YaMZ 238 engine

Characteristics of YaMZ-238

Production	"Autodiesel" Yaroslavl Motor Plant
Engine brand	238
Years of release	1962-present
Cylinder block material	cast iron
engine's type	diesel
Configuration	V-shaped
Number of cylinders	8
Valves per cylinder	2
Piston stroke, mm	140
Cylinder diameter, mm	130
Compression ratio	16.5
Engine displacement, cubic cm	14866
Engine power, hp / rpm	235/1700 240/2100 250/1900 280/2100 290/2000 300/1900 320/2100 330/2000 330/2100 330/2100
Torque, Nm / rpm	1108/1300 882/1500 1108/1300 1029/1500 1128/1400 1280/1300 1117/1500 1225/1400 1225/1300 1274/1200
Environmental standards	Euro 0 Euro 1 Euro 2
Turbocharger	K27-49 K36-87 TKR 11 TKR 122
Engine weight, kg	1075 (YaMZ-238M2)
Fuel consumption at a speed of 60 km / h, l / 100 km (for URAL 4320)	38
Oil consumption,% to fuel consumption, up to	0.5 0.2 (Euro 2)
Engine oil: -summer -winter (less than + 5 ° С)	M-10-G2k M-8-G2k
How much oil is in the engine, l	29 (atmospheric) 32 (turbocharged)
Oil change is carried out, hours	500 1000 (Euro-2)
Dimensions, mm: - length - width - height	1315 1045 1070
Engine resource - according to the plant, hours - in practice, thousand km	8 000 800+
Tuning, h.p. - potential - without loss of resource	300+ ~280
The engine was installed	Combines Don, Kuban, Khersonets, Slavutich, Palesse MAZ-5336, 5432,,,, 5552 MAZ-6303, 6317, 6422, 6425, MoAZ-740, 1405, 6014, 6442, 7505 MoAZ-40484, 40489, 49011 KrAZ-260M, 5133, 5444, 6130, 6133, 6305, 6322 KrAZ-6351, 6443, 6446, 6503, 6505, 7133, 7140 EO-412, 511, 512, 522 Ural-4320, 5323, 5423, CHETRA-60, T15, T20, TG-221 Cranex EK400 Unrolling REM25 GT-TM, GT-TMS and MGSH521M1 MT-LBu, MT-LB EKSKO BM-2501 ML-107 TG-301 MZKT-692378 HTZ 181 CHSDM DZ-240S Kirovets К-700, 702, 703, 740, 744 DZ-98V Boats KS-101, 104, 110 AD-100, DGU-100 ADM-1.5, MPG-6 VPR-02, VPRS-02, 03

Reliability, problems and repair of YaMZ-238

The YaMZ-238 series was put into production in 1962 and replaced the YaAZ-206. This engine has a V-shaped 8-cylinder cast iron block, with a camber angle of 90 °, with wet cast iron liners and a cylinder bank offset of 35 mm relative to each other. Inside the block, a forged crankshaft with a piston stroke of 140 mm and a diameter of the main journals of 110 mm and a diameter of the connecting rod journals of 88 mm is installed on 5 supports, the connecting rods themselves are steel, and their length is 265 mm. For these motors, cast aluminum pistons with a diameter of 130 mm and a height of 100 mm, a piston pin diameter of 50 mm were used.

The cylinder block is covered with two cast iron heads with 8 valves each. The diameter of the inlet valves is 61 mm, the outlet valves are 48 mm, the diameter of the stem is 12 mm.
Here, a camshaft gear drive is used, and the camshaft itself is located in the cylinder block and, through pushers, steel rods and steel rocker arms, actuates the valves. Camshaft characteristics: phase 246/266, lift 13.5 mm.
The valves on the YaMZ-238 (turbo and atmospheric) are adjusted after every 500 hours of operation (if necessary). Valve clearances for both inlet and outlet are 0.25-0.3 mm. The order of adjustment is 1–5–4–2–6–3–7–8, the same as the order of operation of the cylinders (both turbocharged and aspirated).
On these engines, direct fuel injection is used from the 80-30 high-pressure fuel pump (on the YaMZ-238M2) or with other pumps (described in detail for the modifications below).
Nozzle pressure 261 - 230 kgf / cm 2; nozzles 267 - 270 kgf / cm 2.
The oil pressure on a warm engine should be in the range of 4-7 kgf / cm 2 (this applies to both turbo and atmosphere).

In addition to atmospheric options, turbocharged ones were also produced, the list of which knows no boundaries. The main differences between them are indicated below.

This motor had a related series YMZ-236.

The production of the 238th continues now, but they are being replaced by the more environmentally friendly YMZ-7511 and YMZ-658.

