In 2001, the Zavolzhsky Motor Plant began to produce new type engines - ZMZ 409. Similar power units are still installed in almost all cars manufactured in Ulyanovsk. The motor is the heir to the ZMZ 406 power unit, at the same time, it should not be considered as the next step in evolution.
To a greater extent, this is a parallel stage in the development of ZMZ motors. Although a number of innovations that have shown themselves from the worst side have been finalized in the new model. At the moment, there are a large number of modifications of the power unit, while it is constantly being upgraded.
Even at the first stages of development of the previous version of ZMZ (406), everyone understood that it was unlikely that it would be possible to create an engine that would be equally relevant for all machines. Nevertheless, the goal was set, so they began to strive for it.
Thus, they saw a huge potential in the motor, which would allow not only to constantly improve it, but also to create new devices based on the 406 power unit. This is especially true for large and heavy Vehicle who need a big moment already with low speed. However, this model could not provide such indicators. As a result, ZMZ 405 and 409 were born, which were distinguished by their increased volumes.
Like its predecessor, the 409 engine was distinguished by a tented combustion chamber, four valves per cylinder with spark plugs in the central part, as well as microprocessor-controlled ignition and a fuel injection system. Operation requires A-92 gasoline, compression level ninth.
An aluminum alloy is used to make the block head. At the same time, it is cast. In the early periods, one head was used for all types of power units. However, over time, the motors have undergone modernization, as a result of the changes, each engine received its own head. If we talk about the 409 model, then in this case it was made an order of magnitude smaller (weight decreased by 1.3 kilograms), while it does not have idle channels. In addition, they made an electronically controlled throttle. In addition, manufacturers got rid of:
- idle speed controller with its own channel;
- throttle pipe;
- damper position sensor.
In addition, there was no longer a need for a throttle heating function, so they also got rid of the pipes that were responsible for cooling the throttle. But they added fasteners for the front motor cover (they can be found near the head).
Engine ZMZ 409 UAZ Patriot: specifications
If speak about key features model, it is worth emphasizing the presence of hydraulic expansion joints of thermal gaps (their other name sounds like hydraulic pushers). Thus, there is no need to adjust the valves. The gas distribution mechanism is two-shaft. There are separate shafts for intake and exhaust. Since they are made of cast iron, the elements are distinguished by their reliability.
The shaft drive remained unchanged, it is carried out through a two-stage chain drive and intermediate shaft, at the same time, the hydraulic tensioners have changed (they are filled with asterisks). This is one of the most important innovations, since now it is much easier for owners of cars with a 409 engine (UAZ Hunter, Patriot, etc.) to independently improve the unit. But to be completely fair, it is important to say that shoe tension also had its fans, since this type of construction is cheaper and easier to repair.
The cylinder grew slightly in diameter. If earlier it reached 9.2 centimeters, now this figure is 9.55 cm. A similar part is also used for the 405 model, where the volume of the power unit is 2.46 liters.
To increase the volume in the 409 models, they changed the stroke of the connecting rod. At the same time, the 405 engine was invented a little earlier, so that all the main malfunctions that arose there were eliminated when the 409 modification was released. As a result, various shortcomings here are many times less.
In the process of manufacturing the crankshaft, only cast iron, marked as VCh60, is used, while it is mounted on 5 supports. Self-compressing glands are used as seals at both ends of the element. Both the supports themselves and the covers that are attached to them undergo special processing and fitting. As a result, each of them must be installed strictly in a specific place. Bearings are made from an alloy of steel and aluminum. In fact, they remained the same as in the older counterpart. To reduce the deformation of the shaft due to centrifugal and bending forces, four counterweights are used. The diameter of the main journals is 6.2 cm, the connecting rod journals are 5.6 cm.
Connecting rod features:
- forged steel;
- section - two-tee.
In principle, everything is exactly the same as in the case of other motors from this line.
Aluminum is used in the manufacturing process of pistons. Equipped with 3 rings (2 compression and 1 oil scraper). In the bottom, you can find samples, by virtue of which the possibility of contact between pistons and valves is prevented during a violation of the phases of the gas distribution mechanism. It is worth noting that the pistons here are not the same as in other models.
If we talk about the features of the UAZ 409 engine lubrication system, then it is a full-flow combined one. The process of lubricating bearings and bushings occurs under pressure, but lubricant is sprayed onto the cylinder walls. A single-section gear device is used as a pump, which remains the same. No changes are observed on the pump drive side either.
As for the cooling system, it is:
- liquid;
- closed type;
- with an expansion tank;
- circulation type - forced.
It strongly resembles the 406 model, while the channels have changed (in shape and location). As for the crankcase ventilation, it is of a closed type, it is forced. The whole process is carried out by vacuum in the intake. If we talk about new modifications, then the gases are drawn directly into the receiver.
The ignition is now microprocessor controlled. At the same time, the principle of its operation is somewhat different from the usual for Zavolzhsky motors (1–3–4–2).
Engine resource UAZ Patriot
It is worth noting that this power unit, according to manufacturers, will serve 200-250 thousand km. However, these data relate exclusively to ideal conditions, which do not exist in real life. Since the main cars that are equipped with such a motor are classified as SUVs, the operating conditions here are clearly not the easiest (for those who like to go off-road, you can safely divide this figure by 1.5-2 times). Like other power units from the line, it is possible to spend 3 overhaul until power device completely exhausted its resources.
Applications
Such a device is distinguished by its prevalence. The motor is most in demand at the UAZ automobile concern, which, together with the rest of the units, installs it on its own popular models auto. Including, this includes: Bars, Hunter, Loaf - 409 engine can be seen on these and many other vehicles from a domestic manufacturer.
Key modifications
In principle, by the standards of ZMZ, they began to produce a power unit not so long ago. At the same time, quite a lot of modifications were made during this period. this motor. Basically, all these changes are aimed at fixing minor problems, as well as improving the consumer qualities of the device. Thus, in the very last engine UAZ Patriot 409 (EURO 4 engine) complies with all environmental standards of this type. At the same time, the manufacturer clearly does not intend to stop there. As a result, an improved model can be expected soon, which will be executed based on EURO 5.
Among the main varieties of the 409 model, it is worth highlighting:
- 409.10. It is made in such a way as to fully meet the environmental requirements of EURO 2. In horses, the power reaches 142.8;
- 4091.10. Production started in 2007. Eco standard is already higher (EURO 3). Capable of producing 125 horses. Installed in cars, which are commonly called "Loaf";
- 4911.10. The release started in 2012. Used in the same place (Loaves and Tadpoles). The power hasn't changed either. The main innovation is the presence of a sensor absolute pressure, as well as the gear timing chain;
- 40904.10. Goes to modern SUVs. There is also an absolute pressure sensor. 142.8 horsepower;
- 40905.10. There is nothing new, the only thing is that it now functions in accordance with EURO 4.
A small summary
So, motorists who gave their preference trademark UAZ, have been waiting for more than one year to update the power unit in SUVs and other cars. Partly, the 409 lived up to these expectations. On the one hand, you can argue a lot about the fact that the motor is not perfect, but on the other hand, it performs its duties very well. Excellent torque performance, the possibility of inexpensive repairs (even with your own hands), high reliability and the availability of components - all this clearly speaks in favor of such a power unit.
At the same time, it also has some disadvantages. First of all, we are talking about poor elasticity during off-road travel. Yes, and it is expensive to maintain, because bad gasoline and poor quality oil doesn't fit anymore. In addition, the repair process became more complicated, although it did not become super complicated.
But it takes less fuel, is more predictable in operation, and if it is serviced in a timely manner, no intermediate adjustments will be necessary. In addition, there will be excellent potential for further improvement, including in terms of environmental friendliness.
Summing up, it is worth saying that the ZMZ 409 is not the most ideal option for heavy frame SUVs. It contains various malfunctions and breakdowns in work. At the same time, we can safely say that it is a good option if you choose a model that would combine well acceptable price and enough good performance. Despite the fact that it largely inherits the previous versions of ZMZ, this model of the power unit turned out to be new and original. And this applies not only to passport data, but also to the nature of the engine.
Many are familiar, because it can be easily found on the UAZ Patriot, for example. The motor does not scold only the lazy. Low power with a volume of 2.7 liters, high flow fuel, a complex timing system with chain drive and 16 valve mechanism. They tried to modernize the 409 motor more than once. Recently, another version of the 409 ZMZ motor has appeared, this is the ZMZ PRO. Essentially the same in-line 4-cylinder 16-valve gasoline-powered engine. But according to its creators, this is a real breakthrough. After all, the power was brought up to 149 hp. with the possibility of increasing up to 160 horses! Torque has increased to 235 Nm.
