To improve energy performance, improve fuel efficiency, reduce toxicity and noise, based on the UMZ-421 carburetor engine, models with integrated microprocessor control of fuel injection and ignition were developed: the UMZ-4213 engine for UAZ vehicles and the UMZ-4216 engine for GAZelle vehicles. The device of the cooling system on UMZ-4213 and UMZ-4216 is somewhat different, as it has differences in the scheme for connecting expansion tanks and heating radiators.
General design of the cooling system for UMZ-4213 and UMZ-4216 engines on UAZ and GAZelle vehicles.
The cooling system is liquid, closed, with forced circulation of liquid and an expansion tank, with liquid supply to the cylinders. Includes water pump, thermostat, water jackets in the cylinder block and cylinder head, radiator, expansion tank, fan, connecting pipes, and body radiators.
For normal operation of the UMZ-4213 and UMZ-4216 engines, the temperature of the coolant must be maintained within plus 80-90 degrees. A short engine operation at a coolant temperature of 105 degrees is permissible. Such a mode can occur in the hot season when driving a car with a full load on protracted or urban driving conditions with frequent acceleration and stops.
The device of the UMZ-4213 engine cooling system on a UAZ car.
The device of the UMZ-4216 engine cooling system on a GAZelle car.
The operation of the cooling system of UMZ-4213 and UMZ-4216 engines on UAZ and GAZelle vehicles.
Maintaining the normal temperature of the coolant is carried out using a two-valve thermostat TS-107-01 with a solid filler. When the engine warms up, when the coolant temperature is below 80 degrees, a small circle of coolant circulation operates. Top thermostat valve closed, bottom valve open.
The coolant is pumped by a water pump into the cooling jacket of the cylinder block, from where, through the holes in the upper plate of the block and the lower plane of the cylinder head, the liquid enters the head cooling jacket, then into the thermostat housing and through the lower thermostat valve and connecting pipe - to the water pump inlet. The radiator is disconnected from the main coolant flow.
For more efficient operation of the interior heating system when the liquid circulates in a small circle, and this situation can be maintained for a long time at low negative ambient temperatures, there is a 9 mm throttle hole in the liquid outlet channel through the lower thermostat valve. Such throttling leads to an increase in the pressure drop at the inlet and outlet of the heating radiator and a more intensive circulation of fluid through this radiator.
In addition, throttling the valve at the liquid outlet through the lower thermostat valve reduces the likelihood of emergency engine overheating in the absence of a thermostat, since the shunting effect of a small circle of liquid circulation is significantly weakened, so a significant part of the liquid will go through the cooling radiator.
In addition, to maintain the normal operating temperature of the coolant in the cold season, UAZ vehicles can be equipped with shutters in front of the radiator, with which you can adjust the amount of air passing through the radiator.
When the temperature of the liquid rises to 80 degrees or more, the upper thermostat valve opens, and the lower valve closes. Coolant circulates in a large circle through the radiator.
For normal operation, the cooling system must be completely filled with liquid. When the engine warms up, the volume of liquid increases, its excess is pushed out by increasing pressure from the closed circulation volume into the expansion tank. When the temperature of the liquid drops, for example, after the engine stops working, the liquid from the expansion tank returns to the closed volume under the action of the resulting vacuum.
On UAZ vehicles with an UMZ-4213 engine, the expansion tank is directly connected to the atmosphere. The regulation of fluid exchange between the tank and the closed volume of the cooling system is regulated by two valves, inlet and outlet, located in the radiator cap.
Now popular and widespread commercial vehicles of the GAZ brand are equipped with UMZ engines manufactured at the Ulyanovsk Motor Plant.
A bit of history
The Ulyanovsk Motor Plant dates back to the distant 1944, and only in 1969 the company produced the first engine of the UMP brand. Until the sixty-ninth year, the plant was engaged in the production of small-capacity UMZ-451 engines and their components.
Since the release of the first motor, they have faithfully served on trucks, off-road vehicles, on small buses. In 1997, AvtoGAZ became the main consumer of engines, which equipped most models of the GAZelle line with UMP units.