Modifications of YaMZ 238 and their differences

1. YaMZ-238AK - an analogue of YaMZ-238M2 for Euro-0 standards, which was intended for combines Don, Kuban, Khersonets, Slavutich and Palesse FS60. Power 235 HP at 2000 rpm, torque 932 Nm at 1300-1500 rpm. The service life of the motor before overhaul is 8000 hours.
2. YaMZ-238AM2 - version of YaMZ-238M2 with a power of 225 hp. at 2100 rpm, torque 825 Nm at 1250-1450 rpm. Environmental class - Euro-0, and its resource is 8000 hours.
Stands on MoAZ-6014 and 6442.
3. YaMZ-238B - a turbocharged engine based on YaMZ 238M2, where a TKR 100 turbocharger is used. A modified camshaft with the following characteristics is installed here: phase 240/266, nozzles 261-13, another crankshaft, its own pistons, pump 807-40. The motor complies with the Euro-0 standard.
You can meet him on VPR-02, VPRS-02 and 03; MAZ-5336 and 5432; MoAZ-40484, 40489, 49011 and 7505; KrAZ 5444, 6130, 6503 and 6505; ADM-1.5, MPG-6, EO-5225, Ural 5323 and 5423; CHETRA T20, EK400 and REM25. The resource of the motor is 450 thousand km.
4. YaMZ-238BV - analogue of 238BL, but with injection pump 807-40. Installed on GT-TM, GT-TMS and MGSH521M1. Resource - 8000 hours.
5. YaMZ-238BE - the same YaMZ-238B, but with a built-in liquid-oil heat exchanger and modified cooling and lubrication systems. It uses a YAZDA 807-50 injection pump, 261-13 injectors and a TKR 122 turbine. The boost pressure is 0.93 bar. Power 300 HP at 2000 rpm, torque 1180 Nm at 1200-1400 rpm. The engine meets the Euro-1 requirements.
6. YaMZ-238BE2 - an engine with a different crankshaft and connecting rods, with liners protruding 1.6 mm above the block surface, with other pistons (85 mm high), the piston pin diameter increased to 52 mm. Also used here is a cylinder head with annular grooves, a YAZDA 173-20 injection pump, 267-01 injectors, a camshaft with a phase 233/272, and another coarse fuel filter is used. The power remained the same, and the torque increased to 1274 Nm at 1100-1300 rpm. This option meets Euro-2 standards.
7. YaMZ-238BK is a motor for combines Polesie, which is suitable for Euro-0 standards. It is equipped with a TKR-100 turbine and a high-pressure fuel pump 805-40. The 238BK-3 versions use two K27-49 turbines. The resource of such an engine is 8000 hours.
8. YaMZ-238BL - the same 238B, but with a high pressure fuel pump 801-50, with a deep crankcase and another fan drive. Power increased to 310 hp. at 2100 rpm, torque 1177 Nm at 1200-1400 rpm. Found on MT-LBu.
9. YaMZ-238BN - a turbo engine for MoAZ 7529 with a TKR 100-16 turbine. Power 260 HP at 2000 rpm, torque 1080 Nm at 1200-1400 rpm. Service life - 8000 hours.
10. YaMZ-238VM - analogue of YaMZ-238M2 with a different oil pan. Intended for MT-LB. Serves up to overhaul 5000 hours.
11. YaMZ-238GM2 - the same YaMZ238M2, but with a differently regulated fuel (TNVD 809-20). Power reduced to 180 hp. at 1700 rpm. It is found on EO-412, 511, 512, 522 excavators and BM-2501 drilling equipment. Service life 5000 hours.
12. YaMZ-238D - the same 238B, but under the YaMZ 202 checkpoint and with a high-pressure fuel pump 806-40. Internal combustion engine resource - 450 thousand km.
Stands on ML-107, TG-301, MZKT-692378, MAZ-53363, 54323, 5552, 6303 and 64229; KrAZ-5133, 5444, 6130, 6322, 6351, 6443, 6505 and 7133.
13. YaMZ-238DE - the same YaMZ-238BE, but with a YAZDA 806-50 injection pump and a boost pressure of 1.08 bar. Power increased to 330 hp. at 2100 rpm, torque 1225 Nm at 1200-1400 rpm. The engine complies with the Euro 1 environmental class and is found on MAZ 5336, 5432, 5516, 5551, 6303, 6317, 6422, 6425 vehicles and on Polesie combines. The declared resource is 800 thousand km.
14. YAMZ-238DE2 - the same 238BE2, but with a YAZDA 173-30 injection pump. Compared to 238DE, the power remained unchanged, the torque reached 1274 Nm at 1100-1300 rpm. Here the ecological class has been increased to Euro 2, and the resource is 800 thousand km.
Such an internal combustion engine is installed on KrAZ 5133, 5444, 6130, 6133, 6305, 6322, 6443, 6446, 6503, 6505, 7133, 7140, as well as on MAZ-5336, 5432, 5516, 5551, 6303, 6317, 6422, 6425.
15. YaMZ-238DI - the same 238B, but with a K36-30 turbine and an 803-30 injection pump.
16. YaMZ-238DK - a combine motor for Don 680M, an analogue of YaMZ-238BK, but the power has been increased to 330 hp. at 2000 rpm, torque 1225 Nm at 1300-1500 rpm.
17. YaMZ-238IM2 - a motor for diesel power plants AD-100 and DGU-100, its resource is 25,000 hours.
18. YaMZ-238KM2 - analogue of YaMZ-238M2, but adapted for operation on MoAZ-1405, 740 and KhTZ 181 equipment. Power 190 hp. at 2100 rpm, torque 687 Nm at 1250-1450 rpm. Internal combustion engine resource - 8000 hours.
19. YaMZ-238L - multi-fuel engine for KrAZ-260M. It is equipped with a TKR-11 turbine and an 801-11 pump.
20. YaMZ-238M2 - the engine that replaced the YaMZ-238M in 1988, its ecological class is Euro 0. The engine is installed on the ChSDM DZ-240S, MoAZ-6442 and 6014.
21. YaMZ-238MS - option for northern latitudes.
22. YaMZ-238N - turbo engine with fuel injection pump 804-21 and TKR 11, power 300 hp. at 2100 rpm, torque 1078 Nm at 1500 rpm.
23. YaMZ-238ND3 is a turbocharged engine based on 238B, which does not have oil-cooled pistons and a liquid-oil heat exchanger. A TKR 11 turbine and a high-pressure fuel pump 805-30 are installed here, and the engine meets the requirements of Euro 0. The engine's motor resource is 8000 hours. Power 235 HP at 1700 rpm, the moment is 1108 Nm at 1100-1400 rpm. There is an engine on the K-700, 702, 703 and DZ-98V.
24. YaMZ-238ND4 - a turbocharged engine with a liquid-oil heat exchanger based on 238ND3. There is a high-pressure fuel pump 805-40, and the ecological class is Euro 0. It is found on K-744, K-703, KS-101, KS-104, KS-110, T15.01, T-221 and Chetra-60. The service life of the motor is 8000 hours, and its output is 250 hp. at 1900 rpm, the moment is 1108 Nm at 1100-1400 rpm.
25. YaMZ-238ND5 - a turbo engine based on 238B-1. It was equipped with an 805-50 injection pump, its own generator, crankcase, crankshaft pulley and had a resource of 8000 hours. Motor power 300 HP at 1900 rpm, torque 1280 Nm at 1100-1400 rpm. They put it on the K-744R1.
26. YaMZ-238ND6 is a Euro-1 turbo engine developed on the basis of YaMZ-238DE. It differs from the parent engine by the generator, crankcase, flywheel, pump 805-60 and a resource of 10,000 hours. Power is 235 hp. at 1700 rpm, the moment is 1108 Nm at 1100-1400 rpm. The engine was on the K-740.
27. YaMZ-238ND7 - 250 hp version. at 1900 rpm, the torque is the same. The 805-70 pump is used here, and this internal combustion engine is installed on the Kirovets and T15.01 tractors, as well as on the TG-221.
28. YaMZ-238ND8 - model with a pump 805-80 for 300 hp. at 1900 rpm, torque 1280 Nm at 1100-1400 rpm. This option is worth on Kirovtsa and it takes 10,000 hours to overhaul.
29. YaMZ-238NP - a motor created on the basis of 238ND2 and is distinguished by a turbine pipe and a generator.
30. YaMZ-238PM - a turbo engine with a TKR9 turbine with a capacity of 280 hp. at 2100 rpm, torque 1029 Nm at 1500 rpm. Replaced with 238B.
31. YaMZ-238FM - the same 238PM, but with oil nozzles, power increased to 320 hp. at 2100 rpm, torque 1118 Nm at 1500 rpm. The motor was replaced with 238D.