In addition, ZMZ PRO will be offered from the factory in two versions at once - gasoline and gasoline / gas. Liquefied gas (propane-butane) available everywhere will be used as a gas motor fuel. It was possible to increase the power due to the lightweight piston group, increasing the compression ratio of the valve timing changes.
Characteristics of the ZMZ PRO engine (ZMZ 409-051)
Displacement - 2693 cm3 Number of cylinders - 4 Number of valves - 16 Bore - 95.5 mm Stroke - 94 mm HP - 149.6 at 5000 rpm Power kW - 110 at 5000 rpm Torque - 235 Nm at 2650 rpm Compression ratio - 9.8 Timing drive - chain Fuel type - gasoline AI 92Characteristics of the ZMZ PRO engine (ZMZ 409-052)
Displacement - 2693 cm3 Number of cylinders - 4 Number of valves - 16 Bore - 95.5 mm Stroke - 94 mm HP - 143 at 5000 rpm Power kW - 105 at 5000 rpm Torque - 227 Nm at 2650 rpm Compression ratio - 9.8 Timing drive - chain Fuel type - gasoline AI 92 / Gas (propane-butane) In September 2017, in Moscow, at the Crocus Expo exhibition complex, the International Exhibition of Commercial Vehicles Comtrans 2017 was held. At this exhibition, UAZ showed a new commercial vehicle UAZ-Profi in which it is installed new engine ZMZ-PRO. The new engine is naturally a good (hopefully) reworked old ZMZ-409.
With this degree of compression, 95th gasoline is supposed to be poured into it. Which is not very good for commercial vehicles. But there was a modification Gas-Gasoline. Such an engine bears the abbreviation ZMZ-409052. The equipment is Italian, the brains are accordingly tuned to the dual-fuel mode.
The single-row chain, which was torn on the Patriots, was finally changed to a double-row one. (who remembers, the two-row chain was at EURO-3, they returned, so to speak) The tension shoes were gone and sprockets appeared again. INA hydraulic tensioners, ELSE will break this chain too :)
The rollers are also imported. The pan gasket is now metal. This is to prevent oil leakage.
New valves. The valve timing has changed. The gearbox was "adapted" to the new engine. But what exactly has changed - is still unknown. Installed a warranty on the engine for 2 years or 200 thousand km. Wait and see!
Manufacturer Features and Expectations
ZMZ expects success from ZMZ engine Pro. This power unit should be the best in the entire line. As it became known, GAZ plans to resume production of the Volga and wants to install the new 409th engine on the updated passenger version. It should be understood that these are just unconfirmed rumors that may not come true. The new ZMZ 409 Pro will be installed on cargo options vehicles of the Ulyanovsk Automobile Plant. If the engine becomes successful, then this could significantly undermine the sales of the Gazel NEXT, because it was not for nothing that the engine began to be called the “Gazelle killer”. But let's wait and see what happens. The mass production and operation of the ZMZ 409 Pro engine will show how successful the manufacturer's expectations and promises will be. So far, one can only assume that the designers took into account the bitter experience of their elder brother and really modernized the motor, which brought it closer to international quality and standards. The preliminary rating of the power unit is 7 out of 10 points.READ ALSO ON THE SITEHonda NR500 8 valves per cylinder with two connecting rods per cylinder, a very rare, very interesting and quite expensive motorcycle in the world, Honda racers were smart and tricky))) About 300 pieces were produced and now prices ... In 1989, Toyota introduced a new engine family, the UZ series, to the market. Three engines appeared in the line at once, differing in cylinder displacement, 1UZ-FE, 2UZ-FE and 3UZ-FE. Structurally, they are a V-shaped figure-eight with... UZAM-412 is a Moskvich 412 gasoline engine, which has established itself as a reliable and durable power unit, which is economical and easy to maintain. This motor has lasted on the assembly line from 1966 to the present. For this... |
Diesel vehicles are becoming more and more popular. There are many reasons that guide car owners when buying a car with a diesel engine. It should be borne in mind that any technique can fail and require its restoration. Repair of a diesel engine has its own characteristics compared to gasoline.
th system In the cold season - getting into fuel system of water with subsequent freezing Clogging and other malfunctions of the fuel system Reduced compression in the cylinders Burning or jamming of the valves in the seats Destruction of the valve springs In the cold season - malfunction of the glow plugs Failure of the injection pump The engine starts, but stalls after a few seconds HPFP Critical clogging fuel filters The engine stalls when the load increases Water ingress into the fuel Injection pump failure Clogged fine fuel filter Engine stalls for no apparent reason Blockage of the fuel lines due to excessive clogging Breakage of the fuel lines Engine stalls when overloaded Piston stuck in the cylinder Jamming crankshaft Destruction of piston rodsSelf-diagnosis and typical malfunctions of gasoline engines
Almost all new cars today are equipped with on-board computers, which control the operation of the engine, as well as generate and store error and malfunction codes. However, the computer generates fault codes only for the electronic part of the control system, ignition system and other systems in which electronics are involved. AND mechanical failures engine, such as wear, broken parts, etc., is diagnosed only by visual inspection, listening to the operation of the engine, and other external signs.
drives, etc. Now you can start the engine and after it warms up and enters the operating mode, look at the exhaust gases, their color can tell a lot about the state of the power unit. White exhaust. White color indicates the presence of water vapor in the exhaust gases. White exhaust is quite normal for the first minutes of starting the engine, especially in cold weather (since the settled inside evaporates exhaust pipe and muffler condensate), but if such an exhaust remains even after the engine warms up, then this indicates that coolant has entered the cylinders. The white color of the exhaust is given by the steam that occurs due to the presence of water in the coolant. Typically, this situation occurs when cracks appear in the cylinder block or when the gasket between the block and the cylinder head burns out. However, sometimes white smoke from the exhaust pipe has a bluish tint, which also occurs when oil enters the cylinders. Therefore, it is necessary to make sure that white exhaust formedThe engine is one of the most important and complex units in a car. Modern motors are very reliable and efficient, however, under the influence of mechanical and thermal loads, as well as for other reasons, various faults. About breakdowns of gasoline and diesel engines, their causes and solutions are described in this article.
engine operation periods, the SW includes various measures; . TO-1000 - carried out on a new car with a mileage of 500 to 1000 km; . TO-5500 - carried out on a new car with a mileage of 4500 to 5500 km; . TO-1 (first TO) - carried out on a new car with a run of 10-11 thousand km, then TO-1 is carried out every 4-10 thousand kilometers (depending on the car); . TO-2 (second TO) - carried out on a new car with a mileage of 15.5-16.5 km, then TO-2 is carried out every 12-24 thousand kilometers (depending on the car); . Seasonal maintenance (SRT) - carried out twice a year at the change of season, usually in spring and autumn. Activities that are carried out at each type Maintenance, may differ for different cars, so here we will briefly talk about the most important of them. EO includes: . Check withThe main manufacturers of passenger engines in Russia
It is generally accepted that in Russia now they produce little equipment, which, moreover, has an extremely low quality lagging behind the quality of foreign samples. However, everything is far from being the case: now our country has developed mechanical engineering, including engine building for various industries: automotive, tractor, shipbuilding, aircraft building, production of generator equipment, etc. And there are now at least three dozen factories producing motors in Russia.
Z-2111i Injection gasoline engine with a volume of 1.5 liters and a power of 77 hp. It is used in the same models of VAZ cars as the VAZ-21083 engine. VAZ-21114i Petrol injection engine with a working volume of 1.6 liters and a power of 81.6 hp. It has the most wide application on front wheel drive vehicles models from VAZ-2109 to VAZ-2112, as well as on Lada Kalina. VAZ-21116i One of the new injection gasoline engines, has a volume of 1.6 liters and a power of 90 hp. It is used on Lada Granta cars. VAZ-21124i Petrol injection engine with a volume of 1.6 liters and a power of 89 hp. One of the relatively new modifications for cars VAZ-2110, VAZ-2111 and VAZ-2112. VAZ-21126i Injection gasoline engine with a volume of 1.6 liters and a power of 98 hp. It is used for installation on a Lada Priora car. VAZ-21128i Powerful injection engine with a volume of 1.8 liters and a power of 105 hp. It is used for installation on VA vehiclesSOHC and DOHC engines: two against one
Choosing new car, the buyer may be faced with an unusual task at first glance: to take a car with a SOHC or DOHC engine? About what these abbreviations mean, how these engines differ, and what advantages and disadvantages they have - read in this article.
about half a century ago, and today there are several varieties of engines of each design. SOHC Engines Powerplants with a single overhead camshaft experienced the peak of their popularity back in the 60s and 70s of the last century, but they are still being installed in economy class cars today. There are three schemes according to which the SOHC timing belt is implemented, they differ in the type of drive and valve arrangement: - Valve drive using rocker arms that are pushed by the camshaft cams. The valves are located in a V-shape on both sides of the shaft; - Valve drive by levers, which, in turn, are pushed by camshaft cams. The valves are arranged in a row; - Valve drive with pushrods, which are located directly under the camshaft. Valves are arranged in a row. The scheme with rocker arms is simple. The rocker arms are mounted on an axle on which they can swing freely. On the one hand, they rest against the valve stems, on the otherZMZ engines: modifications, characteristics
OJSC "Zavolzhsky Automobile Plant" is one of the leaders among Russian manufacturers internal combustion engines. To date, the plant produces engines of more than 80 different modifications.
