Gazelle SOBOL Operating Instructions Manual

Limited Liability Company «Automobile Plant GAZ»

(LLC «AVTOZAVOD GAZ»)

GAZelle

SOBOL

VEHICLES FAMILY

OPERATING INSTRUCTIONS

3302390211110ИЭ

2ndEdition

RUSSIA

NIZHNIY NOVGOROD

2005

3

INTRODUCTION

“GAZelle” and “SOBOL” trucks and buses are reliable and comfortable
vehicles. 4×2 trucks and buses are designed to be operated over improved roads
(4×4 ones – over all types of roads) in different climatic conditions.

“GAZelle” vehicles family presented in this Operating Instructions com
prises the following models:

GAZ3302 — 4×2 type and GAZ33027 – 4×4 type with threeseat cabin

GAZ33023 – 4×2 type and GAZ330273 – 4×4 type with sixseat cabin

GAZ330202 — longwheelbase, with threeseat cabin

GAZ330232 — longwheelbase, with sixseat cabin

GAZ2705 – 4×2 type and GAZ27057 – 4×4 type allmetal vans, with
threeor sevenseat cabin

GAZ3221 – 4×2 type and GAZ32217 4×4 type buses with 8 (9) passen
ger seats.

GAZ32213, GAZ322132 – 4×2 type and GAZ322173 – 4×4 type buses
with 12 (13) passenger seats

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:

GAZ2752 – 4×2 type and GAZ27257 – 4×4 type allmetal vans with low
or medium height roof and threeor sevenseat cabin.

GAZ2217 – 4×2 type and GAZ 22177 – 4×4 type buses with low roof.

GAZ22171 – 4×2 type and GAZ221717 – 4×4 type buses with medium
height roof.

The manufacturer reserves the right to constantly alter its vehicle design,
therefore some units and parts may slightly differ from those described in this
Operating Instructions.

You can surely expect reliable operation of the vehicle provided you ob
serve maintenance schedule specified in this Operating Instructions and Serv
ice Book.

4

1. USEFUL HINTS

Vehicles with ZMZ4063 and ZMZ40522 engines run on Research Oc
tane Number 9295 gasoline, with ZMZ4061 run on Research Octane Number
76 gasoline and with GAZ560, GAZ5601, 5602 and Sofim 8140.43 engines –
on diesel fuel (see subsection “Equivalents of Fuels, Oils, Lubricants and Flu
ids”).

Coast when the engine starter key is in position III is strictly prohibited
because in this case the steering control might be accidentally locked by the
antitheft device.

It is prohibited to close the doors with the button pushed down into the
“Locked” position. It may cause the damage of the lock.

Do not reset trip distance counter when the truck is running since this
might cause the damage of the counter.

After engine1) washing in cold weather it is necessary to warm it up for 5–
10 minutes at different speed to remove water from toothed pulleys and cam
shaft drive belt.

Do not run the engine1) when alternator drive belt is loose for it will cause
the sharp decrease of 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 disconnect crankcase ventilation system hose from the intake pipe.

When engine runs do not keep the steering wheel turned as far as it will go
for more than 15 sec because it may cause the damage of power steering2) pump.

Do not start the engine when the level of oil in power steering2) tank is not
sufficient.

The exhaust system of the vehicles with ZMZ40522 engine is equipped
with catalyst converter (mounted on some of the vehicles).

To ensure the proper operation of the converter it is necessary to use un
leaded gasoline with Research Octane Number 92, only.

The converter can also go out of order when the ignition system of the
engine misfires, because in this case the gasoline that failed to burn will enter

1)

For GAZ560, GAZ5601, 5602.

2)

For vehicles with power steering.

5

the converter increasing sharply the temperature inside it and in its turn it
will cause appearing of cracks in its ceramic block.

During the operation the converter becomes very hot. Therefore when park
ing the vehicle be sure that there is no combustible material (dry grass, wiping
waste, chip etc.) under the converter.

Never start the engine by towing the vehicle to prevent damaging of the
converter.

When starting cold engine (ZMZ4063) it is necessary to step on the ac
celerator pedal, close the choke and release the accelerator pedal. On violating
of the above stated sequence the carburetor choke rod possibly be 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 vapour recovery system (mounted on some of the
vehicles). It consists of steam pipes and valves such as safety valve and pres
surevacuum control valve, as well as adsorber (adsorbs gasoline vapour) with
electromagnetic valve of blowing.

