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3.2. ENGINE

3.2.1. Gasoline Engines

Model

ZMZ405220

ZMZ40610

ZMZ40630

Type

4stroke, injection

4stroke, carburetor

Number of cylinders and their

arrangement

4, inline

Cylinder bore and piston stro

ke, mm

95.5

Displacement, l

2.464

2.285

Compression ratio

9.3

8.0

9.3

Rated power, net, kW (h.p.)

106.6 (145)

64.8 (88)

72.2 (98)

Max. torque, net, daN·m

(kgf·m)

20.79 (21.2)

16.8 (17.0)

17.2 (17.5)

— at the engine speed, rpm

4200±200

3500

Engine idle speed, rpm

—minimum (n

min. xx

)

850±50

750±50

— increased (n

incr

)

3150±50

2750±50

Fuel grade

“Regular92”

A76

АИ93, А92

Cylinders firing order

1 – 3 – 4 – 2

1 – 3 – 4 –2

Direction of crankshaft rota

tion (looking from the fan
side)

Righthand

Fuel supply system

With liquid heating of airfuel mixture

Carburator

—

K151Д

3.2.2. Diesel Engines

Model

GAZ560

GAZ5601,

Sofim 8140.43C

GAZ5602

Type

Diesel, 4stroke, with boost

Diesel, 4stroke

pressure charge

Without su

With super

percharged air

charged air

cooling

Number of cylinders and their

arrangement

4, inline

Cylinder bore and piston stro

ke, mm

94.4

100

Displacement, l

2.134

2.8

Compression ratio

20.5

18.5

¤— Symbol substituting the letter of engine version.

For “GAZelle” vehicles.

Содержание SOBOL

Страница 1: ...Limited Liability Company Automobile Plant GAZ LLC AVTOZAVOD GAZ GAZelle SOBOL VEHICLES FAMILY OPERATING INSTRUCTIONS 3302 3902111 10ИЭ 2nd Edition RUSSIA NIZHNIY NOVGOROD 2005 ...

Страница 2: ...eats GAZ 32214 4 2 type and GAZ 322174 4 4 type ambulance vehicles Note In brackets there is indicated a number of seats when double passenger seat is installed in bus cabin except for the buses with 12 13 seats where the cabin has double passenger seat and the rear row of the body is three or four seat Sobol vehicle family presented in this Operating Instructions comprises the following models GA...

Страница 3: ... braking efficiency For liquid coolant draining the hose is fitted to monoblock1 cock With out the hose liquid coolant will not drain fully from the monoblock To avoid camshaft toothed timing belt slipping that leads to damage of valve timing gear parts do not throw hot water on the engine1 to facilitate its starting To avoid oil leakage from GAZ 560 GAZ 5601 5602 engines through the seals do not ...

Страница 4: ...broken To prevent damaging of the gearbox when towing the vehicle by its par tial loading disconnect the propeller shaft flange from the axle drive Then fix reliably the disconnected end of the propeller shaft via a wooden block to the bracket cross bar of parking brake system linkage cable equalizer arm On the vehicles with ZMZ 40522 engine fuel tank contacts with atmos phere by means of gasoline...

Страница 5: ...icles VIN B location of cab number vehicles with cargo body or body number vans buses Vehicle Identification Number VIN on the vehicles with cargo body appears on the right side member before the rear spring front bracket Fig 2 2 Fig 2 2 Location of VIN on the vehicles with cargo body and chassis 1 location of identification number 2 rear spring front bracket 3 frame side member right Direction of...

Страница 6: ...25 body cabin serial number ZMZ Engine identification number is stamped on the cylinder block on the left side see Fig 2 3 Fig 2 3 Engine identification number 1 engine model 2 cylinder block number 3 engine serial number 4 engine manufacturer code 5 model year code 6 engine variant code 7 engine version Identification number of cylinder block is punched above the engine iden tification number Ide...

Страница 7: ... 1 engine manufacturer 2 engine vari ant code 3 engine number 4 diameter of cylinder 5 diameter of main bearings 6 certificate 7 engine manufacturer code 8 the last six digits of engine number Vehicle identification data also appears on manufacture s plate Fig 2 6 and 2 7 located on the rear pillar of the cab side panel Fig 2 7 Example of Sobol Vehicle Manufacture s Plate with Identification Data ...

Страница 8: ...9 a vehicle identification number b gross vehicle weight c gross vehicle weight with trailer d maximum front axle weight e maximum rear axle weight f engine index ...

Страница 9: ...01 24101 with Sofim engine 1950 2200 2150 2270 2100 2200 2400 2320 21901 24101 Overall dimensions mm length 5510 6616 5510 6295 5540 5570 5570 5600 width 2095 2095 2095 2095 2075 2095 2095 2075 height2 2120 2120 2275 2275 2200 2200 2355 2300 height over canvas top mm 2570 2570 2570 2570 2660 2660 GAZ 27057 Vehicle model GAZ 3302 GAZ 33023 GAZ 2705 GAZ 33027 GAZ 330273 3 SPECIFICATIONS 3 1 GENERAL ...