Its engine capacity is 2.445 liters. ZMZ-402.10 is installed on cars belonging to the middle class. ZMZ-4026.10 is designed for installation on trucks small load capacity. Engine ZMZ-4021.10, ZMZ-4025.10 This engine, which has the same characteristics as ZMZ-402.10, is distinguished by the possibility of using cheaper fuel, which makes it attractive to residents of rural and remote regions, where it is difficult to find high-quality fuel. ZMZ-4021.10, equipped with an exhaust gas recirculation system, is installed on SUVs and middle-class cars. ZMZ-4025.10 is suitable for light trucks. Engine ZMZ-4104.10 Petrol carbureted engine has 4 cylinders arranged in a row. It is distinguished by high torque and increased power. Improved performance was achieved by increasing the volume of cylinders to 2.89 liters. Engines ZMZ-UAZ engine: reliable heart of the best SUV
UAZ is the first and only domestic SUV that has been in demand for half a century and has been successful in Russia and abroad, and this is due to its engine. And what engines are now installed on UAZ vehicles? What parameters are they characterized by, how do they differ and how long can they work? Read about all this in this article.
installations that are currently operating in all new models of UAZ vehicles. Engines of the Zavolzhsky Motor Plant (ZMZ) Zavolzhsky engine plant(the city of Zavolzhye, Nizhny Novgorod Region) offers wide choose engines for UAZ, including engines of ecological classes "Euro-3" (release has been established since 2008) and "Euro-4". The line includes both traditional carburetor and modern injection engines. All ZMZ engines are four-cylinder. Carburetor: - ZMZ-402.10 (92 hp); - ZMZ-402.17 (92 hp, modification for tropical climate); - ZMZ-4104 (96 hp). Injection: - ZMZ-409 (143 hp); - ZMZ-40904 (143 hp, "Euro-3"); - ZMZ-4091 ("Euro-2", "Euro-3"); The most widespread various modifications engines ZMZ-40904, which are currently installed in UAZ vehicles "Hunter", "Patriot" and others. ZMZ-4091 engines are installed mainly on UAZ-3741 ("TabThe ZMZ-409 engine was created on the basis of the th motor, or rather, on the basis of its successor ZMZ-405. The 405th block is used (the height of all blocks 405, 406, 409 is the same), the crankshaft with an increased stroke (from 86mm to 94mm), the connecting rods remained old, the pistons were changed, with an offset of 4mm.
Engine modifications ZMZ 409
1. ZMZ 409.10 - the main motor, corresponds to environmental standard Euro 2. Power 143 hp
2. ZMZ 40904.10 - an analogue of 409.10 with a new CPG, new gaskets, DBP, complies with the Euro-3 environmental standard. Power 128 hp It is put on the Patriot, Hunter, Pickup, Cargo.
3. ZMZ 40905.10 - analogue of 40904.10, compliance with the Euro-4 environmental standard. Power 128 hp It is put on the Patriot, Hunter, Pickup, Cargo.
4. ZMZ 4091.10 - derated lower version of ZMZ 40904.10, another receiver, camshafts (lift 8, phase 240), firmware, complies with the Euro-3 environmental standard. Used on UAZ loaves. Power 112 hp
5. ZMZ 40911.10 - an analogue of ZMZ 4091.10, DBP, complies with the Euro-4 environmental standard. Used on UAZ loaves. Power 112 hp
6. ZMZ 4092.10 - non-serial motor. Power 160 hp Used on the Volga.
Marking engines ZMZ-409
The engine identification number (VIN) is marked in one line on the machined surface of the cylinder block platform, located on the left side above the front engine mount lugs.
At the beginning, end and in between constituent parts identification number is indicated by a separating character in the form of an asterisk. Above identification number The engine block number may be stamped or stamped on a self-adhesive label. On the valve cover there is a self-adhesive label indicating the engine configuration.
Descriptive part - VDS marking of the engine(consists of six characters):
1 - designation of the engine model (consists of five digits);
2 - zero is always indicated;
Pointing part - VIS engine markings(consists of eight characters):
3 - code of the year of manufacture (number or letter of the Latin alphabet): "D" - 2013, "E" - 2014, "F" - 2015, "G" - 2016, "H" - 2017, "J" - 2018, " K "- 2019, "L" - 2020 ... "Y" - 2030 (except for the letters "I, O, Q, U");
4 – digital code assembly division of the engine manufacturer;
5 – serial number engine
| Designation of the descriptive part /VDS/ of the identification number of the engines of OAO ZMZ when marking them | ||
| Full designation of the engine according to the design documentation | VDS | Characteristic features of the completeness and execution of the engine |
| 409.1000400 | 409000 | Basic completeness in the version "U2" in accordance with GOST 15150-69 with KMPSUD type "Mikas 7. 2", with a piston D = 95.5 mm for UAZ vehicles with power steering |
| 409.1000400-10 | 40900A | Engine "U2" in accordance with GOST 15150-69 with a pulley for two V-ribbed belts for UAZ vehicles with power steering and anti-toxic systems |
| 40907.1000400 | 409070 | Completeness in tropical version with KMSUD type "Mikas 7. 2" with a pulley for two V-ribbed belts for UAZ vehicles with power steering |
| 40907.1000400-10 | 40907A | Completeness in tropical version with KMSUD type "Mikas "7.2"" with a pulley for two V-ribbed belts for UAZ vehicles with power steering and anti-toxic devices |
| 409.1000400-01 | 40900V | "U2" engine with a pulley for two V-ribbed belts with a starter and a "Bosch" lance generator for UAZ vehicles with power steering |
| 409.1000400-11 | 40900С | U2 engine with a pulley for two V-ribbed belts with a starter and a Bosch generator for UAZ vehicles with power steering and anti-toxic devices |
| 40907.1000400-01 | 40907B; | "T2" engine with a pulley for two V-ribbed belts with a starter and a generator from "Bosch" for UAZ vehicles with power steering |
| 40907.1000400-11 | 40907С | "T2" engine with a pulley for two V-ribbed belts with a starter and a generator from "Bosch" for UAZ vehicles with power steering and anti-toxic devices |
| 409.1000400-30 | 40900N | Completeness in the version "U2", with a KMSUD type "Mikas" 7.2, with a generator and a starter from the company "Bosch" for UAZ vehicles with power steering. |
| 409.1000400-02 | 40900D | Completeness in the version "U2", with a KMSUD type "Mikas" 7.2, with a clutch from the company "Luk" for UAZ vehicles. |
| 409.1000400-12 | 40900E | Completeness in the version "U2", with a KMSUD type "Mikas" 7.2, with a clutch from the company "Luk" for UAZ vehicles with anti-toxic devices. |
| 40907.1000400-02 | 40907D | Completeness in execution "T2", with KMSUD type "Mikas" 7.2, with clutch firm "Luk" for UAZ vehicles. |
| 40907.1000400-12 | 40907E | Completeness in execution "T2", with KMSUD type "Mikas" 7.2, with clutch firm "Luk" for UAZ vehicles with anti-toxic devices. |
| 409.1000400-03 | 40900F | Completeness in "U2" version, with KMSUD type "Mikas" 7.2, with alternator and starter by "Bosch", with clutch by "Luk" for UAZ vehicles. |
| 409.1000400-13 | 40900G | Completeness in U2 version, with Mikas 7.2 KMSUD, with Bosch generator and starter, with Luk clutch for UAZ vehicles with antitoxic devices |
| 40907.1000400-03 | 40907F | Completeness in execution "T2", with KMSUD type "Mikas" 7.2, with alternator and starter by "Bosch", with clutch by "Luk" for UAZ vehicles. |
| 40907.1000400-13 | 40907G | Completeness in execution "T2", with KMSUD type "Mikas" 7.2, with alternator and starter by "Bosch", with clutch by "Luk" for UAZ vehicles with anti-toxic devices |
| 409.1000400-33 | 40900J | Completeness in the version "U2", with a KMSUD type "Mikas" 7.2, with a pulley for two V-ribbed belts, with a generator and starter from "Bosch", with a clutch from "Luk" for UAZ vehicles with power steering. |
| 40907.1000400-33 | 40907J | Completeness in execution "T2", with KMSUD type "Mikas" 7.2, with a pulley for two V-ribbed belts, with a generator and starter from "Bosch", with a clutch from "Luk" for UAZ vehicles with power steering. |