Malfunctions YaMZ-238

1. The engine is warming up. Overheating is often caused by a dirty radiator, pump or thermostat. Check and most likely the problem will be right here. If not, then you need to look at the cylinder head gasket and the condition of the heads for cracks.
2. Float turns. The reason is in the injection pump, you need to check how it is adjusted and adjust the idle speed with the screw on the back of it. Another reason is the air in the fuel system.
3. Does not develop momentum. You need to check how the pump is configured, replace filters, look at the fuel system.
4. Twitches at low revs. In this case, you must start with the fuel (pump, injectors, etc.) and with the ignition.
5. Troitus. Perhaps the reason is a lack of fuel and you need to pay attention to the low-pressure fuel pump, fuel filters, injectors or pipes.
6. Stalls or starts and stalls. Check for air leaks, see fuel filters, pump, sometimes something foreign could get into the tank.
7. Knock in the engine. The reasons can be in nozzles, pump, ignition, valves, rings, liners; here you have to open the engine and look.
8. Smokes:
- white smoke- perhaps you have water in the tank or coolant enters the cylinders through a gasket or a cracked cylinder head.
- black smoke- you need to reduce the fuel on the high-pressure pump using the lower power screw, most likely it is unscrewed to the maximum.
- blue smoke- you probably have oil burning.
9. Vibration. The reasons are usually in the flywheel, in the ignition, in the engine mounts, in the propeller shaft, perhaps the crankshaft is not balanced.
10. Will not start. The reason must be looked for in the nozzles and the pump.
11. Cracks in the cylinder head. A typical malfunction for these internal combustion engines and it forms on the valve jumper, but, fortunately, you can try to solve this issue, there are many companies that are ready to restore the head.