Страница 10: ...housing at total mass mm 170 170 170 170 170 190 190 190 Minimum turning radius front outer track m 5 5 6 7 5 5 6 7 5 5 7 5 7 5 7 5 Maximumspeed km h on flat smooth high way not less than for vehicles with ZMZ 4061 4063 engine 115 115 115 115 115 115 100 100 ZMZ 40522engine 130 130 130 130 130 130 130 130 GAZ 560 engine 115 115 115 115 115 100 100 100 GAZ 5601 5602 engine 120 120 120 120 120 120 1...

Страница 11: ...e gradient for laden vehicle 26 26 26 26 26 30 30 30 Cargo body van loading height mm 950 950 950 950 725 725 1040 825 Van freight compart ment capacity m3 9 61 9 61 9 61 Cargo body overall dimensions inner mm length 3089 4168 2339 3089 width 1978 1978 1978 height 400 400 400 400 1 For vans with two rows of seats ...

Страница 12: ...ngine GAZ 5601 5602 2500 2440 2700 2820 2760 2970 with Sofim engine 2500 2440 2750 2820 2760 2970 Overall dimensions mm length 5540 5540 5550 5600 5600 5560 width 2075 2075 2075 2075 2075 2075 height 2200 2200 25004 2300 2300 25804 Wheelbase mm 2900 2900 2900 2900 2900 2900 Front wheels track mm 1700 1700 1700 1720 1720 1720 1 Gross mass of the buses is specified including driver and passengers as...

Страница 13: ...0 190 190 Minimum turning radius front outer track m 5 5 5 5 5 5 7 5 7 5 7 0 Maximum speed km h on flat smooth highway not less than 1151 1151 1151 1101 1101 1101 1202 1202 1202 1152 1152 1152 Overhang angles laden deg front 22 22 22 28 28 28 rear 18 18 18 20 20 20 Maximum climbable gradient for laden vehicle 26 26 26 30 30 30 1 For vehicles with ZMZ 4061 4063 40522 GAZ 560 engines 2 For vehicles ...

Страница 14: ...070 32501 2900 30801 3070 32501 Vehicle kerb mass kg with engines ZMZ 4063 ZMZ 40522 1880 19702 2130 22202 2130 21451 2370 2150 21201 2370 with engine GAZ 560 1930 20202 2180 22702 2180 2420 2180 2420 with engine GAZ 5601 02 1980 20702 2230 23202 2290 2470 2290 2470 Overall dimensions mm length 4840 4910 4840 4910 4840 4910 width 2075 2075 2075 2075 2075 2075 height2 2100 22003 2170 23003 2100 220...

Страница 15: ... 6 0 5 5 6 0 7 5 6 0 Maximum speed km h on flat smooth high way not less than for vehicles with ZMZ 4061 4063 40522 engine 120 110 120 110 120 110 GAZ 560 engine 120 110 120 110 120 110 GAZ 5601 5602 engine 120 120 120 120 120 120 Overhang angles laden deg front 22 28 22 28 22 28 rear 21 30 21 30 21 30 Maximum climbable gradient for laden ve hicle 29 30 29 30 29 30 Van loading height mm 670 770 ...

Страница 16: ...150 50 2750 50 Fuel grade Regular 92 A 76 АИ 93 А 92 Cylinders firing order 1 3 4 2 1 3 4 2 1 3 4 2 Direction of crankshaft rota tion looking from the fan side Right hand Right hand Right hand Fuel supply system With liquid heating of air fuel mixture Carburator K 151Д 3 2 2 Diesel Engines Model GAZ 560 GAZ 5601 Sofim 8140 43C1 GAZ 5602 Type Diesel 4 stroke with boost Diesel 4 stroke pressure char...

Страница 17: ...utor fuelinjectionpump and injectors Pump and injector units 590 1 Turbo compressor C12 or KO4 Glow plugs 0100226227 Beru or 0250 202 022 Bosch or 11721659 АЕТ or ИЮМА 387524 ФГУП УАПО Governor Mechanical all speed High pressure fuel pump HPFP Bosch type VE 3 3 TRANSMISSION Clutch Single plate dry with hydraulic drive Gearbox Mechanical 5 gears with synchro mesh unit in all gears Transmission rati...

Страница 18: ...ear Two longitudinal semielliptic springs with hel per springs5 and antiroll bar6 Shock absorbers Four pcs hydraulic telescopic dual acting Mounted on the front and rear axles 3 4 1 Sobol Vehicles Wheels Steel pressed disk type with solid rim 6J 16H2 Tyres Pneumatic radial with tube 225 75R161 or 215 60R16 or 215 65R16 for buses or 215 65R16 185 75R16C for GAZ 2310 GAZ 2752 Suspension front Wishbo...