| 409.1000400-90 | 40900U | Completeness in the version "U2", with KMSUD type "Mikas" 7.2", with a generator and a starter from Bosch, with a clutch from Luk (since the second half of 2011, clutch from JSC ZMZ), with a power steering bracket 31602-3407059 for cars UAZ-315195-030 at the DYMOS checkpoint, with an anti-toxic system. |
| 4097.1000400-90 | 40907U | Same as 40900U but tropicalised. |
| 409.1000400-70 | 40900R | Completeness in the version "U2", with a KMSUD type "Mikas" 7.2, with a pulley for two V-ribbed belts, with a clutch from "Luk", a generator and a starter from "Bosch" for UAZ-3163 "Patriot" vehicles with a gearbox from "DYMOS" and a power steering pump from ZFLS and an anti-toxic system. |
| 409.1000400-80 | 40900T | Completeness in the version "U2" with a KMSUD type "Mikas" 7.2 with a pulley for two poly-V-belts, with a clutch from the company "Luk" (from the second half of 2011, a clutch from JSC ZMZ), a starter and a generator from Bosch for UAZ-315195 cars with DYMOS gearbox without anti-toxic system. |
| 409.1000400-100 | 40900Y | Completeness in version "U2" with KMSUD type "Mikas" 11 with a pulley for two V-ribbed belts, with a clutch from "Luk", a starter and a generator from "Bosch" or from "ISKRA" for UAZ-3163 "Patriot" vehicles with a gearbox from the company "DYMOS" and a power steering pump from the company "ZFLS" and an anti-toxic system. |
| 4091.1000400 | 409100 | wagon layout. |
| 4091.1000400 | 409100 | Completeness in the version "U2" with KMSUD type "Mikas" 11 with a pulley for two V-ribbed belts, with a clutch from "Luk" or "Valeo", a starter and a generator from "ISKRA" for UAZ vehicles wagon layout. |
| 4091.1000400-20 | 409100 | Completeness with KMSUD Mikas 11, ZMZ clutch, without coolant temperature indicator sensor for wagon-mounted UAZ vehicles. |
| 4091.1000400-30 | 40910B | Completeness with KMSUD Mikas 11, ZMZ clutch, without fan belt, with power steering pump (Borisov), anti-toxic system for UAZ wagon-mounted vehicles |
| 4091.1000400-40 | 409100 | Completeness with Mikas 11 KMSUD, ZMZ clutch, 120 A generator, without coolant temperature indicator sensor for UAZ cars of wagon layout |
| 4091.1000400-50 | 409100 | Completeness with KMSUD (Mikas 11), ZMZ clutch, power steering pump (Borisov), without fan belt, without coolant temperature indicator sensor for wagon-mounted UAZ vehicles |
| 4091.1000400-60 | 409100 | Complete set with Bosch ECM, ZMZ clutch, without coolant temperature indicator sensor for wagon-mounted UAZ vehicles |
| 4091.1000400-61 | 409100 | Completeness with Bosch ECM, with HBO, with a bracket for the tensioner of the fan pulley drive belt, a 90 A generator, a ZMZ clutch for UAZ cars of a wagon layout |
| 4091.1000400-70 | 409100 | Complete set with Bosch ECM, ZMZ clutch, 120 A alternator, without coolant temperature indicator sensor, with power steering pump (Borisov) for wagon-mounted UAZ vehicles |
| 4091.1000400-80 | 409100 | Complete set with Bosch ECM, ZMZ clutch, without coolant temperature indicator sensor, with power steering pump (Borisov) for wagon-mounted UAZ vehicles |
| 4091.1000400-81 | 409100 | Complete set with Bosch ECM, with HBO, with power steering bracket 31602-3407059, ZMZ clutch for UAZ-396295 (Euro-3) cars |
| 4091.1000400-82 | 409100 | Complete with Bosch ECM, ZMZ clutch, without temperature indicator sensor, power steering (Borisov), for UAZ-315196 Hunter. |
| 4091.1000400-120 | 409100 | Complete with Bosch ECM, without temperature indicator sensor, with bracket for tensioning the fan pulley drive belt, 90 A generator, ZMZ clutch, with transport crankcase, for UAZ-315196 Hunter. |
| 4091.1000400-130 | 409100 | Completeness with a bracket for the tension roller of the fan pulley drive belt, a 90 A generator, under the UAZ gearbox for UAZ wagon layout cars |
| 4091.1000400-140 | 409100 | Completeness without a temperature indicator sensor, with a bracket for the tensioner of the fan pulley drive belt, a 90 A generator, under the UAZ gearbox for UAZ wagon layout cars |
| 4091.1000400-150 | 409100 | Complete set with Bosch ECM, without temperature indicator sensor, with a bracket for the tensioner of the fan pulley drive belt, a 90 A generator, under the UAZ gearbox for UAZ railcars |
| 4091.1000400-151 | 409100 | Completeness with Bosch ECM, with a bracket for the tensioning roller of the fan pulley drive belt, a 90 A generator, with LPG, under the UAZ gearbox for UAZ wagon-mounted vehicles |
| 4091.1000400-160 | 409100 | Complete with Bosch ECM, without temperature indicator sensor, with power steering bracket 31602-3407059, for UAZ gearbox. for cars UAZ wagon layout |
| 4091.1000400-170 | 409100 | Complete set with Bosch ECM, without temperature indicator sensor, with power steering bracket 220695-3407059, for UAZ gearbox for UAZ railcars |
| 4091.1000400-190 | 409100 | Complete set with Bosch ECM, without temperature indicator sensor, with power steering bracket 220695-3407059, ZMZ clutch for UAZ railcars |
| 4091.1000400-200 | 409100 | Complete set with Bosch ECM, ZMZ clutch, without coolant temperature indicator sensor, for a five-speed gearbox for wagon-mounted UAZ vehicles |
| 4091.1000400-210 | 409100 | Completeness with Bosch ECM, ZMZ clutch, 120 A generator, without coolant temperature indicator sensor, with power steering pump mounting bracket (Borisov), for a five-speed gearbox for wagon-mounted UAZ vehicles |
| 4091.1000400-220 | 409100 | |
| 4091.1000400-230 | 409100 | Completeness with Bosch ECM, ZMZ clutch, without coolant temperature indicator sensor, with power steering pump mounting bracket (Borisov), for a five-speed gearbox for wagon-mounted UAZ vehicles |
| 4091.1000401 | 409100 | U2 engine in accordance with GOST 15150-69 with Bosch KMSUD, with a pulley for two V-ribbed belts, a clutch manufactured by OJSC ZMZ, a power steering pump in Borisov, a mounting bracket 220695-3407059 for UAZ wagon layout vehicles |
| 4091.1000401-10 | 409100 | Engine U2 according to GOST 15150-69 with Bosch KMSUD, with a pulley for two V-ribbed belts, a clutch manufactured by OAO ZMZ, a generator increased power, power steering pump, Borisov, mounting bracket 220695-3407059 for UAZ wagon layout cars |
| 4091.1000401-40 | 409100 | Completeness with KMSUD Bosch, with a bracket for the tensioning roller of the drive belt of the units, a clutch manufactured by OAO ZMZ for UAZ wagon layout cars |
| 40904.1000400 | 409040 | Basic completeness with individual ignition coils, power steering bracket 31602-3407059-10, Dymos gearbox, for UAZ-3163-231 Patriot, UAZ-23632 Pickup. |
| 40904.1000400-01 | 409040 | Complete set with LPG equipment for UAZ Patriot and UAZ Pickup |
| 40904.1000400-10 | 409040 | Complete set with mounting bracket for units, power steering bracket 31602-3407059-10, for UAZ Patriot and UAZ Pickup with air conditioning compressor, Dymos gearbox |
| 40904.1000400-11 | 409040 | Completeness with HBO, bracket for air conditioning compressor, for cars UAZ Patriot and UAZ Cargo. |
| 40904.1000400-20 | 409040 | Completeness with power steering mounting bracket 31602-3407059 for UAZ Hunter with Dymos gearbox. |
| 40904.1000400-30 | 409040 | Completeness with power steering mounting bracket 31602-3407059 |
| 40904.1000400-21 | 409040 | Completeness with a mechanical tensioner of the drive belt, power steering bracket 31602-3407059 for the UAZ Hunter car with Dymos gearbox |
| 40904.1000400-31 | 409040 | Completeness with a mechanical tensioner of the drive belt for the vehicle with power steering, bracket 31602-3407059 |
| 40904.1000400-70 | 409040 | Basic equipment, with improved ZMZ clutch, with power steering bracket 31602-3407059-10, with transport clutch housing, for UAZ Patriot cars. |
| 40904.1000400-71 | 409040 | Completeness with HBO, with power steering bracket 31602-3407059-10, with improved ZMZ clutch, with transport clutch housing, for UAZ Patriot and UAZ Cargo cars. |