Despite the large list of various faults, this is a very reliable and durable motor. YaMZ-238, with adequate care and maintenance, has a resource in practice of 800-900 and even 1 million km.

Engine number YaMZ-238

The number is located in the flywheel area, on the left.

Tuning of YaMZ-238 engines

How to install a turbine

To convert the usual atmospheric 238 into a turbo, you can leave the standard pistons, you can do without oil nozzles, just put a TKR 36-87 turbine with manifolds from YaMZ-7511, make an oil drain and oil supply to the turbine, put 261 nozzles, adjust the injection pump and drive as it is. So you can get 280-300 hp. It will even ride for years without problems, but for higher reliability it is better to replace the pistons with 238B.

Over the entire period of its existence, the YaMZ-238 engine has undergone many modifications, but the basic design has remained practically unchanged. This power unit is considered one of the most reliable and powerful for trucks and agricultural machinery.

The volume of oil in the engine is the most important characteristic, if not observed, normal operation of the unit is impossible. This indicator is closely related to such data as the number of working hours before replacement and the class of lubricants recommended in the instructions.

The Yaroslavl Motor Plant produces a whole line of engines, the prototype of which can be considered the YaMZ 238. The production of this engine began in 1962. It became an improved version of the previously assembled YaMZ 236 (six-cylinder), but for many years both power units continued to be actively used in parallel with each other. The family has many common features: design features, operating principles, and similar technical indicators. Later, YaMZ 530 appeared - four- and six-cylinder in-line engines, both diesel and gas.

The motors of the Yaroslavl plant are used on powerful trucks MAZ, Ural, KrAZ, tractors and combines, river and sea boats, as well as diesel power plants. Due to its reliability and unpretentiousness, the engine is still in demand, its production continues. The newest version of the YaMZ-238 / Euro-0 Turbo is distinguished by the presence of a turbine. In addition to other design improvements, it is equipped with an oil-liquid heat exchanger and a high-pressure fuel pump.

By design, the YaMZ-238 power unit is an eight-cylinder V-shaped two-row body made of low-alloy gray cast iron, the camber angle of this motor is 90 °.

Main design features and technical characteristics:

displacement of the rows of cylinders relative to each other by 35 mm;
working volume 14.85 l;
naturally aspirated;
power from 180 to 240 hp;
fuel consumption (100% power) - 227 g / kWh.

Oils for YaMZ

The strong point of the YaMZ 238 engine is a carefully thought out and trouble-free oil lubrication system for all units. A mixed scheme is used here, its principle of operation is that the main and connecting rod bearings located in the key units of the unit - the camshaft and crankshaft - are lubricated under pressure. Also serviced are the bushings of the upper connecting rod head, the intermediate gear of the oil pump, the bushings of the rocker arms of the valves, the bushings of the pushers and the spherical supports of the rods. The rest of the elements - cylinder mirrors, rolling bearings, gear drives and camshaft cams - do not require as much lubrication and are serviceable by spraying. On the walls of the cylinder block, a system of oil channels is provided for supplying lubricant to the units and filters of the mechanism.

According to the instructions for servicing motors of the 238 series, diesel oil GOST 5304-54 is used. Also, in the accompanying documents, you can find recommendations for the use of motor oil additives that improve the functioning of the oil filled into the engine.

The main elements of the YaMZ 238 lubrication system:

standard gear-type oil pump;
reactive driven centrifugal filter for fine oil purification;
full-flow metal mesh oil filter with replaceable filter element.

Characteristics of filling tanks YaMZ 238

For the YaMZ 238 engine, a mixed type lubrication system with a "wet" sump is used.

To clarify how much oil will need to be poured into the YaMZ 238 engine, you can focus on the size of the unit's filling tanks. In particular, the lubrication system has a volume of 32 liters of oil.

The cooling system of a motor without a radiator requires 20 liters of lubricants. The fuel pump is sufficient with 0.2 liters, the capacity of the air filter is 1.4 liters. The 238 model, unlike the 236, does not have a regulator.

The volume of oil in the YaMZ 238 engine is measured using a special dipstick marked "maximum" and "minimum". At a time, 24-28 liters are poured, while the working volume of the lubrication system of this power unit reaches 32 liters. if during operation the oil pressure in the system is increased to more than 520 kPa (5.2 kgf / cm 2), excess lubricants are returned through the oil line and simultaneously cleaned by filters.

Maintenance and repair of YaMZ 238

Service maintenance of the YaMZ 238 engine is recommended to be carried out after 20,000 - 25,000 km of run. The oil pressure when checking should give indicators of 4-7 kgf / cm2 on a warm engine. The indicator is the same for atmospheric and turbo systems. Changing lubricants is necessary during maintenance according to the schedule, as well as when drips, smoke, knocks appear during engine operation, while the capacity of various systems differs, as well as the replacement times.

You can familiarize yourself with the technology of servicing power units in the repair and operation manual developed by the manufacturer. The complex of mandatory operations during maintenance of the internal combustion engine of the Yaroslavl plant includes the following manipulations:

Change of oil;
checking and replacing filters:
- fine filter,
- coarse filter,
- fuel purification filters,
- an ecofilter for the exhaust system,
- air filter;
adjustment of valves;
cleaning nozzles;
checking and debugging the fuel pump.