Страница 19: ...gears front wheels Disk rear wheels Drum Emergency brake system Each circuit of service brake system Parking brake system With mechanical cable drive to rear wheel brake gears 3 7 ELECTRICAL EQUIPMENT Type Direct current single wire Negative terminals of electrical equipment elements are connected to frame Rated voltage V 12 Alternator for engines ZMZ 4061 ZMZ 4063 ZMZ 40522 9422 3701 or 2502 3771...

Страница 20: ... nozzles 0 280 150 7111 0280 150 5601 or ZMZ DEKA IA 92612 DEKA ID ZMZ 6354 2 GAZ 560 GAZ 5601 5602 en gines fuel supply control system control unit 2176814 2 for GAZ 560 2176824 0 for GAZ 5601 220 4001 0 for GAZ 5602 accelerator pedal position sensor 2176830 3 engine speed sensor 2176734 2 boost air pressure sensor 2203662 1 air temperature sensor 2174425 2 or ИЦФР 405213 001 coolant temperature ...

Страница 21: ...VARTA Additional storage battery3 50 A h non serviceable with gas absorption type 95502 VARTA Contactor3 KT 123 or 12 KD 510 Fog lights3 ФГ 122 М Battery switch3 4 13 3737 remote control Head lamps right 0301215 202 or 1512 3775000 left 0301215 201 or 1502 3775000 Tail lights for vehicles with cargo body 171 3716 or 7702 3716 for vans and buses 70 3716 right 701 3716 left Windshield wiper 60 52050...

Страница 22: ...s ZMZ 4061 ZMZ 4063 ZMZ 40522 Coolant rated temperature in cool ing system 0 C 80 105 Minimum engine idle speed min 1 engine ZMZ 4061 ZMZ 4063 700 800 engine ZMZ 40522 800 900 Spark plug gap ZMZ 4061 4063 40522 mm 0 7 0 85 Belt sag between alternator and water pump pulley under 8 daN 8 kgf mm 15 For vehicles with engines GAZ 560 5601 5602 Clearance between rocking levers and cam heels of exhaust v...

Страница 23: ...ning 3 5 Total play2 of steering wheel in the position corresponding to vehicle straightforward run deg Not more than 25 20 3 Minimum allowable thickness of friction layer mm front disk brake shoes 3 0 rear drum brake linings 1 0 Minimum slope at which parking brake must hold fully loaded ve hicle 16 GAZelle Vehicles Front wheel geometry camber4 0o 30 1o pivot transverse inclination4 8o caster4 3o...

Страница 24: ...ear inclination1 4o toe in mm 0 3 Tyre inflation pressure3 kPa kgf cm2 front wheels 260 10 2 7 0 1 for buses 320 10 3 3 0 1 for GAZ 2310 GAZ 2752 with 185 75 R16C tires 250 10 2 6 0 1 for GAZ 2310 GAZ 2752 with 215 65 R15 tires rear wheels 270 10 2 8 0 1 for buses with six passenger seats 300 10 3 1 0 1 for buses with ten passenger seats 380 10 3 9 0 1 for GAZ 2310 GAZ 2752 with 185 75 R16C tires ...

Страница 25: ...re inflation pressure1 kPa kgf cm2 front wheels 250 10 2 5 0 1 rear wheels 250 10 2 5 0 1 Note tyre inflation pressure of each axle must be the same according to the values indicated 1 For vehicles type 4 4 ...

Страница 26: ...27 4 CONTROLS AND INSTRUMENTS Fig 4 1 Controls ...

Страница 27: ... horn2 non fixed position see fig 4 2 1 On some of the vehicles transfer case 4WD vehicles gears are shifted by one lever instead of two pos 21 and 23 2 On some of the vehicles the horn is switched on by means of windshield wiper and washer control lever see Fig 4 6 3 For vehicles with engines GAZ 560 GAZ 5601 5602 Sofim 8140 43C Fig 4 2 Turn indicator dimmer and horn switch lever Fig 4 3 Turn ind...

Страница 28: ...th sides turn the key to position 0 The engine is shut down by turning the key to position 0 1 For vehicles with engines GAZ 560 GAZ 5601 5602 Sofim 8140 43C 2 On some of the vehicles the horn is turned on by turn indicator and headlamp switch control lever see Fig 4 2 Fig 4 4 Ignition engine control 1 starter and anti theft device switch 7 Windshield wiper washer and horn2 switch lever The positi...

Страница 29: ...utton switch fig 4 7 are flashing simultaneously Fig 4 7 Emergency flasher warning system button switch Emergency flasher warning system should be switched on in case of vehi cle accidental stop in order to inform other drivers and maintenance services about accidents on the road 9 Left row dome lamps switch of passenger compartment buses Spot light switch above rear door for GAZ 32214 GAZ 322174 ...