| 40904.1000400-80 | 409040 | Completeness with a bracket for the air conditioning compressor, with improved ZMZ clutch, with a power steering bracket 31602-3407059-10, with a transport clutch housing, for UAZ Patriot cars. |
| 40904.1000400-81 | 409040 | Completeness with a bracket for the air conditioning compressor, with HBO, with a power steering bracket 31602-3407059-10, with an improved ZMZ clutch, with a transport clutch housing, for UAZ Patriot and UAZ Cargo cars. |
| 40904.1000400-90 | 409040 | Completeness with power steering bracket 31602-3407059, with improved ZMZ clutch, with transport clutch housing |
| 40904.1000400-91 | 409040 | Completeness with a mechanical tension roller, with a power steering bracket 31602-3407059, with an improved ZMZ clutch, with a transport clutch housing. |
| 40904.1000401 | 409040 | Basic completeness with individual ignition coils, Luk clutch, power steering bracket 31602-3407059-10, for UAZ Patriot cars with Dymos gearbox. |
| 40904.1000401-10 | 409040 | Completeness with a mounting bracket for units, with a Luk clutch, with a power steering bracket 31602-3407059-10, for UAZ Patriot cars with a Sanden air conditioning compressor, Dymos gearbox. |
| 40904.1000401-20 | 409040 | Completeness with power steering mounting bracket 31602-3407059, with Luk clutch, for UAZ Hunter with Dymos gearbox |
| 40904.1000401-30 | 409040 | Complete set with ZMZ clutch, with power steering bracket 31602-3407059-10, for UAZ Patriot with Dymos gearbox. |
| 40904.1000401-40 | 409040 | Completeness with mounting bracket for units, with ZMZ clutch, with power steering bracket 31602-3407059-10, for UAZ Patriot cars with Sanden air conditioning compressor, Dymos gearbox. |
| 40904.1000401-50 | 409040 | Completeness with power steering mounting bracket 31602-3407059, with ZMZ clutch, for UAZ Hunter with Dymos gearbox |
| 40904.1000401-60 | 409040 | Completeness with power steering mounting bracket 31602-3407059, with ZMZ clutch, for UAZ Hunter with ADS gearbox |
Technical characteristics of the internal combustion engine ZMZ 409
The ZMZ-409 engine is a 4-cylinder, in-line engine, with an integrated microprocessor system engine control (KMPSUD).
The working volume is 2.6 liters, the compression ratio is 9. The order of operation of the cylinders is organized according to the scheme 1-3-4-2, the crankshaft rotates to the right. The maximum torque is 230 kg-cm at a speed of 3900 rpm. Motor weight 190 kg.
The engine power system is fuel injection into the pipe.
The ventilation system is closed, forced action, operates due to the vacuum in the exhaust system.
The lubrication system is also forced, combined, with splashing.
The cooling system is liquid, forced, closed.
Engine ZMZ-409 (right view):
1 - oil crankcase; 2- oil filter; 3 - crane oil cooler; 4 - starter; 5 - heating hoses throttle valve; 6 - knock sensor; 7 - hose from the fuel pressure regulator to the idle channel; 8 - inlet pipe; 9 - fuel pressure regulator; 10 - air supply hose; 11 - receiver; 12 - idle speed regulator; 13 - generator; 14 - hydraulic tensioner of the upper chain; 15 - eye (eye) for lifting the engine; sixteen - adjusting bolt tensioning the power steering pump drive belt and fan pulley; 17 - hydraulic booster pump bracket; 18 – an adjusting bolt of a belt of a drive of the generator and the water pump; 19 - crankshaft position sensor (synchronization sensor); 20 - setting marks TDC compression stroke; 21 – lower chain hydraulic tensioner
Engine ZMZ-409 (left view):
1 - coolant drain valve; 2 - hydraulic booster pump; 3 - crankshaft pulley; 4 - water pump pulley; 5 - drive belt for the pump of the hydraulic booster system and fan pulley; 6 - tension roller; 7 – the gauge of the index of temperature of a cooling liquid; 8 - coolant temperature sensor; 9 - thermostat; 10 - drive belt for the generator and water pump; 11 - viscous coupling; 12 - sensor signal lamp emergency drop in oil pressure; 13 - oil pressure indicator sensor; 14 - oil filler cap; 15 - throttle assembly; 16 - throttle position sensor; 17 - ignition coils; 18 - oil level indicator (dipstick); 19 - eye (eye) for lifting the engine; 20 – phase sensor; 21 - heat-insulating screen; 22 - exhaust manifold; 23 - cork drain hole
Cross section of the ZMZ-409 engine:
1 - oil crankcase; 2 - receiver oil pump; 3 - oil pump; 4 - oil pump drive; 5 - gear wheel of the intermediate shaft; 6 – block of cylinders; 7 - inlet pipe; 8 - receiver; 9 – a camshaft of inlet valves; 10 - inlet valve; 11 - valve cover; 12 - camshaft exhaust valves; 13 - oil level indicator; 14 - hydraulic valve tappet; 15 - outer spring of the valve; 16 - valve guide sleeve; 17 - exhaust valve; 18 – a head of the block of cylinders; 19 - exhaust manifold; 20 - piston; 21 - piston pin; 22 - connecting rod; 23 - crankshaft; 24 - connecting rod cover; 25 – a cover of the radical bearing; 26 - drain plug; 27 - pusher body; 28 - guide sleeve; 29 - hydraulic compensator housing; 30 - retaining ring; 31 - hydraulic compensator piston; 32 - ball valve; 33 - ball valve spring; 34 - body of the ball valve; 35 - expanding spring
Tension of drive belts of units: 1 - synchronization sensor; 2 - automatic tension mechanism; 3 - drive belt for the generator and water pump; 4 - generator pulley; 5 - inlet pipe; 6 - receiver; 7 - throttle assembly with throttle position sensor; 8 - oil filler cap; 9 - valve cover; 10 - fan pulley; 11 - water pump pulley; 12 - pulley of the power steering pump; 13 - a bolt of fastening of the pump of the hydraulic booster of a steering; 14 - adjusting bolt; 15 - fan drive belt and power steering pump; 16 - crankshaft damper pulley
Engine design
Crank mechanism
Cylinder block cast from gray cast iron. Coolant passages are made between the cylinders. The cylinders are bored directly into the body of the block. On the cylinder block, special lugs, flanges and holes for fastening parts, assemblies and assemblies, as well as channels of the main oil line are made. At the bottom of the cylinder block there are five crankshaft main bearing supports with removable covers that are bolted to the block. Main bearing caps machined complete with block are not interchangeable. The cover of the third bearing (assembly with the cylinder block) is machined at the ends to install two thrust steel-aluminum semi-rings that limit the axial movement of the crankshaft. The chain cover and stuffing box with crankshaft cuffs are bolted to the ends of the cylinder block. An oil sump is attached to the cylinder block from below.
Cylinder block. View from above: 1 – a flange of fastening of a gear box; 2 - threaded holes for mounting the cylinder head (10 holes); 3 - the plane of contact of the cylinder head; 4 - the place of marking the engine; 5 – cooling jacket windows; 6 - the plane of contact of the chain cover; 7 - hole for supplying lubricant to the cylinder head; 8 – flange of fastening of a cover of a drive of the oil pump
cylinder head cast from aluminum alloy. It has intake and exhaust valves. Each cylinder has four valves: two intake and two exhaust. The intake valves are located right side block heads, and exhaust - on the left. The valves are driven by two camshafts through hydraulic pushers. The use of hydraulic pushers eliminates the need to adjust valve clearances, as they automatically compensate for the clearance between the camshaft cams and valve stems. Seats and valve guides are installed in the cylinder head with a high interference fit. Combustion chambers are located in the lower part of the block head, and camshaft bearings are located in the upper part. Aluminum covers are installed on the supports. The front cover is common to the intake and exhaust camshaft bearings. It has plastic thrust flanges that fit into the grooves on the camshaft journals. The covers are processed assembled with the block head, so they cannot be interchanged. On all covers, except for the front one, serial numbers are embossed.