Important: The YaMZ 238 engine urgently needs repair if blue smoke appears during operation. This indicates that the lubricant is burning.

Today, diesel power units are actively equipped with trucks, agricultural machinery, tractors and other types of large-sized vehicles. This can be explained by the efficiency and throttle response of a diesel engine. The engine copes well with high loads at low revs. The peak torque is reached at relatively low revs - 1500 - 2000 rpm. Due to this, the power unit is able to "pull" on the bottoms, coping with various resistances without any problems.

In the middle of the last century, the engineers of the Yaroslavl Motor Plant were tasked with designing a power plant that would be competitive with imported diesel analogues. At that time, the YaAZ-204 and YaAZ-206 were already actively used, but in constructive terms for the end of the 50s they were somewhat outdated. Legendary Soviet designer Chernyshev G.D. acted as the author of new developments - first YAMZ-236, and after a more advanced analogue of YMZ-238. The high operational and technical characteristics of the YaMZ-238 contributed to the long life of the motor. Its production continued for 50 years. However, even today, in large numbers on the roads of the post-Soviet space, one can find heavy equipment equipped with this famous motor.

General characteristics

The main difference between the older brother of the YaMZ-238 and the YaMZ-236 is the number of working cylinders. The first for eight cylinders, the second for six. A key role in the engine power supply system is played by a mechanical injection pump. The peculiarity of the diesel engine is one pump section installed on each cylinder. Due to this approach, a uniform combustion of diesel fuel occurs. The injection pump in the design of the YaMZ-238 found its place on the collapse of the engine.

The eight cylinders are arranged in two rows, each with two valves. The piston stroke in YaMZ-236 and 238 is the same - 140 mm, and the diameter of the cylinder itself reaches 130 mm. The motor practically does not overheat due to the effective liquid cooling.

The unit was periodically modified and improved. However, subsequent versions did not differ much from the original assembly. Due to various industrial and military needs, the designers of the Yaroslavl plant increased the power of the installation. Initially it was 235 horsepower, but was soon increased to as much as 420 horsepower. The cylinder liners are made of high-strength cast iron, which significantly increases the maximum possible resource of the power plant.

Other important characteristics of a diesel engine:

Environmental standard - from Euro 0 to Euro 4;
Compression ratio - 17.5;
Valve mechanism - OHV;
Fuel - diesel fuel.

The high performance characteristics of the YaMZ-238 allowed a number of domestic auto giants to equip their developments with this particular engine. YaMZ-238 found its application from MAZ-500 to MAZ-6422, equipped with a power unit a number of KrAZ, KamAZ-5320 vehicles in the period from 1976 to 2000. The same engine is used in the Russian large-class bus - LiAZ-5256. Despite the fact that the production of the 238th engine was discontinued, the car plant continues to produce component parts.

Diesel engine fuel consumption

The fuel consumption of YaMZ-238 on different types of trucks is not constant. The amount of diesel fuel consumed by the installation is in strict correlation with the weight of the vehicle, engine modifications and other key parameters. The need for "power" YaMZ-238 on a KrAZ or MAZ truck will differ from buses equipped with the same version of the installation. However, it is quite possible to trace the pattern in the amount of consumed diesel fuel by various types of cars.

Fuel consumption of the 238 diesel engine on popular vehicles:

KamAZ 5320 - from 30 to 35 liters of diesel fuel per 100 km;
KrAZ - from 38 to 42 liters, depending on the modification;
MAZ - from 33 to 40 liters for every 100 km of track;
LiAZ - from 28 to 32 liters in the urban cycle.

It is possible to calculate the maximum possible engine fuel requirement for a particular car by multiplying the power indicator of the diesel modification by the specific fuel consumption. The figure obtained in theory, as a rule, is several percent higher than the real consumption. The fact is that in practice, the power unit does not constantly operate at its maximum.

It should also be borne in mind that the deviation from the norm of consumption of diesel fuel on trucks increases by about 1.5 liters from each ton of cargo. In addition, the actual indicator of the "appetite" of the car is closely related to such parameters as tire pressure, quality of diesel fuel and engine oil. The specific consumption of the YaMZ 238 engine per hour is calculated taking into account the rated power of the vehicle. The 180 hp non-turbocharged version consumes 20% more fuel than modern turbocharged diesel versions.

In the event of a sharp increase in the amount of diesel fuel consumed by the truck, first of all, it is necessary to diagnose the car. This indicator is significantly influenced by the general technical condition of the vehicle. If there is a significant deviation from the norm without objective reasons - weather conditions, high workload - it is important to inspect the car as soon as possible for various defects. Low system pressure, imbalance and abnormal tire pressure are all factors that contribute significantly to overall fuel consumption.