Страница 30: ...e lever Changeover layout is given in fig 4 10 22 Cigarette lighter To use the lighter push it and release The lighter kick out with a click means that the coil is hot Do not reuse the lighter sooner that in 30 s When the lighter is removed it is allowed to use its socket for inspection lamp plug connection 23 Transfer case differential lock engagement lever for 4 4 type of ve hicles with two tran...

Страница 31: ...al lock are en gaged D gearbox 26 Instrument lighting control knob 27 Accelerator pedal 28 Master light switch The switch has five fixed positions fig 4 11 0 all external lighting is OFF I clearance lights instrument cluster lighting rear license plate lamp and some electrical equipment controls lighting is ON II additionally ON is upper or lower beam depending on the position of turn indicator an...

Страница 32: ...dy position for a driver and locked in this position by setting the lever to the initial posi tion Fig 4 12 Steering column adjustment control lever 32 Clutch pedal 33 Storage battery remote button switch for buses 34 Fuse block 35 Bonnet release lever To open the hood pull lock handle to release the catch of the lock and open the hood slightly then push the handle back home To open the hood compl...

Страница 33: ... electronic control system is ready for engine start up Lighting up or flashing of the lamp during vehicle movement informs about a failure of some elements of the engine control system warning lamp orange of glow plugs cutting in used also as a warn ing lamp when checking up of engine electronic control system for vehicles with engines GAZ 560 GAZ 5601 5602 3 Warning lamp red of anti lock brake s...

Страница 34: ...Warning lamp red of oil pressure drop Lights up when the igni tion key is turned on The lamp may glow with the engine running at idle speed and at sharp braking The lamp should go out when the engine speed is in creased above idle level Should the lamp light up under normal conditions shut down the engine immediately and check oil level in the crankcase 19 Warning lamp orange Lights up when rear f...

Страница 35: ...e of anti lock brake system ABS for buses 4 Warning lamp red STOP 5 Warning lamp green of left turn indicators 6 Warning lamp red of brake fluid low level Lights up when brake fluid level in the master cylinder becomes lower than allowed 7 Total distance counter 8 Speedometer 9 Warning lamp red of parking brake engagement Starts flashing after turning on of the engine control switch if the parking...

Страница 36: ...nt for 4 4 vehicles with one transfer case control lever 16 Warning lamp orange of low fuel level in the tank Lights up when less than 10 l of fuel remains in the tank 17 Warning lamp orange of central differential lock engagement for 4 4 vehicles 18 Warning lamp orange of rear fog light turning on 19 Coolant temperature gauge 20 Warning lamp green of clearance light 21 Warning lamp blue of upper ...

Страница 37: ...n opening the door from inside pull the front handle then push the rear part of the door and with the help of the handle located on the front part of the window opening pillar slide the door Use the same handle to close the door from inside Reardoorsareopenedthrough180 andfixedwhenbeingopenedat90 and180 Side door and rear right door locks usage is similar to this of cab door locks To open the rear...

Страница 38: ...icles sec ond row of seats is installed two double seats for four passengers Fig 5 2 Driver Seat 1 adjusting nuts 2 locking handle 3 backrest tilt handwheel Seat belts are effective equipment to protect the driver and any passen gers from severe injury in road accidents To fasten the belt Fig 5 3 it is necessary to pull the belt webbing slow ly by the tongue over the shoulder and across the chest ...

Страница 39: ...he belt low so that it does not come across the abdomen Warning The belts which underwent critical loading in a road accident or they became frayed cut and had other damages must be renewed by new ones in assembly Never make any changes in the seat belt design Never attempt to use the seat belt for more than one person Keep hard or fragile objects such as glasses fountain pens away from the belt a...

Страница 40: ...ig 6 1 When engine is running accelerator pedal position sensor and engine con dition sensors signals are transmitted into control unit The information is an alyzed in the control unit and electromagnet operating the pump and injector unit racks receives the control signal Fig 6 1 GAZ 560 Engine Control Diagram A to diagnostic connector B to engine control system relay 1 electronic control unit 2 ...

Страница 41: ... Control Diagram A to diagnostic connector 1 electronic control unit 2 accelerator pedal position sensor 3 air temperature sensor 4 engine speed sensor 5 glow plugs relay 6 fuel injection advance angle control servo mechanism 7 servo mechanism position sensor 8 servo mecha nism gear unit 9 supercharging air pressure sensor 10 glow plugs 11 rack position sensor 12 rack position sensor 13 coolant te...

Страница 42: ...directional effect section is installed on entresol in the left front part of the compartment Compartment dome light and stretches lamp are turned on by switches located on the instrument panel and medical equipment control panel Moni tor dome light switch is installed on its housing ELECTRIC POWER SUPPLY SYSTEM The vehicle is equipped with power supply system СЭС 97 designed to feed 220 22 V 50 0...

