ZMZ-409: technical characteristics and repair

Ulyanovsk Automobile Plant closely cooperates with ZMZ. The latter actively supplies gasoline engines to Ulyanovsk. These motors are installed on light commercial vehicles, in particular, on "GAZel". In the article we will consider the engine UAZ ZMZ-409. Let's find out what the features of this motor are. The reader will be presented with the characteristic of the engine ZMZ-409, technical characteristics and features of its repair.

General acquaintance

For the first time this power unit was published in the 96th year. This is an atmospheric gasoline engine, which was characterized by a relatively high compression ratio and a lower fuel consumption. Most often it was equipped with an engine ZMZ-409 UAZ "Patriot". But also this motor is found on "GAZel" and "Sable". Previously, Ulyanovsk used the 409th engine and on "Symbiere", which became the successor to the outdated 469th UAZ.

The motor in 2003 suffered minor changes. So, now he began to meet the emission standards of Euro-3, thanks to the installed catalyst and the modernized system of camshafts.

What does ZMZ-409 look like?

Based on the engine described, the 405 engine was injected. The new model has a similar cast - iron block of cylinders. Its height is comparable to the 405th motor. However, the design uses a modernized crankshaft. 409 ZMZ has a mechanism with increased stroke. If on the 405th it was 86 millimeters, then on the 409th it is 94. It is noteworthy that the connecting rods remained the same. Many parts are interchangeable with the 405-m engine. However, the pistons themselves have a displacement of 4 millimeters.

The head of the block, the pallet and the attachments remained the same.

And more about what ZMZ-409 has technical characteristics:

• The engine is characterized by an injector power system and in-line arrangement of the cylinders.
• The gas distribution system operates from the chain transmission.
• In the inlet, 2 valves per cylinder are used (the unit is marked 8V).
• The head of the block is aluminum.
• The compression ratio is 10 atmospheres.
• The cylinder diameter is 95.5 millimeters.
• With a working volume of 2.7 liters (to be more precise, 2693 cm³), the motor develops from 112 to 143 horsepower, depending on the degree of forcing.
• The torque is from 210 to 230 Nm.

The engine is designed for fuel consumption with octane number - A92. The curb weight of the Volga engine without attachments is 190 kg. The motor is equipped with a five-speed manual gearbox.

Fuel consumption

The fuel consumption of the manufacturer is not regulated. And for that there are understandable reasons. After all, this engine aggregates both cars and trucks. So, by car UAZ "Patriot" in a mixed cycle, this indicator, as a rule, is 16 liters in summer and 18 liters in winter operation. And on the "Loaf" and "Sobol" this figure is 15% higher.

Butter

The engine uses a combined lubrication system. In total, 7 liters of oil is used here. However, when replacing, only 6 liters can be drained. As for the type of oils, in this motor can be used products of different viscosities - from 5W-30 to 20W-40.

The manufacturer regulates the replacement of fluid once for 8 thousand kilometers. Also, the Zavolzhsky Engine Plant identifies such a parameter as the natural oil consumption per unit of run. So, for 1 thousand kilometers this indicator should not be more than 100 grams (roughly, a liter for topping up to a subsequent replacement).

Resource

According to the theoretical data of the manufacturer, the resource of the Zavolzhsky engine ZMZ-409 is 150 thousand kilometers. In practice, the figures are significantly different. At one car owners the motor breaks down to 100 thousand, and at others major repairs come only after 180.

How to extend the resource?

The first rule of increasing the resource is the timely replacement of consumables. Air and oil filters change every 8 thousand kilometers. If the car is used in a polluted (dusty) terrain, it is recommended to change the air element 2 times more often.

Together with the lubricant, the oil filter also changes. The regulation here is 7 thousand km, but no more than 10 thousand km. Also pay attention to the color of the oil. Periodically check its level, as the natural care of the lubricant can be up to one liter.

The resource of the chain mechanism of the timing is 80 thousand kilometers. Then the drive begins to stretch and produce a characteristic sound. This negatively affects the operation of the valves and the camshaft.

If this motor is used on commercial vehicles, overloads should be avoided. The described engine does not like high loads.

ZMZ-409 today

Ironically, this engine is still produced serially. Now it can be found on many UAZ models:

• "Hunter";
• "Loaf";
• "Patriot";
• "Canter".

As for GAZ cars, the modern Gazels are equipped with Cummins engines or UMP-4216 (Evotec, 2.7 liters capacity). Gradually ZMZ-409 is losing popularity due to the fact that it has weak technical characteristics.

ZMZ-409 and its malfunctions

For several years of operation, car owners have identified a whole list of problems with this motor. The first is the chain tensioners. The mechanism can jam. Because of this, the engine will require major repairs. ZMZ-409 in the absence of fluctuations begins to make noise in the vicinity of the chain. As a result, the "shoe" is destroyed and the drive jumps to one or more teeth.

Another problem is the tendency to overheat. Also, owners of cars with 405-m and 406-m motor are faced with this. The fault is a clogged radiator or jammed thermostat, which causes the cooling fluid to circulate only over a small circle. It is necessary to change the antifreeze every 60 thousand km run or every 3 years to avoid problems with internal corrosion, and also constantly check the system for the presence of air plugs.

Now about the consumption of oil in the engine ZMZ-409. The technical characteristics of this engine we examined, and we mentioned the "natural" oil consumption. The manufacturer knows this problem, but has not taken any measures to eliminate it. Motorists say that the maslaughter is covered in a labyrinth slinger with rubber tubes.

The design is not technological. If there is a gap between the maze plate and the valve lid, the oil instantly exits. Is it possible to repair? The solution of the problem is the spreading of the metal plate by the sealant. This problem does not solve the problem of oil control, but it allows to reduce its consumption to 500 milliliters by 8 thousand.

Problems with electronics

Very often there are problems with the wiring and the relay. In the latter case, the machine can not be started at all. Under the hood are the relay to start the starter and the gasoline pump. Both can "buggy", and on the go (the machine stalls because of the interruption of fuel supply by the pump). The solution to the problem is cleaning the contacts. Often the relay closes "on the ground". But this procedure does not save for a long time.

Conclusion

So, we found out which ZMZ-409 features. The motor did not turn out to be revolutionary. This is the same 405 engine with the same problems. That is why the Gorky Automobile Plant refused to purchase this power unit.