To avoid fire dangerous situation and damaging of the adsorber when fuel
gets into it, fuel tank design insures fuel cutoff during fuelling. Forced filling
of extra fuel is not allowed.

6

2. VEHICLE IDENTIFICATION DATA

Identification number of the vehicle (VIN) and identification numbers of
cabin or allmetal body, engine and cargo body vehicle chassis refer to the ve
hicle identification data.

Vehicle Identification Number (VIN) on the vans with allmetal cargo
body and buses appears on the cab front outer panel under the hood on the

right side in direction of vehicle movement (see Fig. 2.1, arrow “A” view);

Fig. 2.1. A — location of vehicles 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 movement

Example of Vehicle Identification Number:

X9633020050140794, where:
X96 – manufacturer international identification code,
330200 – “GAZelle” vehicle model,
221710 — “Sobol” vehicle model
5 – model year code (5 – 2005, 6 – 2006),
0140794 – vehicle serial number.

7

Model year is a period equal on the average to calendar year during which

the vehicles with identical design features are being manufactured.

Cab number (vehicles with cargo body) or body number (vans and bus

es) is located on the front outer panel under the hood, on the left in direction

of vehicle movement (see Fig. 2.1, arrow “B” view).

Example of Body (Cab) Number:

27050040100125,where:
270500 – “GAZelle” body index,
330200 – “GAZelle” cabin index
22171 – “Sobol” body index
5 – model year code,
0100125 – 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.

Identification number of GAZ560, GAZ5601, 5602 engines (Fig. 2.4)

is stamped on the plain surface of engine framework (in its front part, on the
right, above alternator mounting flange). It contains engine index (GAZ560
or GAZ5601, 5602), model year code (5 — 2005; 6 — 2006) and engine serial
number.

8

Identification number of Sofim 8140.43C engine (Fig. 2.5) is punched
on the plane surface of the cylinder block in the rear part of the engine at the
right side.

Fig. 2.4. Identification Number of

GAZ560, GAZ5601, 5602 Engines

Fig. 2.5. Identification Number of Sofim

8140.43C Engine

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

Fig. 2.6. Example of “GAZelle” Vehicle

Manufacture’s Plate with Identification

Data

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

10

Type Biaxial with rear axle drive 4 × 4 biaxial
Vehicle gross mass, kg 3500 3500 3500 3500 3500 3500 3500 3500
Vehicle kerb mass, kg:

— with engines
ZMZ4061, 4063,
40522 1850 2100 2050 2170 2000/ 2100 2300 2220/

2090

1)

2310

1)

— with engine
GAZ560 1900 2150 2100 2200 2050/ 2150 2350 2270/

2140

1)

2360

1)

— with engine
GAZ5601, 02 1950 2200 2150 2270 2140/ 2200 2400 2360/

2190

1)

2410

1)

— with Sofim engine 1950 2200 2150 2270 2100/ 2200 2400 2320/

2190

1)

2410

1)

Overall dimensions,

mm:
— length 5510 6616 5510 6295 5540 5570 5570 5600
— width 2095 2095 2095 2095 2075 2095 2095 2075
— height

2)

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 DATA

3.1.1. “GAZelle” General Data
Trucks

1)

For vans with two rows of seats.

2)

Height over cab is given for the vehicles with the cargo body.

GAZ330202 GAZ330232

11

GAZ27057

Vehicle model

GAZ3302 GAZ33023 GAZ2705 GAZ33027

GAZ330273GAZ330202 GAZ330232

Wheelbase, mm 2900 3500 2900 3500 2900 2900 2900 2900
Front wheels track,

mm 1700 1700 1700 1700 1700 1720 1720 1720

Rear wheels track

(between centres
of twin tyres), mm 1560 1560 1560 1560 1560 1560 1560 1560

Ground clearance

(under rear axle
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

Maximum speed, 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40522 engine 130 130 130 130 130 130 130 13 0
— GAZ560 engine 115 115 115 115 115 100 100 100
— GAZ5601, 5602
engine 120 120 120 120 120 120 115 115
— Sofim 8140.43C
engine 120 120 120 120 120 120 — —

Overhang angles

(laden), deg.:
— front 24 24 24 24 22 22 28 28
— rear 24 17.5 24 23 18 18 26 20

12

GAZ27057

Vehicle model

GAZ3302 GAZ33023 GAZ2705 GAZ33027

GAZ330273GAZ330202 GAZ330232

Maximum climable

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, m

3

— — 9/6

1)

9/6

1)

— 9/6

1)

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.