Cylinder head. View of the intake pipe flange, the upper plane and the front cover flange:
1 - camshaft covers; 2- candle wells; 3 - front cover of camshafts; 4 – a flange of fastening of a forward cover of a head of cylinders; 5 - threaded holes for fastening the top bracket of the generator; 6 - flange for fastening the cover of the hydraulic tensioner; 7 - inlet pipe mounting flange
Camshafts cast iron. The cam profiles of the intake and exhaust shafts are the same. The cams are offset by 1.0 mm relative to the axis of the hydraulic pushers, which causes the hydraulic pushers to rotate when the engine is running. This reduces wear on the surface of the hydraulic pusher and makes it more uniform. From above, the cylinder head is closed with a cover cast from an aluminum alloy.
Pistons also cast in aluminum alloy. On the bottom of the piston there are four recesses for the valves, which prevent the piston from hitting the valves when the valve timing is disturbed. For correct installation piston into the cylinder, the inscription “Front” is cast on the side wall near the boss under the piston pin. The piston is installed in the cylinder so that this inscription is facing the front of the engine. Each piston has two compression rings and one oil scraper. The compression rings are cast iron. The barrel-shaped working surface of the upper ring is covered with a layer of porous chromium, which improves the running-in of the ring. The working surface of the lower ring is covered with a layer of tin. A groove is made on the inner surface of the lower ring. The ring must be installed on the piston with this groove up to the piston bottom. Oil scraper ring consists of three elements: two steel disks and an expander. The piston is attached to the connecting rod with a floating type piston pin, i.e. the pin is not fixed in the piston or in the connecting rod. The pin is kept from moving in the axial direction by two spring retaining rings, which are installed in the grooves of the piston bosses.
Piston and connecting rod:
1 - retaining rings;
2 - piston;
3 - connecting rod;
4 - connecting rod bolts;
5 – connecting rod cover;
6 - nuts;
7 – piston rings;
8 - piston pin;
9 - connecting rod bushing
connecting rods steel, forged, with an I-section rod. A bronze bushing is pressed into the upper head of the connecting rod. The bottom head of the connecting rod is equipped with a cover attached with two bolts. The nuts of the connecting rod bolts have a self-locking thread and are not additionally locked. The connecting rod caps are machined complete with the connecting rod, so they cannot be moved from one connecting rod to another. The numbers of the corresponding cylinders are stamped on the connecting rods and their covers. To cool the piston bottom with oil, holes are made in the rod and the upper head of the connecting rod. Thin-walled liners are installed in the lower head of the connecting rod.
Crankshaft cast from ductile iron. The shaft has eight counterweights. It is kept from axial movement by thrust half rings mounted on the middle neck. A flywheel is attached to the rear end of the crankshaft, into the hole of which a spacer sleeve and a toe bearing of the gearbox input shaft are inserted. The water pump pulley is driven together with the alternator pulley by a V-ribbed belt from the crankshaft pulley. Belt tension is adjusted by changing the position tension roller. The same belt drives the drive pulleys of the power steering pump and the viscous clutch.
Gas distribution mechanism
Camshafts- Cast iron. To achieve high wear resistance of the working surface, the cams have been bleached.
The shafts rotate in bearings formed by the cylinder head and removable aluminum covers. These covers are machined complete with the cylinder head and are therefore not interchangeable.
in engines ZMZ-40904 and ZMZ-40905 same cam profile, and provide a valve lift of 9 mm.
On the engine ZMZ-40911 inlet and outlet camshafts have different cam profile and provide an 8 mm intake valve lift and 9 mm exhaust valve lift.
Camshaft drive chain, two-stage.
Includes: crankshaft sprocket 1, intermediate shaft driven sprocket 5 and drive 6, camshaft driven sprockets 12 and 14, two chains (72 and 92 links) 4 and 9, hydraulic tensioners with reinforced spring 2 and 8, tensioner levers 3 and 7 and chain dampers 13, 16 and 17 .
The chain tension of each stage is carried out by hydraulic tensioners located: one on the front cover of the cylinder block (chain cover), the other on the cylinder head.
Camshaft drive (with sprockets):
1 - crankshaft sprocket;
2 - lower hydraulic tensioner;
3 - the lever of the tension device of the lower chain;
4 - lower chain;
5 - an asterisk of an intermediate shaft driven;
6 - an asterisk of an intermediate shaft leading;
7 - the lever of the tension device of the upper chain;
8 - upper hydraulic tensioner;
9 - upper chain;
10 - installation mark on the sprocket;
11 - locating pins;
12 - asterisk camshaft inlet valves;
13 – upper chain damper;
14 – an asterisk of a camshaft of final valves;
15 - the upper plane of the cylinder head;
16 – medium chain damper;
17 - lower chain damper;
M1 and M2 - installation marks on the block
Camshaft drive with shoes: 1 - crankshaft sprocket; 2, 8 - chain tension shoe; 3, 9 - hydraulic tensioner; 4 - chain of the first stage; 5 - an asterisk of an intermediate shaft conducted; 6 - an asterisk of an intermediate shaft leading; 7 - shoe bolt support; 10 - soundproof washer; 11 - chain of the second stage; 12.18 - installation marks on the asterisks; 13.17 - locating pins; 14 – an asterisk of a camshaft of inlet valves; 15 - top chain damper; 16 – an asterisk of a camshaft of final valves; 19 - the upper plane of the cylinder head; 20 – medium chain damper; 21 - lower chain damper; M1 and M2 - alignment marks on the cylinder block
Valve timing
Hydraulic tensioner- steel, made in the form of a plunger pair matched to the gap, consisting of body 4 and plunger 3. The hydraulic tensioner provides a constant chain tension and damping of its vibrations due to the oil pressure in the lubrication system, and the action of the plunger pair spring.
Hydraulic tensioner:
1 - valve body assembly;
2 - locking ring;
3 - plunger;
4 - body;
5 - spring;
6 - retaining ring;
7 - transport stopper;
8 - hole for supplying oil from the lubrication system
valves- made of heat-resistant steel and have the ability to rotate during operation. The valves are interchangeable with similar valves of the VAZ-2108 engine.
Valve drive from the camshafts directly through the cylindrical hydraulic pushers 7, for which guide holes are made in the cylinder head. The use of hydraulic tappets eliminates the need to adjust clearances.
Valve drive:
1 - inlet valve; 2 - cylinder head; 3 - valve spring plate; 4 - oil deflector cap; 5 - external valve spring; 6 - camshaft exhaust valves; 7 - hydraulic pusher; 8 - valve cracker; 9 - exhaust valve; 10 - internal valve spring; 11 - valve spring support washer; 12 - intake valve camshaft.
Valve springs- double. Springs and parts of their fastening are interchangeable with similar parts of the VAZ-2108 engine.
hydraulic pushers- made in the form of a cylindrical cup with a hydraulic compensator plunger pair inside and a groove with an opening for supplying oil from the line in the cylinder head outside. Hydraulic pushers provide backlash-free contact of the camshaft cam with the end of the valve due to oil pressure and the action of the hydraulic compensator spring. During operation, the hydraulic pushers rotate due to the shift in the width of the middle of the camshaft cam relative to the axis of the hydraulic pusher, which ensures uniform running-in and reduced wear of the end face of the hydraulic pusher.
hydraulic pusher:
1 – hydraulic compensator guide sleeve;
2 - body of the hydraulic pusher;
3 - retaining ring;
4 - hydraulic compensator body;
5 - hydraulic compensator piston;
6 - check ball valve;
7 - spring
The principle of operation and the main malfunctions of hydraulic pushers are described in a separate article.
intermediate shaft- serves to drive the oil pump. A steel countershaft of a one-piece design or a prefabricated design can be used. The front and rear support journals of the prefabricated intermediate shaft are made of powder material by powder metallurgy and pressed onto a steel roller.
Intermediate shaft: 1 - bolt; 2 - locking plate; 3 - leading asterisk; 4 - driven sprocket; 5 - front shaft sleeve; 6 - intermediate shaft; 7 - pipe; 8 - driven gear of the oil pump drive; 9 - ring; 10 - nut; 11 - key; 12 - the drive gear of the oil pump; 13 - rear hub shaft; 14 - cylinder block; 15 - intermediate shaft flange; 16 - pin
Lubrication system
Lubrication system- combined with oil supply to rubbing surfaces under pressure and splashing.
Lubrication system includes: oil sump 1, oil pump 2 with suction pipe and pressure reducing valve, oil pump drive, oil passages in the block, cylinder head and crankshaft, full-flow oil filter 3, oil dip stick 5, oil filler cap 4, oil pressure sensors 6 and 7.
