ZMZ-409 engine: specifications, repairs, reviews

2024 Author: Erin Ralphs | [email protected]. Last modified: 2024-02-19 11:42

In our country, the ZMZ 409 engine was especially popular and widely used. UAZ Patriot cars were equipped with this engine. The engine was also installed on Sable and Gazelle.

History of the plant

The history of the Zavolzhsky Motor Plant has been going on for 45 years. In 1958, ZMZ, which produced mainly spare parts and castings from aluminum alloys, was reorganized into a motor plant in a small village. It produced power units for the Gorky, Ulyanovsk, and Moscow automobile enterprises.

The first engine that was assembled on it is a GAZ 21 for the Volga Automobile Plant. The motor plant constantly increased its capabilities and capacity. Equipment, workshops, production technologies were constantly improved. Particular attention was paid to the foundry at the engine plant.

In the 80s, the first 4-cylinder and 16-valve gasoline engine was designed at this plant. Its volume was 2.3 liters, and the operation of the internal combustion engine was controlled by a microcontroller, which was responsible for the injection and ignition system. This engine was named ZMZ 4062.

Motor ZMZ 409

Onconveyor this motor was delivered in 1996. Today, on the basis of this internal combustion engine, several units are produced with a volume of 2.3 to 2.7 liters. These are the installations of models 406 and 405. This included the 409 engine. This motor was mainly installed on new and modern domestic UAZ and GAZ cars. All generations of these power plants are equipped with a gas converter and are produced completely in accordance with EURO-2 standards.

For several years of production, the engines have undergone major changes and improvements several times. In 2003, the design of the camshafts was changed. The plastic tensioner shoes were replaced with sprockets, which made it possible to get rid of the problem of failure of hydraulic tappets due to clogging of engine oil with plastic wear products.

Then, along with the fact that the plant switched to imported components for critical engine components, the management decided to make even more serious modifications to its products. The camshaft system was replaced with a simplified assembly. This immediately affected the reliability. Many other upgrades have also been made.

Today, the Zavolzhsky Motor Plant is a leading domestic enterprise. The products produced here are of high performance and quality.

Technical characteristics of internal combustion engine ZMZ 409

409 engine is a 4-cylinder, in-line engine controlled by microprocessors. The working volume of the unit 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,crankshaft rotates to the right. The maximum torque is 230 kg-cm at a speed of 3900 rpm. The mass of the motor is 190 kg. The power supply system of this engine is fuel injection into the pipe. The ventilation system, which is used in this power unit, is closed, forced-action, working due to a vacuum in the exhaust system. The lubrication system is also forced, combined, with splashing. The cooling system is presented in the form of liquid, forced and closed. The electrical part is presented as a single-wire system.

Motor design

Consider the design and main components of the ZMZ 409 motor. First, about the cylinder block. The main material for this assembly was gray cast iron. Between the cylinders, engineers made special channels through which coolant circulates. The monoblock design already has everything you need and all the holes for attaching attachments and lubrication channels. The lower part of this assembly is equipped with main bearing supports for mounting the crankshaft. These bearing caps are not replaceable.

Cylinder head is cast aluminum. The cylinder head is equipped with intake and exhaust valves. Each of the cylinders is equipped with two valves. The intake valves are on the right and the exhaust valves are on the left. Hydraulic pushers made it possible to get rid of the process of manually adjusting the gaps. Now the gaps of the cams are adjusted automatically.

Pistons are also made ofaluminum. These parts have thermostatic inserts. The skirt is made according to a barrel-shaped profile, and is also equipped with a special micro-relief, which can significantly improve the running-in, as well as significantly reduce friction losses.

The bottom of each piston has black grooves, which are made in order to prevent as much as possible the possible impacts of the piston on the bottom of the valve plates in case of possible malfunctions.

Piston rings are mounted three on each of the pistons. On the 409 engine, the specifications include two compression rings and one oil scraper ring. As for the outer surface of the compression ring, it is covered with a layer of special porous chromium. The bottom ring is tin plated and the rest of the rings are phosphated.

The crankshaft is made of extra strong cast iron. It is five-supported, for better unloading of the supports it is equipped with counterweights. The crankshaft toe as well as the shank come with rubber seals.

The shaft has been dynamically balanced at the factory. To prevent it from moving along the axes, the engineers limited it with two washers, which are located on both sides of the middle or third bearing. Thrust washers, in turn, consist of half washers.