Design features
At the moment, there is a wide range of internal combustion engines of the UMP model range, which are installed on various models of Sobol, UAZ, GAZelle cars. Installed engines have a number of common features, but may differ in some details and principles of operation:
- Carburetor and injection.
- Four-cylinder in-line.
- Power 89-120 liters. With.
- Environmental standards "Euro-0", "Euro-3", "Euro-4".
All engines are light, small and reliable. They are distinguished by an affordable price.
One of the features of the engine can be called the original design of the cylinder block, cast from aluminum, with pressed-in liners made of gray cast iron. Crankshafts of motors of all modifications are hardened during manufacture of the main and connecting rod journals with high-frequency currents. Self-clamping seals the rear of the crankshaft.
Lineup modifications
UMP motors have two lines of power units designed to equip various vehicles.
Cars of the GAZelle family are equipped with the following models: UMZ-4215; UMZ-4216; UMZ-42161; UMZ-42164 "Euro-4"; UMZ-421647 "Euro-4"; UMZ-42167.
The main part of the engines is published in several variations, which differ in their configuration, power and economical performance. At the moment, the production of units running on gasoline with an octane rating of 80 has ceased.
All engines are designed for 92 and 95 gasoline, as well as with the ability to run on gas.
This review is dedicated to the UMZ-4216 power plant, its characteristics and properties will be detailed.
pros
The advantages of the motor rightfully include maximum torque at low speeds, excellent technical characteristics, as well as ease of maintenance of components and assemblies. The 4216 engine has become the first domestic device that has a warranty period when gas equipment is installed on it.
Modernization
The unit is equipped with a microprocessor control system for fuel mixture injection and ignition system. The knock and oxygen sensors of the 4216 engine directly affect the operation of the integrated electronic control system and the unit as a whole. To change the economic characteristics and increase competitiveness, the following design additions were made to the power plant:
- To improve performance, the compression ratio in the cylinders was increased.
- To reduce oil consumption, the crankcase exhaust system was modernized.
- The reliability of the motor is ensured through the use of advanced parts and materials.
At the same time, the unit has not changed in terms of overall parameters and standard characteristics (working volume - 2.89 liters, piston stroke, cylinder size).
For the first time, the GAZ-4216 engine began to be equipped with imported parts, which only increased the quality of work and durability in operation. The power unit was equipped with spark plugs and fuel injectors manufactured by Siemens, as well as a German-made Bosch throttle position sensor.
The main malfunctions of UMP
In the past, the most common engine failure was intake manifold damage. According to the developers, a manifold made of fragile material was installed on the 4216 engine. But already in 2010, this shortcoming was corrected by the use of better material.
A flaw was also found in the cooling system.
At medium engine speeds and when the car was moving at a speed of 60 km / h, the coolant temperature was normal, but as soon as the speed was reduced or it got into a traffic jam, the 4216 engine rapidly gained temperature, until the coolant boiled. The reason lay in which included a forced cooling fan.
Technical specifications
The engine runs on AI with an octane rating of 92 and 95. Four-cylinder, in-line cylinder, eight-valve. The cylinders have the following working order - 1243. Its diameter is one hundred millimeters, and the piston movement is 92 millimeters. The engine capacity is 2.89 liters, it develops a power of 123 "horses" at four thousand revolutions. motor - 8.8. The maximum torque is 235.7 at 2000-2500 rpm.
A GAZelle with an UMZ-4216 engine can reach a maximum speed of 140 kilometers per hour, which is a good indicator for this class of car. Fuel consumption depends on the workload of the car, driving style and road conditions, but in general it looks like this: at a speed of 90 kilometers per hour - 10.4 liters. When driving at a speed of 120 km / h - 14.9 liters.
Supply system
It consists of a fuel supply device and various fuel lines, injectors, fuel and air filters, air supply pipes and a receiver, an idle speed controller.
The fuel supply is controlled by a variety of sensors: charge air temperature element, crankshaft and camshaft position sensors, absolute pressure detail, throttle position.