Страница 43: ... 3 To check operation of safety cut off device for this purpose make use of controls and signaling located on safety cut off device housing push Test button Off indicator should light up therewith push Return button Off indicator should go out therewith If it does not happen pull out the plug with safety cut off device from the socket and insert it again in 3 5 sec If even in this case the indicat...

Страница 44: ...nd automatic switches 4 and 3 are turned on it is prohibit ed to connect the storage batteries or disconnect them from the safety cut off device change the fuses 3 The outer connection cable plug with built in safety cut off device should be connected to two pole socket with side ground contacts of 220V 50Hz stationary electric circuit Be sure to connect the side ground contacts of two pole socket...

Страница 45: ...on II short siren Y position III short siren H Siren signal of Y type can be also turned on by pushing horn button on steering wheel For repeating vocal information microphone should be connected to sock et 7 Set key 2 to position I OFF and press speaking key on the microphone body It is possible to repeat information from tape recorder or radio set for this purpose their line OUTPUT should be con...

Страница 46: ...d near splitter plate Inside the tank for clear water there is electric pump for water supply into the wash stand Electric pump is turned on by means of switch 11 Timely pour clear water and drain dirty one space for ДКИ Н 04 on left hand side wall underneath table rack cover space for Пневмокомп 1 apparatus above table rack space for AH 8 apparatus behind the seat located at left hand side wall 1...

Страница 47: ...middle of the compartment allowing to shift the stretches block across the compartment and to fix it in traveling position pipe holder on compartment ceiling for medicine dropper and lamp which can be moved along the pipe holder two sockets to connect medical equipment on compartment side walls piece of fabric to carry the sick stored in the recess above the cab ...

Страница 48: ...an arm steering knuckle arms tie and drag link joints spring U bolts wheels silencer intake pipe flange and steering column location mech anism 5 Check fan and alternator belt tension1 because it stretches mostly dur ing the running in period 6 Driving speed should not exceed 20 km h in first gear 30 km h in sec ond gear 50 km h in third gear 70 km h in fourth gear and 90 km h in fifth gear Conduc...

Страница 49: ...up a warm or hot engine depress the accelerator pedal to 1 3 1 2 of its travel Do not close down the choke as this produces an excessive ly rich fuel mixture and makes proper starting difficult Engine stopping is carried out by turning the ignition key into position 0 If the engine has been operated in heavy duty cycle its instantaneous shut down is not allowed Let it run for 2 3 minutes at idle s...

Страница 50: ...engine starting check coolant level in engine cooling system and oil level in engine crankcase When starting from cold glow plugs bolting in stalled in monoblock cylinders turn on automatically Glow plugs bolting op erating time depends on the engine temperature Engine cold starting is carried out in the following sequence 1 Turn on the storage batteries switch 2 Move the gearshift lever into the ...

Страница 51: ... engine in the following sequence 1 Turn on the storage batteries switch for buses 2 Move the gearshift lever into the neutral position 3 Start the engine by switching on the starter without delaying the key in position I Engine stopping If the engine has been operated in heavy duty cycle its instantaneous shutdown is not allowed Let it run for 2 3 minutes at idle speed To stop the engine turn the...

Страница 52: ...et gearshift lever to neutral turn on the storage battery turn engine control switch key to fixed position I In so doing if the temperature under hood is below plus 3 1 o C the con trol unit automatically turns on glow plug preheating and the warning lamp lights up After 20 25 seconds glow plug preheating terminates and the warn ing lamp goes out If the temperature under hood is above plus 3 1 o C...

Страница 53: ...ply Note To increase the engine warming up efficiency it is necessary to fasten the heating cover to the radiator shell 8 2 FUEL AIR MIXTURE PREHEATING ZMZ 4061 4063 40522 ENGINES Fuel air mixture preheating is carried out by the coolant of the engine cool ing system in the intake manifold At the ambient air temperature below 5 C the hose of the air filter should be shifted on the connection pipe ...

Страница 54: ...lock warning lamp lights up on the instrument cluster On reaching the hard road the differential lock should be disengaged to avoid the excessive wear of vehicle tires and transmission as well as the increase of fuel consump tion The differential lock can be engaged both from the high gear and the un derdrive of the transfer case Gear shifting differential engagement and disengagement in the trans...

Страница 55: ...ne should stop while the vehicle is in mo tion braking will require much more effort 8 6 HEATING AND VENTILATION OF THE CAB PASSENGER COMPARTMENT Heating Fig 8 2 Heating and ventilation control panel 1 Handle of air distribution control in the cab passenger compartment air flow is directed to the windscreen and door windows air flow is directed to the chest of the driver and passenger air flow is ...

Страница 56: ...indscreen and door win dows do the following turn handle 1 Fig 8 2 of air distribution control to position turn handle 4 of air temperature control to the extreme right position wide part of the red symbol turn handle 2 of air amount control to the fast speed of the blower To achieve a favourable climate in the cab passenger compartment turn handle 1 of air distribution control to the chosen posit...