13

GAZ322174Vehicle model GAZ3221 GAZ32213 GAZ32214 GAZ32217 GAZ322173

Buses and Ambulances

With allmetal body
Type Biaxial with rear axle drive 4 x 4 biaxial
Vehicle gross mass

1)

,

kg 3250 3500 3500 3470 3720 3500

3550

2)

3760

2)

3500

3)

Vehicle kerb mass, kg:

— with engines
ZMZ4061, 4063,
40522 2500 2440 2600 2720 2660 2870
— with engine
GAZ560 2450 2390 2650 2770 2710 2920
— with engine
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 2500

4)

2300 2300 2580

4)

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 per number of mounted seats.

2)

— For vehicles with engines GAZ560, GAZ5601, 5602.

3)

— For vehicles with Sofim 8140.43 engines.

4)

— Height is specified over Signaling and Loudspeaker System.

14

GAZ322174Vehicle model GAZ3221 GAZ32213 GAZ32214 GAZ32217 GAZ322173

Rear wheels track

(between the centres
of twin tyres), mm 1560 1560 1560 1560 1560 1560

Ground clearance

(under rear axle
housing at total
mass), mm 170 170 170 190 190 190

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 115

1)

115

1)

115

1)

110

1)

110

1)

110

1)

120

2)

120

2)

120

2)

115

2)

115

2)

115

2)

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 with GAZ5601, 5602 and Sofim engines.

15

GAZ221717Vehicle model GAZ2752 GAZ27527 GAZ2217 GAZ22177 GAZ22171

1)

For 10passenger seat buses.

2)

For vans with two rows of seats.

3)

For vans with mediumheight roof.

Type Allmetal van Bus

4×24×44×24×44×24×4

Vehicle gross mass, kg

— with engines
ZMZ4063, ZMZ40522 2800 3000 2800/2980

1)

3000/3170

1)

2800/2980

1)

3000/3170

1)

— with engine GAZ560 2800 3000 2850/30301)3020/3200

1)

2850/3030

1)

3020/3200

1)

— with engine GAZ
5601, 02 2800 3000 2900/3080

1)

3070/3250

1)

2900/3080

1)

3070/3250

1)

Vehicle kerb mass, kg:

— with engines
ZMZ4063, ZMZ40522 1880/1970

2)

2130/2220

2)

2130/2145

1)

2370 2150/2120

1)

2370

— with engine GAZ560 1930/2020

2)

2180/2270

2)

2180 2420 2180 2420
— with engine GAZ
5601, 02 1980/2070

2)

2230/2320

2)

2290 2470 2290 2470

Overall dimensions, mm:

— length 4840 4910 4840 4910 4840 4910
— width 2075 2075 2075 2075 2075 2075
— height

2)

2100/2200

3)

2170/2300

3)

2100 2200 2200 2300

Wheelbase, mm 2760 2760 2760 2760 2760 2760
Front wheels track, mm 1700 1720 1700 1720 1700 1720
Rear wheels track, mm 1700 1700 1700 1700 1700 1700
Ground clearance (under

rear axle housing at to
tal mass), mm — 205 — 205 — 205

3.1. “SOBOL” GENERAL DATA

16

GAZ221717Vehicle model GAZ2752 GAZ27527 GAZ2217 GAZ22177 GAZ22171

Ground clearance (under

front suspension arms
at total mass), mm 150 — 150 — 150 —

Minimum turning radius

(front outer track), m 5.5 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 — — — —

17

3.2. ENGINE

3.2.1. Gasoline Engines

Model ZMZ405220¤ ZMZ40610¤ ZMZ40630¤
Type 4stroke, injection 4stroke, carburetor
Number of cylinders and their

arrangement 4, inline 4, inline 4, inline

Cylinder bore and piston stro

ke, mm 95.5×86 92×86
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.xx

) 3150±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 8140.43C

1)

GAZ5602

Type Diesel, 4stroke, with boost Diesel, 4stroke

pressure charge

Without su With super

percharged air charged air

cooling cooling

Number of cylinders and their

arrangement 4, inline 4, inline 4, inline
Cylinder bore and piston stro

ke, mm 85×94 94.4×100
Displacement, l 2.134 2.8
Compression ratio 20.5 18.5

¤— Symbol substituting the letter of engine version.