Service life and maintenance of the YaMZ-238 diesel engine

The practice of operating vehicles equipped with a YaMZ-238 engine shows that it is an extremely reliable and unpretentious power unit. There are many examples of how a diesel engine covered 850 thousand kilometers before the first overhaul. A stunning installation resource was achieved due to the use of simple but extremely effective technologies during the manufacture of the engine. The two cylinder heads installed on the unit are made of cast iron, and the camshaft is made of steel. The liners are made of durable cast iron, which significantly increases the possible service life of the motor. Fuel equipment YaMZ-238 is still considered one of the most advanced trucks in the world. It is a plunger type with a self-adjusting centrifugal clutch.

In order to exhaust all the potential laid down in the engine by the manufacturer, it is necessary to adhere to simple maintenance rules for YaMZ-238:

Change engine oil periodically;
Adjust the valve train;
Replacement of consumables: fine and coarse filter, air and fuel filters;
Clean the fuel injectors in a timely manner.

According to the manufacturer's recommendations, scheduled maintenance should take place at least once every 20-25 thousand kilometers. Drivers who comply with the maintenance regulations managed to fully develop the entire resource of the diesel engine. Since the YaMZ-238 is installed mainly on trucks that are exposed to daily heavy loads, it is recommended to service the engine daily.

After the end of the work shift, the driver's primary task is to check the condition of the power unit, to make sure that the factory operating and technical characteristics are intact. Subject to all the above recommendations, the YaMZ-238 will be able to cover up to 1 million kilometers.

Typical malfunctions

Despite the almost perfect design of the engine, its resource and a large margin of safety of the main working units and assemblies, some malfunctions are inherent in the diesel engine. However, all these problems are observed on other diesel units operating in the territory of the post-Soviet countries. The following breakdowns often occur during the operation of a diesel engine:

Malfunction of the high pressure fuel pump due to low quality diesel fuel;
Contamination or wear of the gas distribution mechanism due to untimely replacement of the oil filter and the use of an unsuitable lubricant;
The formation of cracks and chips on the bearings of the crankshaft due to excessive high loads;
Wear and formation of defects on the surface of the piston rings.

However, replacing any component of the engine will not be difficult. The work can be performed either independently or by a specialist in the field of diesel power units. YaMZ-238 is a common motor, thoroughly studied by craftsmen. Its maintenance and repair is relatively inexpensive due to the vast number of spare parts and components on the Russian automotive market.

At the same time, the engine is easy to overhaul. It is possible to extend the duration of its work even after overcoming 800 thousand kilometers. The cylinder block and crankshaft lend themselves to boring, and the liners are grinded without problems. On average, major repairs cost 150 thousand rubles, the amount may vary, it all depends on the region and the cost of the work. In any case, the cost of overhaul will be significantly less than the cost of purchasing another power plant.

Owner reviews

The high performance characteristics of the engine make it in demand today among various manufacturers of heavy vehicles. Owners of vehicles with a YaMZ-238 diesel engine installed under the hood note the excellent maintainability of the unit, relatively inexpensive maintenance and the availability of the motor. There is no difficulty in finding component parts; it is quite possible to get a power unit in proper condition. The average cost of the engine varies within 350 thousand rubles.

Cars with this power unit are distinguished by high power and reliability. You can read more about the informative reviews of the owners below.

YaMZ-238 is a legendary invention of Soviet engineers. For 50 years of practical use, the diesel unit has proven itself exclusively from the best side. Numerous reviews of the owners confirm the fact of the excellent maintainability of the installation, its inexpensive and easy maintenance. The actual resource of the engine is 12,000 hours, and fuel consumption per hundred on average varies from 30 to 50 liters of diesel fuel. The excellent technical characteristics of the motor ensure the current popularity of the YaMZ-238 and the demand among large automotive enterprises.

Power units are designed for operation at ambient temperatures from minus 60 ° C to plus 50 ° C, relative humidity up to 98% at 25 ° C, dust content up to 0.4 g / m3, as well as for driving in mountainous conditions at an altitude of up to 4500 m above the level sea and overcoming passes up to 4650 m above sea level with a corresponding decrease in power and economic indicators.

Long service life and reliable engine performance depend on timely maintenance.

Maintenance works are preventive, therefore, they must be performed on time.

Daily maintenance is carried out once a day.

Maintenance after engine break-in.

The first maintenance (TO-1) is performed every 500 hours of engine operation.

The second maintenance (TO-2) is carried out after 1000 hours of engine operation.

Seasonal maintenance is carried out prior to winterization and at the transition to summer.

Cooling system

Liquid, closed type, with forced circulation of coolant

Equipped with a thermostatic device for automatically maintaining the thermal mode of the engine

Water pump

Centrifugal type, belt driven

Fan

Six-blade, with a gear drive and a friction clutch for switching on the fan

Liquid-oil heat exchanger

Plate or tubular type. Equipped with a tap or plug for draining the coolant

Thermostats

With solid filler. Opening temperature 80 ° C.

Electrical equipment

Single-wire circuit. Rated voltage 24V

Generator

Alternating current, belt-driven double-strand drive, with a nominal voltage of 28V.

The generator model is determined by the equipment.

Starting device

Electric starter model 25.3708-21 or AZF 4581 manufactured by Iskra (Slovenia), rated voltage 24 V.

The use of the ST-142D starter is allowed.

