In our country, the ZMZ 409. engine was especially popular and widespread. UAZ Patriot cars were equipped with this engine. Also, the engine was put on "Sables" and "Gazelles".
Factory History
The history of the Zavolzhsky Motor Plant has been going on for 45 years. In 1958, ZMZ, which mainly produced spare parts and castings from aluminum alloys, was reorganized into a motor plant in a small village. It produced power units for Gorky, Ulyanovsk, as well as the Moscow automobile enterprises.
The first engine that was assembled on it was the GAZ 21 for the Volga Automobile Plant. The engine plant constantly increased its capabilities and power. Constantly improved equipment, workshops, production technologies. Particular attention was paid at the engine factory to the foundry.
In the 80s, the first 4-cylinder and 16-valve gasoline engines were 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 is called ZMZ 4062.
Motor ZMZ 409
This motor was put on the conveyor in 1996. Today, several units with a volume of 2.3 to 2.7 liters are produced on the basis of this ICE. 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. The entire generation of these power plants is equipped with a gas neutralizer and is fully manufactured in accordance with the EURO-2 standards.
For several years of production, engines have undergone major changes and improvements several times. In 2003, the design of the camshafts was changed. Asterisks came to replace the shoes of the tensioners made of plastic, which eliminated the problem of failure of the hydraulic pushers due to clogging of the engine oil with plastic wear products.
Then, along with the fact that the plant switched to imported components for critical engine assemblies, the management conceived even more serious modifications to its products. The camshaft system was replaced by a simplified assembly. This immediately affected reliability. Many other upgrades have also been made.
Today Zavolzhsky Motor Plant is an advanced domestic enterprise. The products that are released here have high characteristics and quality.
Technical characteristics of the internal combustion engine ZMZ 409
The 409 engine is a 4-cylinder, in-line engine that is controlled by microprocessors. The working volume of the unit is 2.6 liters, the compression ratio is -9. The order 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. The mass of the motor is 190 kg. The power system of this engine is an injection of fuel into the pipe. The ventilation system, which is used in this power unit, is closed, forced, working due to vacuum in the exhaust system. The lubrication system is also forced, combined, with spraying. 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 motor ZMZ 409. First, about the cylinder block. The main material for this site 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 fixing attachments and lubrication channels. The lower part of this assembly is equipped with bearings for main bearings for mounting the crankshaft. These bearing caps are not replaceable.
The cylinder head is made in the form of a cast aluminum part. The cylinder head is equipped with inlet and outlet valves. Each of the cylinders is equipped with two valves. On the right are the inlet and exhaust valves on the left. Hydropushers allowed to get rid of the process of manual adjustment of gaps. Now the clearances of the cams are adjusted automatically.
Pistons are also made of aluminum. These parts have thermoregulatory inserts. The skirt is made on a barrel-shaped profile, and is also equipped with a special microrelief, which can significantly improve the running-in, as well as significantly reduce friction losses.
The bottom of each piston has black grooves that are made in order to maximally prevent possible piston impacts on the valve disc bottom in case of possible malfunctions.
Piston rings are mounted three on each of the pistons. On engine 409, 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 covered with tin, and the entire remaining surface of the rings is phosphated.
The crankshaft is made of especially durable cast iron. It is five-bearing; 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 was dynamically balanced at the factory. To exclude its movement along the axes, 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
Camshafts in this engine are cast. The material was high-strength cast iron. To achieve greater resistance to wear, the surface of the camshaft has undergone a special treatment.
These parts rotate on bearings, which are formed by the cylinder head and special removable covers made of aluminum.
The drive is a 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. The 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 between friction parts under pressure. The lubrication system consists of an oil sump, a pump, pipes and valves, oil channels in the cylinder head, a crankshaft, an oil filter, as well as 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, and an ambient heating sensor.
The ZMZ 409 engine provides the most optimal thermal regime in the range of 80-90 degrees. It is supported by a thermostat. It works automatically. The correct temperature regime allows us to make an UAZ off-road vehicle unpretentious in maintenance. The engine of the 409th model has high efficiency, and its parts have enormous wear resistance.
So that the driver would be calm, and the ZMZ 409 engine would not overheat, the engineers brought an emergency temperature lamp to the dashboard. The indicator will work if the temperature goes beyond 104 degrees. The sensor is located on top of the radiator reservoir. It is necessary to ensure that the motor does not overheat, otherwise 409 engine repairs will be required.
Supply system
The power system that the 409 engine has is an injector. Therefore, it is made in the form of injection of fuel sweep into the pipe using an injector. The latter is fully controlled by the controller or computer. The motor power supply system itself is organized from a fuel tank, drives, electric gasoline pump, filters, as well as a fuel line for the engine.
Maintenance
In order for this motor to work properly in joy to its owner, regular maintenance is necessary. Then, when this condition is met, the engine will have high performance. For this unit you need to use only high-quality fuel and lubricants.
All motor and car systems need to be looked after and maintained. Only under such conditions will the motor last a long time and will work without breakdowns. It is necessary to regularly check the levels of oil, coolant, tension of the belts of the cooling pump.
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. You need to be sure that all fuel pipe connections are reliable, and you also need to clean the fuel injectors from time to time.
Repair Issues
Engine repair may be necessary if the mileage is about 300 thousand kilometers. The need for repairs may occur earlier if the car or unit was used in particularly harsh conditions.
Repair 409 of the engine is needed if the power drops, the oil pressure level decreases, if the engine smokes, and the fuel consumption is increased.
Spare parts are sold for the engine, so replacing worn parts or assemblies is not difficult.
Reviews
"Patriot" UAZ (409 engine 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 reviews are mixed. Someone claims that the engine is oil, someone writes on the forums that he encountered increased fuel consumption. Many write that in a UAZ jeep, the 409 engine is unsuitable for driving on asphalt. But on other cars, this motor performs very well.
In conclusion
In general, the 409 engine (Patriot) is a good power unit, despite the fact that its cost is much lower, and the operating parameters and technical characteristics of this motor are at least no worse than some foreign cars. But modern foreign cars, SUVs cost a lot more money than the UAZ Patriot.
Also, work was done to remodel these ICEs for gas, although the results of such alterations are not particularly encouraging.
Be that as it may, the Patriots were sold and are being sold in the automotive market. You can also buy a 409 engine separately. As already mentioned, they are installed not only on the "Patriots", but also on the "Gazelle", "Sables" and "Volga".
So, we found out what the 406 engine has technical specifications, device, design and history of origin.