There are marks on the oil level indicator: upper level - "P" and lower level - "0". The oil level must be between these marks.
Oil circulation occurs as follows. The pump sucks oil from the crankcase and through the channel in the block brings it to the full-flow filter. After the filter, the oil enters the main oil line and through the channels in the block lubricates the main bearings, the intermediate shaft bearings, the upper bearing of the oil pump drive shaft and is supplied to the chain tensioner of the first stage of the camshaft drive. From the main bearings, oil lubricates through the internal channels of the crankshaft connecting rod bearings and piston pins are lubricated from them through the holes in the connecting rods.
From the upper bearing of the oil pump drive roller, oil is supplied through the transverse drillings and the inner cavity of the roller to lubricate the lower roller bearing and the bearing surface of the driven gear of the drive.
The oil pump drive gears are lubricated by a jet of oil through a hole in the main oil line.
To cool the piston, oil is sprayed through the hole in the upper head of the connecting rod onto the piston crown.
From the main oil line, oil enters the cylinder head through a channel in the block, lubricates the camshaft bearings and is supplied to the hydraulic chain tensioner of the second stage of the camshaft drive, to the hydraulic pushers and to the oil pressure sensors. Escaping from the gaps and flowing into the crankcase at the front of the cylinder head, oil lubricates the chains, tensioner arms and camshaft sprockets.
The oil pressure is controlled by a pressure sensor 6 and a pointer on the instrument panel. In addition, the system is equipped with sensor 7 and emergency oil pressure alarm. The emergency oil pressure indicator lights up at 40...80 kPa (0.4...0.8 kgf/cm2). The pressure transducers are screwed into a fitting installed in oil channel cylinder heads.
Oil pump- gear type, installed inside the oil sump and attached to the cylinder block with two bolts and an oil pump holder. The drive gear 1 is fixedly fixed on the shaft 3 with a pin, and the driven gear 5 rotates freely on the axis 4 pressed into the pump housing 2. The pump housing is made of aluminum alloy, the partition 6 is made of cast iron, the gears are made of cermet. A intake pipe 7 cast from an aluminum alloy with a grid is attached to the body with three screws.
Oil pump:
1 - drive gear;
2 - body;
3 - roller;
4 - axis;
5 - driven gear;
6 - partition;
7 - inlet pipe with a grid and a pressure reducing valve.
Oil pump drive carried out by a pair of helical gears from the intermediate shaft 1 of the camshaft drive. The intermediate shaft rotates in bushings pressed into the bores of the cylinder block. On the shaft, with the help of a key 3, the drive gear 2 is installed and fixed with a flange nut, which is engaged with the driven gear 7, pressed onto the shaft 8, rotating in the bores of the cylinder block. A sleeve 6 is pressed into the upper part of the driven gear, which has an internal hexagonal hole. A hexagonal shaft 9 is inserted into the hole of the bushing, the lower end of which enters the hexagonal hole of the oil pump shaft.
Oil pump drive
1 - intermediate shaft;
2 - drive gear;
3 - key;
4 - cover;
5 - gasket;
6 - bushing;
7 - driven gear;
8 - roller:
9 - hexagonal shaft of the oil pump drive
pressure reducing valve plunger type, located in the oil receiver housing. The pressure reducing valve is adjusted at the factory by setting a calibrated spring. It is not recommended to change the valve setting in operation.
Oil filter. An oil filter 2101-1012005-NK-2 of single use is installed on the engine.
Cooling system
Cooling system - liquid, closed, with forced circulation coolant.
The cooling system consists of an engine cooling jacket, a radiator, a water pump, a thermostat, an expansion tank, a viscous fan drive coupling, an electric fan, connecting hoses and tubes. Heater radiators and an electric pump for an additional (optional) interior heater are also connected to the cooling system. The pressure in the system is created by a water pump, which is driven by a belt from the crankshaft. From the pump, liquid is supplied to the engine cooling jacket, and from the jacket it enters the thermostat. Depending on the temperature, the liquid then passes into the water pump (at low temperature) or into the radiator (at high temperature), from where, after cooling, it enters the water pump.
Cooling system: 1, 2 - heater radiators; 3 – electric pump; 4 - engine; 5 - throttle branch pipe; 6 - thermostat; 7 – the gauge of the index of temperature of a cooling liquid; 8 – the gauge of an alarm lamp of an overheat of a cooling liquid; 9 – viscous coupling of the fan drive; 10 - fan; 11 - radiator cap; 12 - radiator; 13 – a stopper of a broad tank; 14 - expansion tank; 15 - electric fan; 16 - water pump; 17- drain tap cylinder block
The most favorable temperature regime of the coolant lies within 80 ... 90 ° C. The indicated temperature is maintained using an automatic thermostat and shutters controlled by the driver. Maintaining the thermostat at the correct temperature in the cooling system has a decisive influence on the wear of engine parts and the efficiency of its operation. To control the temperature of the coolant on the instrument panel of the car there is a temperature gauge, the sensor of which is screwed into the thermostat housing. In addition, there is an emergency temperature indicator on the instrument panel of the car, which lights up red when the liquid temperature rises above 104 ° C. The emergency temperature alarm sensor is screwed into the upper tank of the radiator. If the indicator lights up, immediately stop the engine and eliminate the cause of overheating of the coolant.
Water pump centrifugal type. The bearing 7 is separated from the coolant by a self-clamping gland 4 of a non-separable design, inside which a cuff and a sealing washer are located. The liquid seeping through the stuffing box does not enter the bearing, but flows out through the control hole 6, which must be cleaned periodically. The bearing is kept from moving by retainer 2, which is screwed up to the stop and centered. The bearing is filled with grease during assembly and no relubrication is required during operation. Hub 1 and impeller 5 are pressed onto the bearing shaft.
Water pump
1 - hub;
2 - latch;
3 - body;
4 - stuffing box;
5 - impeller;
6 - control hole for the exit of the coolant;
7 - bearing
Pump drive(and alternator) is carried out by poly V-belt 6RK 1220.
Fuel supply system
Fuel supply system It is carried out by means of fuel injection into the intake pipe by electromagnetic nozzles controlled by a microprocessor.
The power system consists of fuel tank 6, fuel lines 8, 5 and 10, electric fuel pump 9, fuel filters 8 and 11, engine fuel line 2, cast from aluminum alloy, with fuel pressure regulator 4 and electromagnetic injectors 3.
Scheme of the engine fuel supply system
1 - throttle valve
2 - engine fuel line;
3 - electromagnetic nozzles;
4 - fuel pressure regulator;
5 - fuel line for removing fuel to the tank;
6 - fuel tank;
7 - low pressure fuel line;
8 - fuel filter rough cleaning;
9 - electric fuel pump;
10 - high pressure fuel line;
11 - fuel fine filter.
Maintaining a constant fuel pressure in the line to ensure guaranteed fuel supply by injectors in all engine operating modes is provided by a pneumo-mechanical pressure regulator - it maintains 3 kgf / cm2 (300 8 kPa). The fuel pressure regulator is located on the fuel rail, the fuel level sensor is part of the submersible fuel pump module located in the fuel tank.
Location of the main components of the fuel injection system:
1 - receiver; 2, 25 - fuel supply pipeline; 3 - fuel rail; 4 - fuel drain pipeline from the pressure regulator; 5 - pressure regulator; 6 - pipeline from the fuel pump to the fuel fine filter; 7 - fuel pump; 8 - pipeline from the jet pump to fuel pump; 9 – a stopper of a fuel tank; 10 – a bulk pipe of a fuel tank; 11, 17, 19, 27, 30, 31 - steam outlet hoses; 12 – right fuel tank; 13 - connecting hose; 14 - connecting tube; 15 – left fuel tank; 16 - drain plug; 18 - separator; 20 - pipeline from the left tank to the jet pump; 21 - jet pump; 22 - clamp for fastening the fuel fine filter; 23 – fuel fine filter; 24 - fuel drain pipeline to the jet pump; 26 - steam outlet pipeline; 28 - adsorber; 29 - fuel tank valve
Fuel rail and injectors- made of aluminum alloy, cylindrical section.
The fuel rail with four nozzles is fixed to the intake pipe with two bolts. The nozzles 4 are held in the rail 2 by means of special connections. At the front end of the rail there is a fitting for supplying fuel from the fuel tank 1. At the rear end of the fuel rail there is a pressure regulator 3 with a fitting for discharging fuel to the fuel tank. The landing of the nozzles in the inlet pipe is sealed with rubber rings 5 of round section, which must be lubricated with engine oil to facilitate installation.