The feed control system is also equipped with an oxygen indicator. The latter is installed in the exhaust system in front of the converter. For greater reliability and durability, the 4216 engine (injector) should only run on high-quality gasoline, taking into account regular replacement of fuel filters and periodic diagnostics of fuel equipment. Motorists say that with proper operation, the total resource of the power unit can reach 500 thousand kilometers. Injector installations also differ in this feature (meaning the ZMZ 405 and 406 engines).
Gas distribution mechanism
In 2010, the gasoline engine underwent the process of modernizing the gas distribution mechanism. In general, this affected the change in the profile of the camshaft cam, which contributed to an increase in the valve stroke by one millimeter. These innovations were necessary to improve the stable operation of the unit at idle, as well as to achieve the norms and requirements of the Euro-3 standard.
At the same time, the valve springs did not change, and this led to the fact that the acting force on the springs crossed the norm, and now it was equal to 180 kgf. When installing a conventional set of rods on a new engine, until the state of a warm engine was reached, the knocks of hydraulic lifters were heard.
To prevent this problem, change the spring force by removing the internal valve springs.
Benefits of booms with hydraulic lifters
The UMZ-4216 engine with hydraulic compensators does not require additional maintenance due to the absence of valve clearances throughout the entire period of operation. This significantly reduces the noise level. High engine speeds are no longer critical, since the design of hydraulic compensators includes a factor for stabilizing the appearance of critical loads. The degree of wear of the mating surfaces of the mechanism parts is significantly reduced. Due to the optimization of the gas distribution phases, harmful impurities in the exhaust gases are consistently low throughout the entire period of operation.
crankcase ventilation
The motor is equipped with a closed-type crankcase ventilation system. Part of the gases passing through the compression rings is discharged into the intake manifold in a combined way. The operation of the system is carried out due to the pressure difference between the crankcase and the intake tract. At the moment when the 4216 engine is operating in the increased load mode, the gases are discharged through a special large branch.
On a small branch, the removal of gases occurs at the time of operation of the installation at and at minimum loads.
A ventilation system is installed in the front cover of the pusher block, which performs the function of separating oil microparticles from gases and serves to prevent dust from entering the crankcase at the time of increasing thrust in the intake system.
Oil
Engine lubrication system - combined type (spray and under pressure). The oil that the oil pump draws from the sump passes through the oil passages into the oil filter housing. Then it enters the cavity of the second jumper of the block, and from there - into the highway. The crankshaft and camshaft main journals receive oil from the oil line.
The connecting rod journals are lubricated due to the flow of oil through the channels from. According to this principle, the parts of the gas distribution mechanism are lubricated.
The volume of oil poured into the crankcase is 5.8 liters.
Cooling system
The cooling system is closed, water. It consists of a water pump (pump), a thermostat, a water jacket in the cylinder block and head, a cooling radiator, an expansion tank, a forced cooling fan, connecting pipes and a passenger compartment heater radiator.
The GAZelle 4216 engine, depending on the modification, may have distinctive features in the way the expansion tank and heater radiator are connected.
At this time, the cost of the engine will vary depending on the year of manufacture and on its modification. For example, the first configuration with a generator and a starter, with a diaphragm-type clutch, with flat support brackets for an updated frame will cost about 130 thousand rubles.
If you buy a 4216 engine from your hands, the price will drop significantly (depending on the mileage of the car).
So, we found out what technical characteristics the unit of the Ulyanovsk plant UMZ-4216 has.
Question: GAZelle-Business, UMP 4216 elimination of overheating
Good time of the day.
Factory defective cooling system on all vehicles with this engine. Found out just when I picked up the pump. there is no circulation of coolant at all in the region of 3-4 cylinders. To eliminate, we buy a tee with a diameter of 20mm. half a meter hose by 20mm, 4 clamps and the most difficult thing is to order a threaded fitting from a turner and a 20mm hose outlet. We screw in the fitting from above instead of the plug in the region of the 4th cylinder. Who remembers at 402, 421 there used to be a faucet. We cut the tee into the hose going into the pump, this is the lower hose (the upper one is the outlet from the thermostat). Already tested on 2 gazelles. The temperature is stable there are no emissions when the engine is stopped. Good luck.