1)

For “GAZelle” vehicles.

18

Rated power, net, kW (h.p.) 70.0 (95) 81.0 (110) —
Engine speed at rated power,

min

1

3800 3600 —

Max. torque, net, daN·m (kgf·m) 20.0 (20.4) 25.0 (25.5) 25.0 (25.5)

— at engine speed, rpm 2300 2000 —
Maximum power, kW (h.p.) — — 78 (106.1)
Engine idle speed, rpm

— minimum (n

min xx

) — — 800±25

— increased (n

incr. xx

) — — 4200±50
Fuel grade Diesel fuel
Cylinders firing order 1—3—4—2
Direction of crankshaft rota

tion (looking from the fan
side) Righthand

Fuel supply system Multipoint

with distributor

fuel injection pump

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 ratios:
— 1

st

gear – 4.05

— 2

nd

gear – 2.34

— 3

d

gear – 1.395

— 4

th

gear – 1.0

— 5

th

gear – 0.849

— reverse gear – 3.51

Transfer case

1)

Mechanical, with two gears: high gear (i = 1.07)
and underdrive (i = 1.87) and equalizing central
controlled slip differential

1)

For vehicles type 4×4

19

Cardan drive Two shafts with three universal joints (with

nee dle bearings) and intermediate support.

Three shafts

1)

with six open type cardan joints,

with needle bearings

Front axle

1)

— final drive Hypoid, transmission ratio is 5.125
— differential Bevel, geartype
— steering knuckles With Hook’s joints

Rear axle

— final drive Hypoid, transmission ratio is 5.125

3)

(4.556)2), (4.1)

4)

— differential Bevel, geartype
— axle shafts Full floating

3.4. RUNNING GEAR

3.4.1. “GAZelle” Vehicles

Wheels Disk type with solid rim 5Ѕ1/2× 16H2
Tyres Pneumatic, radial, with tube, size 175R16C or

185/75R16C (195R16C)

5)

Suspension:

— front Two longitudinal semielliptic springs
— rear Two longitudinal semielliptic springs with hel

per springs

5)

and antiroll bar

6)

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, 225/75R16

1)

or
215/60R16 or 215/65R16 – for buses or 215/65R16,
185/75R16C (for GAZ2310, GAZ2752)

Suspension:

— front Wishbonetype independent suspension with

cylindrical springs and lateral stabilizer; shock
absorbers – filled with gas, telescopic, dual acting.
Two

1)

longitudinal semielliptic springs

1)

For vehicles type 4×4.

2)

For “GAZelle” vehicles with ZMZ40522, GAZ5601, 5602 engines and “Sobol” vehicles.

3)

For “Sobol 4×4” vehicles and “GAZelle” vehicles with ZMZ4061, 4063 and GAZ560 engines.

4)

For vehicles with Sofim engine.

5)

Except for 4×2 type buses.

6)

Optional.

20

— rear Two longitudinal semielliptic springs with later

al stabilizer; shock absorbers – hydraulic, tele
scopic, dual acting

3.5. STEERING GEAR

Steering gear without

power steering Mechanical, “screwball nut” type

Steering gear with

power steering Integral type, “screwball nut”
Power steering pump ШНКФ 45347111540 for Sofim engine,
Power steering pump ZF firm product
Steering gear transmission

ratio (in the middle part) 23.09 (for vehicles without power steering), 17.3

(for vehicles with power steering)

3.6. BRAKE SYSTEMS

Service brake system Doublecircuit, with hydraulic drive and vacuum

booster

Brake 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
— for engines GAZ560,
GAZ5601, 5602 Bosch 6 033 GB001

Starter:

— for engines ZMZ4061,
ZMZ4063, ZMZ40522 6012.3708000 or 4216.370800007 or 406.3708000
— for engines GAZ560,
GAZ5601, 5602 Bosch 0 001 109042 or Iskra Avtoelektrika AZE 2573

ZMZ4061, ZMZ4063

engine control system:
— control unit 243.376301 or 309.376301 or 243.376321

or 309.376302

1)

1)

— With the function of fan electric coupling relay control.