Gas distribution system

The camshafts in this engine are cast. The material was high-strength cast iron. The surface of the camshaft has been specially treated to achieve greater wear resistance.

These parts rotate onbearings, which are formed by the cylinder head and special removable covers made of aluminum.

Drive - chain, two-stage. The chain tensioning system is carried out using hydraulic tensioners.

The valves in this motor are made of special heat-resistant steel. 409 engine is equipped with valves that rotate during operation. The drive is carried out from hydraulic pushers of camshafts. Since this is a 409 engine, its technical characteristics make it possible not to adjust the gaps due to the use of hydraulic pushers. Valve springs are made in the form of double springs. These parts are unified with engines from the VAZ 2108. The hydraulic pushers are made in the form of a cylindrical cup, and oil is supplied from the cylinder head.

Lubrication system

The 409 engine (UAZ Patriot) is equipped with a combined lubrication system that sprays oil under pressure between the rubbing parts. The lubrication system consists of an oil sump, a pump, pipes and valves, oil channels in the cylinder head, a crankshaft, an oil filter, and electronic oil pressure sensors.

Cooling system

The ZMZ 409 engine is equipped with a liquid, closed, forced cooling system. The system is presented in the form of a water jacket on the cylinder block, on the cylinder head, a water pump, as well as a thermostat, coolant temperature sensor, ambient heating sensor.

The ZMZ 409 engine provides the most optimal thermal regime within 80-90degrees. It is supported by a thermostat. It works automatically. The correct temperature regime allows you to make the UAZ SUV unpretentious in maintenance. The engine of the 409 model is highly economical, and its parts are extremely wear resistant.

In order for the driver to be calm and the ZMZ 409 engine not to overheat, the engineers put an emergency temperature light on the dashboard. The indicator will work if the temperature goes beyond 104 degrees. The sensor is located on top of the radiator tank. Care must be taken that the motor does not overheat, otherwise the 409 engine will need to be repaired.

Power system

The power supply system that the 409 engine has is an injector. Therefore, it is made in the form of injection of the fuel mixture into the pipe using an injector. The latter is fully controlled by the controller or ECU. The engine power system itself is organized from a fuel tank, drives, an electric fuel pump, filters, and a fuel line for the engine.

Maintenance

For this motor to work properly to the delight of its owner, regular maintenance must be carried out. Then, under this condition, the engine will have high performance. For this unit, you need to use only high-quality fuel and lubricants.

You need to take care and maintain all the systems of the motor and car. Only under such conditions the motor will last a long time and will work without breakdowns. It is necessary to regularly check the levels of oil, coolant, belt tensioncooling pump.

In order for the engine to work reliably, it is imperative to take care of the power system. Only with regular maintenance can stable operation be achieved. Be sure all fuel line connections are secure and clean the fuel injectors from time to time.

Repair issues

Engine repair may be needed if the mileage is about 300 thousand kilometers. The need for repairs may come earlier if the vehicle or unit has been used in particularly harsh conditions.

Repair 409 engine is needed if power drops, oil pressure decreases, if the engine smokes, and fuel consumption is increased.

For the engine, parts are sold, so it is not difficult to replace worn parts or assemblies.

Reviews

"Patriot" UAZ (engine 409 is installed on it) shows itself well in the absence of roads. Off-road driving this car is a pleasure. However, the rest of the 409 engine has mixed reviews. Someone claims that the engine has oil, someone writes on the forums that they have encountered increased fuel consumption. Many people write that the 409 engine is unsuitable for driving on asph alt in a UAZ jeep. But on other cars, this engine performs quite well.

As a conclusion

In general, the 409 engine ("Patriot") is a good power unit, despite the fact that its cost is much lower, andthe operating parameters and technical characteristics of this motor are at least no worse than those of some foreign cars. But modern foreign SUVs cost much more money than the UAZ Patriot costs.

Also, work was carried out to convert these internal combustion engines to gas, although the results of such alterations are not particularly encouraging.

Be that as it may, "Patriots" were sold and sold in the automotive market. You can also buy the 409 engine separately. As already mentioned, they are installed not only on the "Patriots", but also on the "Gazelle", "Sable" and "Volga".

So, we found out what the 406 engine has technical specifications, device, design and history of origin.