By the way, internal combustion engine cooling fans are also defective, with blades directed in the opposite direction, as a result, it blows oncoming flow.
Answer:
The old guard did the right thing. The current one just stupidly screwed the cork
Miniatures
Answer:
Hello!
Best wishes,
Website:
Question: Need a repair book for UMZ-4213
We need a book like this: "Engines UMZ-4213, UMZ-4216, Euro-3. Repair, device, maintenance" Publishing house Ulyanovsk Automobile Plant. Couldn't find it on their website. Tell me where can I download?
Answer:
Hello!
If you need to have a book version with you, you can buy this edition in the online store 469-452.ru.
Best wishes,
Online store 469-452.ru.
Website:
Question: Pushers for umz 4216, a problem.
Greetings dear colleagues.
The other day I was picking umz 421. It turned out that the pushers cannot be reached up (they rest against the block) only by removing the camshaft and, accordingly, down.
On umz 417, zmz 402, I don’t remember such an ambush.
Am I so lucky or do all 4216 have this?
Thank you in advance.
Answer:
|
Message from Kosska On all 421 so |
umz-solid hemorrhoids.
Question: Which is better, the 405th or the UMP motor?
Somehow I was listening to a conversation, driving gazelles, so they blame the motor of the Ulyanovsk Motor Plant, such as there is not enough power, it eats a lot.
And they praise the 405th motor, I forgot which plant produces them.
Gazelle at UMP eats 17.5 liters per 100 kilometers, and the 405th 12.5 liters.Who has such knowledge which motor is better to order for a gazelle? serial UMP or another engine plant, 405th.
Answer:
In Nizhny Novgorod, several companies put 405 engines on new gazelles, sell new cars with 405 engines
So there are firms in other cities.
There was a problem with toxicity according to Euro-4, now we have received permission.Diesel Kamens is excluded.
There equipment with HBO.I myself have been operating diesel engines for 20 years, and there is no desire to operate a diesel engine in the cold.
Question: Capital ZMZ-409 or replacement for UMZ-4216?
Good day to all.
I faced a choice. Replace my ZMZ-409 with an almost new UMZ-4216.
Or just make the capital of your ZMZ 409.
What do you advise, maybe someone has come across such a choice, what are the arguments in favor of each engine?
Thank you all in advance for your replies
Answer: For the province, if the roads are primers and spring-autumn is mud, then UMP, if it’s just asphalt for fishing and an exit to the river, then 409 can be used ... Completely different engines, there should be a choice according to the mind, but the Plant doesn’t give us a choice ... A traction modification of the 409th appeared and immediately disappeared, the diesel was pissed off ... I have everything ...
Question: a question about the motor 4213
Hi all.
I thought about changing my vehicle. To wave Goat at something loaf-shaped. I want to take a car with a 4213 engine. So as not to block the injector from the 417th again.
and here is the question. They told me here that you can find horseradish spare parts for this motor. From 4216, even the sensors are not all suitable. And there are some problems with the catalytic converter.
As far as I always thought, 4213 is the same 4216 from the gazelle business. Only the bell is different with a clutch for a Gazelle gearbox and a propeller lower on the bracket. Well, the mounts are still different.
The injector is the same as the 4216. The motor itself is the same as the 4218 carb.
enlighten me on what I'm wrong.
Answer:
I don’t really believe that after injection on the carb you will return, but there will hardly be any problems with spare parts.
Question: Which injection motor to choose
Hi all!
Still not finished with the resuscitation of the UAZ. I'm already thinking about my plans for next winter. Or rather, changing the 402 motor, to something more ....
I looked at inodizels - now it's expensive.
Now I'm looking at domestic injection engines ...
406,405,409 are good, but expensive parts put me off.
It remains UMZ 4216. Simple as 402, repaired on the knee, good bottoms. But ancient as a mammoth, low-powered, noisy.
For some reason, I tend to install 4216.
Guys, tell me, am I right?
Answer:
now there are a lot of lows in bulk, so it’s better to go at 3000 rpm, when your pump pumps normally and the lubrication system works, than to go at 1500 rpm. Everything has been tested for a long time, the old stunted and gluttonous engine, from which oil is always flowing, is no longer interesting.
