a vice so that the holes for the fittings are at the bottom. turning the VZ, drain the remaining oil from the PM
f) Lightly press the air intake with your hand along the axis and rock the bipod. If axial movement of the air intake is felt, adjust the tension of the thrust bearings of the PM screw.
- carefully straighten the shoulder of the bearing cup into the grooves of the crankcase wall with light blows of a hammer on the beard. The bearing cup is located in the front wall of the PM crankcase along the vehicle's direction.
- turn the glass clockwise to eliminate the backlash
- insert the edge of the glass into the grooves of the crankcase wall.
g) If the axial movement of the air intake is not felt or is eliminated, and a gap is felt in the middle position of the bipod shaft when swinging by the bipod, it is necessary to adjust the gearing:
- use a “27” wrench to unscrew the bipod fastening nut and remove it
- remove the upper and lower protective covers of the bipod shaft, locking rings and adjusting washers from both ends of the bipod shaft, respectively,
- straighten the adjusting washers,
- simultaneously turning the bipod shaft supports counterclockwise (as viewed from the splined end of the bipod shaft), eliminate the gap in the engagement. The adjustment is made in the position of the bipod shaft corresponding to the middle position of the gear sector,
- check the turning torque of the bipod shaft, which should be within 34..45 N*m (3.5..4.5 kgf*m). If, after adjusting the bearing tension, the gap cannot be eliminated, then the gap is caused by wear of the ball drive "screw" -screw". In this case, the RM is subject to repair in a specialized repair facility.
- install the adjusting washers and locking rings, bend one of the whiskers in both adjusting washers into the groove of the bipod shaft support.
h) Place bipod 18 on the RM power steering shaft in accordance with the REA. Using a wrench set to “27”, tighten the nut to a torque of 196...274 N*m. (20..28 kgf*m)
i) Install RM power steering with bipod on the car. Tighten the bolts with keys “17” and “19”.
j) Attach the steering rod to the bipod and secure it. Tighten the pin nut with a wrench to "22". The tightening torque of the nut is 58.8..78.4 N*m (6..8 kgf*m). Tighten the nut.
k) Connect the discharge and drain hoses as indicated in paragraph 5. Fill the hydraulic system in accordance with paragraph 6.

Pump maintenance:

Pump maintenance consists of flushing the flow and safety valves when they are dirty. For this:
a) unscrew the plug above the pump outlet
b) remove the spring and spool of the flow valve, and replace the plug-plug to prevent oil leakage.
c) Wash the spool and the safety valve, which is installed inside the spool
d) Reassemble in reverse order.