Страница 57: ...1 turn handle 2 to get the desirable rate of the air flow coming to the pas senger compartment adjust the direction of air flows by turning the shutters of ventilation grids To make heating and ventilation effective be sure that the grid of the hole for air intake located on the hood before the windscreen is free from leaves snow etc Cab and medical compartment heating and ventilation of GAZ 32214...

Страница 58: ...onnector 2 light beam hori zontal adjustment knob 3 and 5 covers 4 opening for light beam vertical adjustment To replace main beam bulb remove rubber cover 5 and unscrew connec tor 1 to replace turn indicator bulb Knob 2 is designed to adjust the direction of light beam in horizontal plane Vertical adjustment of the light beam is carried out through opening 4 using hexagon spanner or cross head sc...

Страница 59: ... 8 5A 8 5B the inclined section of the light and shade border must correspond to Fig 8 5A with AL marking on the lenses and Fig 8 5B with ОСВАР marking on the lenses and the points of hori zontal and inclined sections of the line and shade border intersection must co incide with G G and D D lines 8 8 FUSES Vehicles with ZMZ 4061 4063 40522 Engines Under the hood on the right there is a fuse box БП...

Страница 60: ...ПР 13 are installed on the instrument panel Vehicles with Sofim 8140 43C Engine Under the hood on the right there is a fuse box БПР 4 In БПР 4 fuse box 90 A fuse protects power electric circuit of alternator thermostarter glow plugs and fuel heater in fuel filter 40 A fuse protects out door illumination circuit 60 A fuse protects the circuit of the rest of power consumers except for lighting and s...

Страница 61: ...g light speed sensor parking brake warn ing lamp breaker windshield wiper relay 11 5A oxygen sensor ZMZ 40522 12 15A engine control system ZMZ 40522 microprocessor ignition system ZMZ 4061 4063 engine control system power supply GAZ 560 5601 5602 13 10A turn indicator Lower fuse box fuses protect the circuits of 1 25A spare 2 15A right headlamp main beam main beam warning lamp 3 15A left headlamp ...

Страница 62: ...ondition on the ice en suring minimum braking distance of the vehicle for this road surface ice while maintaining its stability and steerability Pulsating vibrations are felt on the brake pedal during ABS operation Attention To get the best effect during emergency braking of the vehicle using ABS it is necessary to press the brake pedal with maximum effort pushing the clutch pedal simultaneously T...

Страница 63: ...hen ABS failure is confirmed the troubleshooting should be carried out at service station ABS electrical diagram is shown in Fig 8 6 1 Moreover ABS failure warning lamp lights up in case of wire breakage between ABS control unit and warning lamp Fig 8 6 ABS System Electric Circuit Diagram ...

Страница 64: ...l below the lower mark Pour fresh engine oil via the filler neck covered with the cap 9 2 CHECKING OIL LEVEL IN GEARBOX TRANSFER CASE for 4WD Vehicles AND REAR AXLE Check oil level on an unladen vehicle standing on level ground with the units cold Oil level in the gearbox must be to the level of the filler hole lower edge Fig 9 1 for the plug located on the right side or 7 mm below the filler hole...

Страница 65: ...i freeze mixture through the expansion tank hole covered by cap If the coolant level falls frequently inspect the cooling system for leakage 9 4 CHECKING BRAKE FLUID LEVEL IN BRAKE MASTER CYLINDER TANK The level of the brake fluid can be checked visually through semi translu cent tank 2 Fig 9 4 of brake master cylinder 1by the level marks on the tank body Fig 9 4 Checking Brake Fluid Level in Mast...

Страница 66: ...g the fluid level in the tank it is necessary to check the brake fluid low level sensor as well For this purpose depress the center potion of cap 4 when the ignition is turned on The warning lamp should illuminate on the instrument cluster therewith 9 5 CHECKING BRAKE FLUID LEVEL IN CLUTCH MASTER CYLINDER TANK The level of the brake fluid in the clutch master cylinder tank should be 15 20 mm below...

Страница 67: ...cle charge the battery bringing the density up to 1 25 1 27 g cm3 Depending on climatic zone of the vehicle operation the electrolyte density should be corrected see storage battery operating in structions During the prolong parking of the vehicle disconnect the storage battery from the vehicle frame to ensure fire safety precautions 9 7 CHECKING OIL LEVEL IN POWER STEERING RESERVOIR power steerin...

Страница 68: ... idler pulley using shifting bolt 6 set pulley 2 into the position providing the required belt tension tighten bolt 3 check the belt sag Fig 9 7 Checking the Oil Level in the Power Steering Reservoir Fig 9 8 Accessories Drive Belt Tension Diagram A 15 mm I for vehicles without power steering II for vehicles with power steering 1 crankshaft pulley 2 idler pulley 3 idler pulley fastening bolt 4 poly...