Question: How to make an injector from 4218 carbs?
Actually, the thoughts do not leave me, to get away from the carb to the injector. There is everything attached with UMP 4216: inlet / outlet, muffler with lambdas, fuel rail, throttle assembly for a cable, brains with MIKAS 10.3 wiring. I can make a tank with a built-in Gazelle pump. I understand that you need:
1) Pulley with damper from 4216
2) Shut off the drive of the distributor and fuel pump
3) DPKV somehow fasten, DPRV, in principle, there are firmware without it
What else? Has anyone done this before please let me know...
Answer:
A little off topic:
And what if the other and on the mechanics?
It's easier to switch from one to another.
For spare parts - I agree - you take a pig in a poke ...
Answer:
throws nothing away
Question: Help in connecting MIKAS 7.2 to UMZ-4213
Hello, tell me, I want to put a umz 4213 on a carburetor, a Mikas 7.2 to it, but there is no braid. From 4216 a braid is suitable
or not and does anyone have a wiring diagram
Answer: It’s easier with a native oblique, from 4216 you will have to install an ignition module. And so, in principle, they put everything ... And there is a diagram on the drive with explanations.
Question: High level in the dispenser
Good evening, members of the forum, I began to prepare the car for hunting, and when checking the oil in the razdatka, I found a specific excess of the filler neck, in the box, underfilling 600 grams. I called the service and they said that 80% of the cars that come to them all have a different level and it makes no sense to disconnect the box with the transfer case and change the gasket, it makes no sense, the level will still jump, they offered to just add it to the box and not bother. Tell me, does it make sense to do something or score and go hunting, given the fact that there are only four days left. UMZ 4216 engine, five-step ADS box, straight-tooth transfer case.
Answer:
You can’t do it without removing it, now I’ll wait for the removal, and then I’ll do it. Thanks everyone for the replies. Share and let him drive out.
Question: oil pressure
Good day to all! I came across this parsley. When the engine warms up at idle and under load up to 1500 rpm, the oil pressure light blinks while driving, when the engine is braking, the light goes out. the pump is new, the shaft is polished, the sensor and
the filter has been changed, the oil is lukoil semi blue 10-w40 engine umz 4216.
Who can faced such nonsense? Could it be that the oil loses viscosity and becomes like water, but why then, when coasting in gear, the light does not light up to the idle level?
Answer: Fill the shell.
Question: UMP 4216 no oil pressure
Gazelle business, there is oil pressure for cold, as soon as the machine reaches operating temperature, the pressure disappears, the pump has changed, the filter has changed, the pump drive has working wear, in appearance it seems to be working, where to dig further, thanks
Answer:
Message from Ours won!
Does the radiator get hot? He is generally cold. Young lady. Maybe you should not guess and go for diagnostics?
The oil cooler has nothing to do with the temperature of the antifreeze.The San oil cooler is constantly hot, I have it that cannot be switched off.
Question: Replacing the outboard bearing with a Gazelle business
Greetings to all!
I see here a very active forum and knowledgeable people, so again I turn to you with a question
Who can tell how to replace the outboard bearing with a Gazelle BusinessI am attaching a picture of the bearing to make it easier to understand what it is.
Thank you
Answer:
Get rid of the outboard altogether
Question: Was 4213 and 4216 put on a goat
4216 or 4213 officially from the factory on 3151 with front drums set or not?
Answer: UAZ-421300
gazelle 421600 as already mentioned ..
there is general confusion with bridges .. that was what they put and the brakes in the same way.
Question: Radiator from a patriot on 31514
I decided that I don't need this. There is no such cry on the topic of overheating on the forums of patriots.
Plus, at the same time, I decided to stick a fluid coupling from the same patriot.
The fitting shows that honeycombs fit exactly into our TV, but not tanks.
You can put it in this position, but then the Patrovsky diffuser will not enter and you will need to collect your own.
Therefore, I simply measured the distance and moved the radiator in the face.
You can make a bracket that is screwed to the frame and holds the radiator, but I decided to hang it on the face, as is done on the patre.