Fuel rail with injectors: 1 - protective cap of the threaded fitting; 2 - fuel rail; 3 - fuel supply fitting; 4 - nozzle; 5 - sealing ring
Submersible fuel pump module
Air intake and exhaust system
intake system consists of an inlet pipe and a receiver, cast from an aluminum alloy. Geometric parameters systems make it possible to implement gas-dynamic supercharging of the engine. At idle and light loads, air enters the engine through a separate system directly to the intake valves.
Exhaust manifold cast iron. To improve the cleaning of the engine cylinders from exhaust gases, the pipes from each cylinder are interconnected 1 and 4, 2 and 3. This reduces the influence of the operation of one cylinder on the other and allows the effect of a tuned exhaust gas to be realized.
Exhaust system consists of exhaust manifold engine, exhaust pipe 1, catalytic converter 2, muffler 3 and resonator 4. All components of the system are suspended from the bottom of the body by means of brackets and rubber shock absorbers. The flanges of the catalytic converter, muffler and resonator are sealed with metal-reinforced gaskets.
Exhaust system:
1 - receiving pipe;
2 - catalytic converter;
3 - silencer;
4 - resonator
Crankcase ventilation system
Crankcase ventilation system- closed, forced, acting due to vacuum in the intake system. The oil deflector is located in the valve cover.
Engine ventilation scheme
1 - valve cover;
2 - oil deflector;
3 - oil deflector tube;
4 - longitudinal channel of the idle system;
5 - receiver with inlet pipe;
6 - hose of a small branch of ventilation;
7 - hose of the main ventilation branch.
When the engine is idling, gases from the crankcase are sucked out through a small branch into the channel of the idle air supply system, from where they enter the intake channels of the cylinder head. In other modes, ventilation is carried out through the throttle of the receiver and the intake pipe.
Movement crankcase gases in the valve cover
INTEGRATED MICROPROCESSOR ENGINE CONTROL SYSTEM (KMPSUD)
The integrated control system is designed to control the fuel injection and ignition timing of the engine.
Functionally, the control system consists of two subsystems:
- fuel injection control subsystems;
- subsystems for controlling the ignition timing (UOZ).
Both subsystems are interconnected and work synchronously with the main cycle of the engine. Synchronization of the subsystems is carried out according to the signals of sensors installed on the engine. The system consists of a microprocessor control unit (CU), which controls the actuators according to the program embedded in the unit, taking into account information from the sensors.
The sensors include:
1. Mass air flow sensor 0 280 212 014* hot-wire type to determine the mass filling of cylinders with air. Installed on a vehicle between air filter and receiver.
* - product numbers according to the catalog of the company "BOSSN" (Germany)
2. Throttle position sensor 0 280 122 001* or 406.1130000-01 resistive type mounted on the throttle. The signal from the sensor is used to determine the operating mode of the engine (idling, partial loads or full power).
3. Synchronization sensor(crankshaft position) 23.3847 or DS-1 inductive type, mounted on the chain cover near the crankshaft pulley. The sensor generates a special electrical signal when the sensor's magnetic field interacts with a special toothed disk (60-2 tooth disk) mounted on the crankshaft pulley. The electrical signal from the sensor informs the control unit about the angular position of the crankshaft during its rotation. The sensor and disk 60-2 teeth (timing disk) are installed in such a way that the moment of passage through the continuation of the axis of the rear cut sensor twentieth tooth of the disk! corresponds to being in top dead piston point of the first or fourth cylinder. In this case, the tooth number is counted from the gap in the direction opposite to the disk rotation.
4. Phase sensor(camshaft position) DF-1, or 406.3847050-04, or 406.3847050-05 mounted on the cylinder head. The sensor generates a signal at the moment of passage of a marker in the magnetic field of the sensor, made in the form of a bent plate mounted on the exhaust camshaft. The appearance of a signal from the sensor indicates the beginning of the compression stroke in the first cylinder. At the time of the signal from this sensor, the rear cut of the first tooth of the 60-2 tooth disk (counted from the gap in the direction opposite to the rotation of the disk) must pass through the continuation of the axis of the crankshaft position sensor.
5. Engine temperature sensor 19.3828 semiconductor type, mounted on the thermostat housing. The sensor generates a signal to the control unit to provide correction of fuel supply and ignition timing depending on the thermal state of the engine.
6. Intake pipe temperature sensor 19.3828 semiconductor type, mounted on the intake pipe. The sensor generates a signal to the control unit to provide correction of fuel supply and ignition timing depending on the air temperature, indirectly determined by the temperature of the intake pipe.
7. Knock sensor ST-305 (domestic production) is installed in the area of the 4th cylinder on the block from the side intake system and is designed to correct the ignition timing when detonation is detected by the control unit.
The executive devices include:
1. Four electromagnetic injectors(EMF) 0 280 150 560* or 9261 ZMZ DEKA 1A*, or 6354 ZMZ DEKA1D** for fuel dosing. Installed on intake pipe.
**-product numbers according to the SIEMENS VDO Automotive catalog
2. idle speed controller(additional air regulator) РХХ-60 based on a two-phase torque motor. The regulator is intended for dosing the amount of air entering the inlet pipeline in the modes of starting, warming up, idling and forced idling of the engine. The regulator is located on the intake system receiver.
3. Electric fuel pump 0 580 464 044 *, which serves to create pressure in the fuel line. Installed under the car body.
4. Electromagnetic relays power supply and fuel pump relay 111.3747, designed to enable / disable executive devices from onboard network directly from the control unit. Relays installed in engine compartment car.
5. Spark plug type A14DVR or LR17US in the amount of 4 pieces. Candles are screwed into the cylinder head in the center of the combustion chambers.
6. Two ignition coils 406.3705. Mounted on the valve cover.
Electric equipment of UAZ Patriot cars (release since 2007)
The ZMZ-409.10 engine complies with Euro3 toxicity standards.
The motors are manufactured in U2 climatic version, designed for operation in moderate climates at ambient temperatures from minus 45°C to plus 40°C and relative air humidity up to 100% at plus 25°C.
Top view of the ZMZ-409.10 engine
The left side of the engine ZMZ-409.10
The right side of the engine ZMZ-409.10
Front view of the engine ZMZ-409.10
Technical characteristics of the engine and its systems
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Petrol, 4-cylinder, 4-stroke, in-line, with a complex microprocessor control system for fuel injection, ignition and air intake |
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Cylinder diameter and piston stroke, mm |
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Cylinder displacement, cm 3 |
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Compression ratio |
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The order of operation of the cylinders |
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Direction of rotation of the crankshaft (pulley side) |
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Rated power at a rotation frequency of 4500±50 min -1 gross according to GOST 14846, kW (hp) |
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Maximum torque at a speed of rotation 3900±200 min -1 gross according to GOST 14846, Nm (kgcm) |
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Supply system |
Multipoint fuel injection electromagnetic injectors in the intake pipe |
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Minimum specific consumption fuel, g/kWh (g/l.sch) |
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Oil consumption for waste, % of fuel consumption |
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Weight of unfilled engine with clutch, kg |
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Air filter |
With dry replaceable filter element (installed on the car) |
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Ventilation system |
Closed, forced, acting due to vacuum in the intake pipe |
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Lubrication system |
Combined, with automatic oil temperature control |
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Oil filter |
Full flow, non-separable, fine cleaning 2105С-1012005-NK-2 |
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Oil pressure gauge sensor |
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Oil Pressure Alarm Sensor |
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Cooling system |
Liquid, closed, with forced circulation of liquid |
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Thermostat |
two-valve, with main valve opening temperature 82±2˚ C TS 107-05 or TP2-01 or TA107-05 |
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Electronic control system |
Controls the air supply distributed fuel injection with electromagnetic injectors into the intake pipe and ignition |
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spark plug |
DR17YC/Aor A14DVR |
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Ignition coils |
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electrical equipment |
DC, single wire, negative terminals of sources and consumers are connected to the motor frame |
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Rated voltage, V |
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Generator |
with built-in rectifier unit and voltage regulator 9422.3701 or 2502.3771 |
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with remote electromagnetic switch and reducer 6012.3708 or 405.3708000 (AZE2154 12V1,9 kWz9 11.131.262) |
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coolant overheat warning sensor |
thermistor type ТМ111-02 |
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Clutch |
dry, single disc, with diaphragm pressure spring |
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Pressure in the lubrication system on a warm engine at the installation site of the emergency oil pressure sensor at an idle speed of the crankshaft 850 ± 50 min -1, kPa (kgf / cm 2), not less than |
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Gap between electrodes of spark plugs, mm |
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Coolant operating temperature, °C |
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The minimum frequency of rotation of the crankshaft at idle, min -1 |
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Increased crankshaft speed, min -1 |