Страница 69: ...emove rust from the wheels and restore their colour To ensure maximum service life of the tires the following rules should be observed maintain the required air inflation pressure in the tires Pressure should be checked when the tires are cold before starting out When stopping during a trip carry out visual inspection of the tires and inflation pressure in them Never drive the vehicle with the und...

Страница 70: ...ermined by measurement or by tread wear indicators These indicators of 1 6 mm high will appear as wide bands incorporated in the tread pattern and marked on the tire sidewalls by TWI marks 9 11 CHANGING A WHEEL 9 11 1 Wheel replacement by means of mechanical jack GAZ 3302 33023 Wheel replacement should be carried out in the following sequence apply the handbrake place chocks at the front and rear ...

Страница 71: ... beneath the vehicle with the lifting jack as the only sup port To carry out adjustment and mounting dismounting operations lift the vehicle on the jack and then lower it on suitable stands 3 Avoid fouling of threaded surfaces of screws and periodically apply graph ite grease on them 9 11 2 Wheel replacement using hydraulic jack buses vans and 4WD vehicles Replace the wheel in the following sequen...

Страница 72: ...de and apply the handbrake 2 Do not work beneath the vehicle with the lifting jack as the only sup port To carry out adjustment and mounting dismounting operations lift the vehicle on the jack and then lower it on suitable stands 3 In storage jack screw 2 should be driven all the way in the operating and delivery plungers must take the lowermost position and shut off needle 7 be unscrewed through ...

Страница 73: ...e one A after 10000 km of run 3 Maintenance two B after 20000 km of run 4 Seasonal maintenance C Seasonal maintenance is performed once a year along with maintenance one A or two B 9 14 PROCEDURES CARRIED OUT DURING MAINTENANCE 9 14 1 Daily maintenance EO Procedure description Specifications Tools and materials 1 2 3 Check the level of oil in engine crankcase See item 9 1 Visually fluid in cooling...

Страница 74: ...Check operation of instru With the engine running make Visually ments windshield wiper sure that the devices are in sound illumination and warning condition by their successive tur devices ning on 1 For vehicles with power steering 9 14 2 Periodic maintenance Procedures for periodic maintenance are stated in the service book supplied with the vehicle 9 14 3 Vehicle lubrication 1 Never use fuels oi...

Страница 75: ... Т At the temperature from 40 C to 20 C oil Лукойл ТМ5 SAE 75W 90 Universal joint needle bear 3 60 g Oil Супер Т 3 Substitute ings 61 1201 oils Девон Супер Т Splined joints1 of propeller 2 100 g Oil Супер Т 3 Substitute shafts oils Девон Супер Т Front axle housing1 1 1 8 l At the temperature from 25 C to 40 C oil Супер Т 3 Substitute oils Девон Супер Т At the temperature from 40 C to 20 C oil Луко...

Страница 76: ... 24 Substitutes splines grease ЛИТА solid oil C or Ж Front axle journal2 seal 2 10 g Grease Литол 24 Substitutes greases ЛИТА solid oil C or Ж Shock absorbers 42 1 06 l АЖ 12T Substitute fluid 23 0 53 l spindle oil AУ Idle arm shaft needle bear 1 50g Lubricant УссА ings3 Substitute Solid oil Ж Left idle arm support wash 1 2g Lubricant УссА er3 Substitute Solid oil Ж Right idle arm bushings3 2 15g ...

Страница 77: ...e door1 3 30 g Grease Литол 24 Substitutes mechanisms grease ЛИТА Hood lock 1 1 g Oil ВМГЗ or МГЕ10А Hood lock control 1 15 g Grease Литол 24 Substitutes grease ЛИТА Hood hinges 2 2 g Oil ВМГЗ or МГЕ10А Side door1 upper roller bear 1 20 g Литол 24 ЛИТА or ЦИАТИМ ing 201 Cooling system of ZMZ 1 9 7 l2 Coolant ТОСОЛ А40М ОЖ 40 4061 4063 ZMZ 40522 11 5l3 Лена ТЕРМОСОЛ А40 engines Cooling system of So...

Страница 78: ...D ONORM C 1104 Austria 75 2D ASTM 975 81 USA Class C1 Class C2 Class A1 Class D BS 2869 83 UK Class A2 Class M1 BSMA 100 82 UK M 15007 82 France NFM 15009 76 France DIN 51601 78 Germany DIN 51603 81 Germany SN 181160 1 83 Switzerland EO1 SS 155103 81 Sweden SS 155432 84 Sweden TYPE B CAN 2 3 6 M 83 Canada Special N1 N2 N3 JIS K 2201 83 Japan З Z 35 Z 50 PN 67 C 96048 Poland diesel winter 35 STAS 2...