Approximately this arrangement
First, I made up the upper mounts from what was, then I also redid it for regular Patrovsky
The sawn muzzle was reinforced with 16 profiles in a circle
Immediately there I made a mount for an oil cooler, and also from a patriot
Then boiled the whole face.
The hood cable can no longer be placed in its regular place, so I made a copper tube for it, bypassing the reinforcement
After painting, I hung the electric valves again from Patra. In extreme cases, controlled from the brain.
Expansion tank attached as high as possible
The diffuser was sawn in the area of the power steering pump and the crankshaft pulley and sawn in half so that it could be pushed in with the fluid coupling installed, and in order to facilitate work with this part of the motor in the future
Finished look:
Satisfied with the first test. The fan blows like hell, much more powerful than the 11-bladed meat grinder that stood before, the diffuser also helps a lot.
The radiator is two-way, that is, first the liquid goes from left to right, then back. So, at a working temperature of about 85 degrees, the right tank feels barely warm, that is, a passage in one direction is already more than enough in St. Petersburg's conditions.
The temperature arrow is now pinned. And the main surprise that befell me was that the motor immediately after stopping does not heat up, as before, but immediately cools down! After driving along the highway and stopping at a gas station, I start the engine that has cooled down by 5-10 degrees, and not heated by 10-15.
So, about 2 months ago, I was returning from a flight on my Gazelle 32215 with an engine 4216 from a trip, suddenly, quite unexpectedly, the temperature of the engine began to drop (at least it showed DTOZH on the dashboard) to a non-working 40-50 degrees, it blew cold from the stove !!! 0 km to the box and parked the car.
I decided to tritely find out why CHEK caught fire after a laptop diagnostics, the following errors were revealed - a temperature sensor, an absolute pressure sensor, and a phase sensor. What exactly is wrong with them, the program does not give out, but it says that the signal is incorrect. Further, "knowledgeable servicemen" in a voice change the temperature sensor and you will be happy .......... I followed their lead - put the catalog, start the car - it warms up for a long time even in the garage + 10C ..... I begin to understand that either the sensor shows the wrong temperature, or TOSOL does not circulate in the system (hence the sensor shows the wrong temperature) .......... Soon I turn off the engine, and lo and behold, Tosol starts spitting into the expansion tank and moreover so that the cork almost breaks off !!!...... One specialist suggested that a skiff came to the gasket under the cylinder head, they say change it ... - changed it - it didn’t help .......... the same song continues, another specialist says they say - definitely a skiff to the thermostat, change it for sure !!! - changed - it didn’t help .............. it got worse - when the engine was running, the pipe going from the pump to the radiator became quite soft, it became clear - Khana pump impeller - removed the pump - so the impeller simply switched from a solid state to a liquid one (it’s plastic on UMP) .......... changed the pump because I didn’t find a repair kit ........... Bottom line, the motor continues to boil while driving, while the temperature sensor starts to to show that the tamper is supposedly falling - in fact it is not so ...... and even when the engine is stopped, antifreeze is thrown into the expansion tank, it is already cracking ......
Tell me good people, maybe someone has come across sores umz4216, what are these symptoms and how to treat them ............... The most terrible thought comes - maybe the cylinder head is tryndets, but I'm driving it for now .......
Answer:
Message from Grom 22rus
I am carefully watching the discussion. I don’t pour water.))))
Your thoughts on the discussion ........ what ideas can you?
Question: I FURIOUSLY ask for help on 4216 Gazelle
The people ... The background is that the camshaft caught a wedge because of the previous rider. Prior to this, the cars went and everything was fine. They made a capital with the replacement of a shitty cloud of mechanical parts. Purely for myself, so as not to bother later, that is, the switchgear is new, its bushings too. Crankshaft and block boring Both new timing gears. Now the machine works somehow tolerably ... but when the coolant heats up to about 75 degrees, the computer turns off 2-3 cylinders and alga .. Restarting helps for a short time (min 5) and again the same story ... the valves were adjusted three times by 0.20, 0.25 and 0.30. At 0.30 it works cleaner. 2 diagnostics showed incorrect operation of the crankshaft sensor and the trailer from it the camshaft sensor. Like the ignition is set to the wrong mark. Today we dismantled the face once again to make sure that the marks are in their places .. rearranged the nozzles in this way; -2-1 4-3 in order to exclude a non-working nozzle ... all to no avail ... I am in the area of \u200b\u200breversal 2 hundred where my unit can go to no avail .... I'm already exhausted from this shaitan cart ... please no flood .. There are already any diagnostics, let alone spare parts, so already "thrown away" 35 thousand....