To facilitate starting a cold engine, an electric torch device is provided

Weight of the unfilled power unit in the scope of delivery, kg:

With individual cylinder heads:

Without clutch and gearbox - 1250

With clutch - 1295

With clutch and gearbox - 1685

With common cylinder heads:

Without clutch and gearbox

YAMZ-238BE - 1180

YAMZ-238BE2 - 1215

YAMZ-238DE - 1180

YAMZ-238DE2 - 1215

With clutch

YAMZ-238BE - 1225

YAMZ-238BE2 - 1260

YAMZ-238DE - 1225

YaMZ-238DE2 - 1260

With clutch and gearbox

YAMZ-238BE - 1580

YAMZ-238BE2 - 1615

YAMZ-238DE - 1580

YAMZ-238DE2 - 1615

Refueling capacities, l:

lubrication system - 32

cooling system without water radiator volume - 22

lead clutch injection - 0.14

	Powertrain models

engine's type	Four-stroke with compression ignition and turbocharging
Number of cylinders
Arrangement of cylinders	V-shaped, camber angle 90º
The order of the cylinders
Direction of rotation of the crankshaft
Cylinder diameter, mm
Piston stroke, mm
Working volume, l
Compression ratio
Rated power, kW (h.p.)
Crankshaft speed at rated power, min -1
Maximum torque, Nm (kgfm)
Rotational speed at maximum torque, min -1
Idling speed, min -1: Maximum, no more Minimum
Specific fuel consumption by speed characteristic, g / kW h (g / h.p. h): Minimum At rated power
Specific oil consumption for waste in% to fuel consumption, no more
Mixing method	Direct injection
The combustion chamber	Unseparated type in piston
Camshaft	One for both rows of gear-driven cylinders
Gas distribution phases: intake valves Opening, deg. to TDC Closing, deg. after NMT exhaust valves Opening, deg. to NMT Closing, deg. after TDC
Number of valves per cylinder	One inlet and one outlet
Thermal valve clearances on a cold engine, mm
Lubrication system Mixed, with oil cooling in a liquid-oil heat exchanger: Under pressure, the bearings of the crankshaft, camshaft, pushers, rocker arm shafts, spherical surfaces of the pusher rods are lubricated, high pressure fuel pump, turbocharger. The rest of the rubbing surfaces are spray lubricated.
Gear type oil pump, single section
Oil pressure on a warm engine in the block line, kPa (kgf / cm 2): At rated speed At the minimum speed, not less	400 - 700 (4 - 7)
Oil filters Two: full-flow purification filter with filter element and centrifugal filter
Oil cooling system With a liquid-oil heat exchanger, which is installed on the engine block on the left
Oil pressure of opening lubrication system valves, kPa (kgf / cm 2): Oil pump pressure reducing valve Differential valve Oil filter bypass valve	700 - 800 (7,0 – 8,0) 490 - 520 (4,9 - 5,2) 200 - 250 (2,0 - 2,5)
Fuel supply system	Split type
High pressure fuel pump (TNVD) with a regulator and fuel priming pump	Eight-section, plunger, spool-type plungers: Plunger diameter 10 mm, plunger stroke 11 mm - YAMZ-238BE, YMZ-238DE; Plunger diameter 12 mm, plunger stroke 14 mm - YAMZ-238BE2, YMZ-238DE2

Main parameters and characteristics
Injection pump model		(238DE-1, -5, -10, -11)	(238DE2, -1, -3, -5, -8, -11)
The order of operation of the fuel pump sections
Speed regulator	Centrifugal, all-mode
Fuel priming pump	Piston with a manual fuel priming pump
Injectors	Closed type with multi-hole nozzles: 261.1112010-11 on engines YAMZ-238BE, YAMZ-238DE; 267.1112010-02 or 204.1112010-50.01 on engines YAMZ-238BE2, YaMZ-238DE2 with common cylinder heads; 51.1112010-01 on YaMZ-238DE2 engines with individual heads
Pressure of the beginning of injection of the nozzle, MPa (kgf / cm 2)	20,6+0,8 (210+8) - 261.1112010-11 26.5 + 0.8 (270 + 8) - 267.1112010-02 and 26.5 + 1.2 (270 + 12) - 204.1112010-50.01 26,5+1,2 (270+12) - 51.1112010-01
Installation angle of advance of injection of fuel	It is installed according to the marks on the flywheel and the injection pump housing and is: 13º ± 1 - on engines YAMZ-238BE, YMZ-238DE; 6º ± 1 - on engines YMZ-238BE2, YMZ-238DE2 with common heads; 8º ± 1 - on YaMZ-238DE2 engines with individual heads
Fuel filters: rough cleaning fine cleaning	With replaceable element (YAMZ-238BE, DE), sump (YMZ-238BE2, DE2). With replaceable filter element. There is a bypass nozzle valve on the cover. Opening pressure of the nozzle valve 20 ... 40 (0.2 ... 0.4) kPa (kgf / cm 2)
Pressurization system	Gas turbine, one turbocharger, with radial centripetal turbine and centrifugal compressor
Turbocharger (TKR)	Model 122 or TKR 100 *
Boost pressure (excess) at nominal operating mode, kPa (kgf / cm 2)

* - the turbocharger is similar in design to the TKR model 122

Diesel engines in the modern world are installed on trucks, tractors, agricultural vehicles and tractors. The domestic analogue of reliable foreign motors is the YaMZ-238. It is installed on such well-known vehicles as MAZ, KRAZ, KAMAZ, ZIL, DON, K-700 and other vehicles. Of course, the engine was originally intended for Minsky's products.But over time, it proved that the YaMZ-238 engine, whose technical characteristics are high, is the best diesel engine in the USSR and the post-Soviet space, and can easily compete with such well-known brands as MAN and DAF.