21

— timing sensor 02612101131) or 23.3847 or ДС1
— absolute pressure sensor 45.3829 or 0261230037

1)

— coolant temperature sensor
(engine control system sensor) 19.3828 or 405226
— knock sensor 0261231046

1)

or GT 305 or 18.3885

ZMZ40522 engine control system:

— control unit 241.376364
— mass airflow sensor 20.3855
— air throttle position sensor 0 280 122 001

1)

or НРК 18
— oxygen sensor 5WK91000
— phase sensor 0 232 103 006

1)

, 406.384705001 or ДФ1
— engine speed and timing sensor 0 261 210 113

1)

or 23.3847 or ДС1
— inlet pipeline air temperature
sensor, coolant temperature sensor 19.3828 or 405226
— knock sensor 0 261 231 046

1)

, GT305 or 18.3855
— engine idle run governor 0 280 140 545

1)

or PXX60
— electromagnetic nozzles 0 280 150 711

1)

, 0280 150 5601) or ZMZ DEKA

IA 9261

2)

, 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 sensor 2174623/3 or ИЦФР 405213.002
— electric fuel pump 2173396/1
— pumpandinjector units con
trol electromagnet with rack
position sensor 2205211/2
— electromagnetic control valve
of exhaust gases recirculation
system 1902.3741
— glow plug relay 0332.002156 Bosch
— engine electronic control sys
tem and electric fuel pump cut
tingin relay (2 pcs.) 2206107/0 or 94.374.000

Servo drive reducing gear of fuel ДПР281212

injection timing control mech
anism (GAZ5602)

1)

— Made by “BOSCH” .

2)

Made by “SIEMENS”.

22

Thermostarter control unit (Sofim

8140, 43C) 500 337969
Electric fuel pump (ZMZ40522) 505.1139
Electric fuel pump relay (ZMZ

40522), engine electronic control

system relay (ZMZ40522) 113.374710, 90.374710 or 85.3747
Submersible electric fuel pump

module (ZMZ40522) 505.1139 or 9П2960012
Ignition coil (ZMZ4061, ZMZ

4063, ZMZ40522) 3012. 3705 or 406.3705 (2 pcs. each)
Electromagnetic valve ЭПХХ

(ZMZ4061, ZMZ4063) 19.3741 or ИЖКЭ3741
Spark plugs (ZMZ4061, ZMZ

4063, ZMZ40522) А 14ДВР or WR8DC

1)

or LR17YC

2)

Storage battery: 6CT66A

3)

— for ZMZ4061, 4063, 40522

engines 6CT55A

— for GAZ560, 5601, 5602

engines 6CT74A VARTA
Additional storage battery

3)

50 A·h, nonserviceable with gas absorption, type
95502, “VARTA”

Contactor

3)

KT 123 or 12 KD 510

Fog lights

3)

ФГ 122 М

Battery switch

3, 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 60.5205010 or 70.5205000
Horns 22.3721/221.3721

3.8. BODY OF VANS AND BUSES

Body Allmetal, semihood, fivedoor.

Two swing doors of the cab, one side sliding door
and two rear doubleswing doors of passenger
compartment or one rear flap door (for “Sobol”

vehicles with low roof)
— bus cab Two or three seat
— van cab Three or sevenseat

1)

Made by “BOSCH”.

2)

Made by “BRISK”.

3)

For GAZ32214, GAZ322174 vehicles.

4)

For buses.

23

Overall dimensions (inner) of van

cargo compartment, mm:

“GAZelle” Vehicles “Sobol” Vehicles

— length 3140/2000

1)

2460/1330

1)

— width 1830 1830
— height 1500 1430/1530

2)

— van cargo compartment capac
ity, m

3

9/6

1)

6,4/3,4

1)

3.9. CAB AND CARGO BODY

Cab GAZ3302, GAZ330202, GAZ33023,

GAZ330232, GAZ33027 GAZ330273

Metal, twodoor, Metal, twodoor,

threeseat sixseat

Cargo body Metal, with tail gate and side flaps

3.10. MAIN ADJUSTMENT AND CHECKING DATA

For vehicles with engines 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 valves
on cold engine at 15–20

o

C, mm 0.3 – 0.34

Clearance between rocking levers

and cam heels of intake valves on
cold engine at 15–20

o

C, mm 0.15 – 0.19

Rated coolant temperature,

o

C 85–95

1)

For vans with two rows of seats.

2)

For “Sobol” vehicles with medium roof.