Страница 79: ...10 C to 45 C SAE 5W 40 from 25 to 0 C ACEA E2 or E3 Transmission oils API GL 5 SAE 85W 90 Oil Р ISO 6074 HM 22 Shell Tellus 22 Mobil DTE 13 Castrol Hyspin AWS 22 Oil А ATF Oil МГЕ 10A ISO 6079 HV 15 Oil ВМГЗ ISO 6074 HV 15 Lubricant ЦИАТИМ 201 Mil G 24139 Mil G 19608 DEF STAN 91 28 DTD 577 Grease Литол 24 Mil G 18709A Mil G 10924C Grease ЛИТА SM 1C 4515A Ford Solid oil C or Ж VWTL 738 Mil G 10924C...

Страница 80: ...r Fig 9 14 is full flow and non detachable one ensuring high quality of fuel cleaning ПНТП КОЛАН make Fig 9 14 Oil Filter 1 spring 2 by pass valve filter element 3 by pass valve 4 body 5 filter element 6 drain proof valve 7 cover 8 9 gaskets 2101C 1012005 HK 2 filter provides that no dirty oil will enter the en gine lubricating system unlike the filters of common design When starting cold engine o...

Страница 81: ...013 03 04 05 06 or 31029 01 02 03 Filter element of GAZ 560 GAZ 5601 5602 engine air filter 3105 1109013 3110 1109013 or 3110 1109013 13 01 Filter element of Sofim 8140 43C engine air filter is 3302 1109010 10 5 Spark plugs ZMZ 4061 ZMZ 4063 and ZMZ40522 engines see Specifications subsection 3 10 6 Filter element of power steering system1 reservoir ШНКФ 453473 400 In case of installation of power ...

Страница 82: ...s КЛ9У ТБЦ 3 41 Bus step lighting dome lamp AC12 5 1 1 Van freight compartment dome lamp AC12 21 3 1 Dome lamp2 individual above the table A12 4 1 1 Glove box dome lamp AC12 5 1 1 Rear fog lamp buses and vans version A12 21 3 1 Hood light A 12 10 1 Tail light turn indicator A12 21 3 2 stop light A12 21 3 or A12 21 5 2 clearance light A12 5 or A12 21 5 2 fog light A12 21 3 2 backing light A12 21 3 ...

Страница 83: ... case reinforcing element bolts 2 9 3 6 Water pump water pump pulley thermostat housing chain damper chain cover bolts exhaust manifold nuts 2 0 2 5 Cylinder head front cover idler pulley bolts 1 4 1 8 Oil crankcase hold down bolts 1 2 1 8 Oil seal holder bolts 0 6 0 9 Transmission Transfer case shaft flanges nuts2 20 28 Gear cases bolts 1 4 1 8 Front and rear gear case and transfer case covers bo...

Страница 84: ... 7 0 Silent block bolts of springs 12 0 15 0 U bolt nuts 12 0 15 0 Shock absorber reservoir nuts of rear suspension 9 0 15 0 Wheel nuts 15 17 0 Steering knuckle pivot lock pin nuts1 3 2 3 6 Steering Gear Steering rod ball joint nuts 7 0 10 0 Steering arm to steering knuckle hold down bolts GAZelle vehicle 11 0 12 5 Tie rod clamp bolts GAZelle vehicle 2 2 2 5 Steering links to support hold down bol...

Страница 85: ... vans with two rows of seats 11 5 10 0 1 Engine oil system l 6 0 6 5 1 Gearbox case l 1 2 Transfer case housing2 l 1 65 Front axle housing1 l 1 8 Rear axle housing l 3 0 Steering gear case for vehicles with power steering l 0 55 0 6 Power steering system for vehicles with power steering l 1 3 Shock absorbers each l 0 265 Brake hydraulic drive system l 0 67 Sobol 0 52 GAZelle Clutch hydraulic drive...

Страница 86: ...0 8 9 Thermostarter Control Unit Sofim 8140 43C engine 63 8 10 Anti lock Brake System 63 9 Vehicle Maintenance 65 9 1 Checking Engine Oil Level 65 9 2 Checking Oil Level in Gearbox Transfer Case for 4WD Vehicles and Rear Axle 65 9 3 Checking Coolant Level 66 9 4 Checking Brake Fluid Level in Brake Master Cylinder Tank 66 9 5 Checking Brake Fluid Level in Clutch Master Cylinder Tank 67 9 6 Checking...

Страница 87: ...ls Lubricants and Fluids 79 9 17 Parts to be Replaced on the Vehicle during Maintenance 81 10 Supplements 83 10 1 Electric Bulbs Used 83 10 2 Tightening Torque of Most Important Junctions 84 10 3 Filling capacities 86 Инструкция по эксплуатации автомобилей семейства ГАЗель и Соболь на английском языке Отпечатано в ООО Печать НН з 5498 Е5 ...

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