General information

YaMZ-238 replaced the outdated YaAZ-204 and YaAZ 206 engines. It was developed in the 50s by the legendary Soviet designer GD Chernyshev, who was also the author of YaMZ-236.

This engine has gained its popularity due to its reliability and compatibility with many cars and tractors. 65 years have passed since the creation of the first motor, and the popularity of these engines has only increased. The ease of operation, repair and maintenance made YaMZ-238 an indispensable assistant to many agricultural and construction companies that use this engine in their cars.

Of course, over the years of development and implementation of new technologies, this engine has received many modifications, but the basic structure has not changed, only adjustments have been made to the overall design.

Specifications

Consider the YaMZ-238 engine, the technical characteristics of the motor.

The engine has a V configuration with 8 cylinders arranged in 2 rows. 16 valves ensure perfect injection and discharge. Like the 236, the piston stroke is 140 mm, the cylinder is 130 mm in diameter. The liquid cooling system of the YaMZ-238 engine provides maximum effect and does not allow the engine to overheat.

The working volume is 14.866 liters, and the power, depending on the modification, can be 235-420 horsepower. The YaMZ-238 engine, whose technical characteristics allow in some cases to develop power up to 500 horsepower, is installed not only on the recommended equipment, but also on cars with other design data. Also on the new modifications, turbocharging is used, which gives even more confidence and traction during operation.

Device

TNVD YaMZ-238 is a fuel pump, which can be called a fuel station. It is located in the collapse of the power unit and supplies fuel to each cylinder separately, and the injection is performed directly.

The engine has two heads of the block, which are made of cast iron. steel, manufactured using stamping technology. The main power unit is made of cast iron, and is made from a hardened workpiece by turning.

The injection system is designed so that the YaMZ-238 injection pump supplies fuel under pressure to the injectors that inject. The fuel equipment on this engine is considered one of the most advanced in the world. The type of this system is plunger, it has a centrifugal clutch, which itself is regulated.

The pistons are cast from high-strength aluminum, which allows them not to break under heavy loads. Each of them has 1 oil scraper ring and 3 compression rings.

The YaMZ-238 engine, the technical characteristics and design of which is reliable and simple, has a motor life of 800 thousand km, and with proper maintenance it can reach 1 million km.

Installation on other vehicles

The YaMZ-238 engine, the technical characteristics of which are high, can be installed on other vehicles. So, cargo, construction and agricultural equipment were subjected to alterations. For example, KAMAZ with a YaMZ-238 engine showed itself very well, which made it possible to reduce fuel consumption, in contrast to the original Kama engine.

Of course, on many cars it was necessary to redo the fasteners of the power unit, install a different gearbox, but all this was justified in the process of operation and repair.

Repair

Repair of the YaMZ-238 engine is quite easy if you give it to specialists in this field. The main problem remains the search for spare parts, but many manufacturers provide an opportunity to choose from a wide range. With the onset of the crisis, the pricing policy has grown, but less than for foreign-made motors.

Consider which spare parts are changed more often when overhauling the YaMZ-238 engine undergoes. Technical characteristics in this case also play a very important role, since there are several generations of the motor, and therefore there is some dissimilarity. So, let's list the list of spare parts:

Crankshaft and camshaft oil seals.
K / shaft bearing.
Sleeve sets (piston, pin, sleeve, rings).
Connecting rod bushings.
Exhaust and inlet valves.
Valve seats.
Guide bushings.
Valve oil seals.
and connecting rod.
Filters.
Butter.
Gasket set.
And other small details.

During repairs, the crankshaft is usually bored to fit the repair dimensions, and the cylinder head planes are ground. The average cost of a YaMZ-238 overhaul is about 80,000-100,000 rubles, depending on the region and the selected spare parts. It's cheaper than buying a new engine.

Service

It is quite easy and simple to maintain the YaMZ-238 engine (the technical characteristics of which have high results). So, regular replacement of oil and filters will allow not only to develop a full working life, but in some cases to surpass it. Consider what needs to be changed with regular maintenance:

Oil in a volume of 25 liters. That is how much is poured into this motor. By the way, such lubricants as M10G2K and M10DM are ideal for this diesel engine.
Oil filter. Depending on the design and modification, it can be of different sizes and types.
Fuel filters, which must be replaced without fail, since the quality of domestic fuel leaves much to be desired.
Repair kits for coarse and fine fuel cleaning.

In some cases, it is required to read the injectors and the high pressure fuel pump.