24

Minimum engine idle speed, min

1

850

Belt sag

1)

(between alternator and
fan pulleys) under 4 da·N
(4 kgf), mm 10

Camshaft drive toothed belt ten

sion, daN (kgf) 50±5 (50±5)

Pumpandinjector unit plunger

setting travel, mm 8,04

+0,.05

(GAZ560, 5601, 5602 engines)

Pumpandinjector unit plunger 3,2

–0.04

(GAZ560, 5601)

travel up to TDC in the first cyl 3,14

–0.004

(GAZ5602)

inder, mm

For vehicles with Sofim 8140. 43C engine

Optimum fluid temperature in

cooling system,

o

C 85–95

Minimum idling speed, min

1

800±25
Clutch pedal free travel, mm 12–28
Brake pedal free travel when the

engine is not running 3–5

Total play

2)

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:

— camber

4)

0o30' – 1

o

— pivot transverse inclination

4)

8

o

— caster

4)

3o28' ± 30' (4o)

5)

— toein, mm 0 – 3

Tyre inflation pressure, kPa

(kgf/cm

2

)

— front wheels 290 + 10 (3.0 + 0.1)

240 + 10 (2.5 + 0.1)

5)

1)

For reference only, nonadjustable.

2)

Total play of steering wheel for the vehicles with power steering is taken with the engine

running.

3)

For buses.

4)

The parameter is provided (for vehicle gross mass) by vehicle design and is not to be adjusted.

5)

For 4x4 types of vehicles.

25

— rear wheels 290 + 10 (3.0 + 0.1)

240 + 10 (2.5 + 0.1)

1)

270 + 10 (2.8 + 0.1)

2)

Note: air pressure in the tyres of each axle must be the same according to the

values indicated.

“Sobol” Vehicles

Front wheels

3)

geometry:

— caster +4

o

30' ± 1o (+3o±1o)

4)

— left and right wheels angles
difference while adjusting caster,
not more 0

o

30'

— camber 0

o

30'±30' (+1o±30')

4)

— left and right wheels angles
difference while adjusting cam
ber, not more 0

o

30'

— toein (of every wheel to ve from +0

o

03' to +0o10'

hicle longitudinal axis) (from +0

o

01' to +0o08')

4)

Front wheels geometry

1)

— camber

5)

1

o

— pivot transverse inclination

1)

8

o

— pivot linear inclination

1)

4

o

— toein, mm 0–3

Tyre inflation pressure

3)

, kPa

(kgf/cm

2

)

— 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
290+10 (3,0+0,1) – for GAZ2310,

GAZ2752 with 215/65 R15 tires

1)

For 4x4 types of vehicles.

2)

For buses GAZ3221, GAZ32213.

3)

For vehicles type 4x2.

4)

Angle values for vehicles of kerb mass are given in brackets, angle values for vehicles of gross

mass are given without brackets.

5)

The parameter is provided (for vehicles of gross mass) by the vehicle design and is not to be

adjusted.

26

Tyre inflation pressure1), kPa

(kgf/cm

2

)
— 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.

27

4. CONTROLS AND INSTRUMENTS

Fig. 4.1. Controls

28

Positions of controls1) are given in fig. 4.1

1. Headlight aiming device control knob depending on vehicle loading

(see subsection 8.7).

2, 11, 13 and 18. Reserve.

3. Warning lamps condition checkup switch.

4. Side ventilation grids.

5. Turn indicator, dimmer and horn2) switch lever. The switch lever has

six fixed positions (from I to VI) and four nonfixed positions “A” (fig. 4.2 and

4.3).
If the lever is in position I and master light switch knob – in position II,

the lower beam is on. When the lever is moved to position II upper beam is
switched on and blue indicator lights up.

Pulling the lever repeatedly from position I along the steering column (non

fixed position) switches on headlamp upper beam for a short time. Depressing
the switch lever button (in any position of the lever) turns on the horn

2)

(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 indicator and dimmer switch

lever

To operate turn indicators move the lever from positions I or II up to posi

tions VI or IV (right turn) or down to positions V or III (left turn). A green
warning light comes on flashing on the instrument cluster. After the turn is
completed the switch lever automatically returns to position I or II. To switch
on turn indicator momentarily shift the switch lever to suitable “A” nonfixed
position. When released the lever returns to position I or II.

6. Ignition (engine control)3), starter and antitheft device switch.

The key positions are given in fig. 4.4.