Answer:
I dug up such a topic. For many, a similar problem was treated by replacing the pulley mortar. It breaks the groove and the master disk shifts.
We tirelessly monitor the work of Ulyanovsk engines on controlled GAZelles. Of the 300 thousand kilometers declared by the manufacturer, the UMZ-4216 motors passed a third before overhaul. However, those who know the engines of the UMP family of past years of production will note that 100 thousand is a rather critical mileage. Meanwhile, UMZ-4216 continues to work quite normally, although some engineering miscalculations and the low quality of components make themselves felt. But the Ulyanovsk plant, albeit belatedly, nevertheless implements measures to improve the quality of its products.
The carrier operating these domestic trucks has long abandoned branded service stations and maintains equipment, as well as struggling with malfunctions on its own. In order not to once again put the GAZelle for repair due to a faulty fan clutch, savvy mechanics installed a casing with an electric fan on the inside of the radiator. These spare parts, originally intended for GAZelles with ZMZ-405, are sold in any store and cost about 2,500 rubles.
Of course, in addition to the casing with the fan, I had to purchase more relays, temperature sensors that will turn the fan motor on and off and a tee for inserting the sensor into the pipe. Re-equipment of one cooling system took a couple of hours and did not require high qualifications from mechanics. The main thing in this work is high-quality assembled and neatly laid electrical wiring. After all, the fan motor consumes a current of 15–20 A, and in the event of a bad
contact or use of too thin wire before a fire is close.
The rest of the assembly should also not be treated carelessly. For example, on the GAZ conveyor (as applied to the ZMZ-406 engine), the fan switch-on sensor is installed in the left radiator tank, where the liquid temperature is lower than in the right one, since it has time to cool down when passing through the radiator channels, the liquid enters the right tank directly from the engine cooling jacket. It is better and more correct to install a tee with a sensor on the UMZ-4216 in the lower pipe (it is already detachable), at the inlet to the water pump.
Crashing and soldering the threaded part for the sensor into the radiator itself is more difficult. However, the mechanics of our GAZelles introduced sensors into the upper radiator pipe (less messing around). As a result, the fan turns on earlier than necessary - at a lower temperature. At the same time, the engine warms up somewhat worse, and since it is equipped with electronically controlled fuel injection, errors in the operation of the fuel system may occur - a mixture enriched in composition will be prepared. This will increase fuel consumption. In addition, the following is also possible: the upper pipe is hot, but there is no circulation of fluid through the radiator. But the sensor will not “understand” this - the fan will turn on and will work completely pointlessly, in addition, the load on the wiring will increase, the cyclical operation of the relay and sensor contacts will become higher. The correct installation of the sensor, in the lower branch pipe of the UMZ-4216 engine, allows you to get a more stable temperature regime of the engine.
In addition, the engine warms up faster after starting, consumes less fuel. The switched on electric fan rotates quickly enough even at low engine speeds and this reduces the risk of engine overheating in traffic jams and when working with a load in difficult road conditions at low speeds. In such cases, a mechanically driven fan is not always effective on the GAZelle.
Due to constant breakdowns in the cooling system fan clutches, we began to install diffusers with fans equipped with electric motors on radiators. We already have successful experience in operating this design on the UMZ-4216 engine - back in the summer, as an experiment, we converted one GAZelle in this way. So far, four cars have gone through this procedure. Most recently, we measured the fuel consumption of GAZelles with Ulyanovsk engines. For these purposes, they used a loaded car, refueled a full tank, fixing the amount of fuel, and sent it on a flight. Upon arrival, the GAZelles again drove to the gas station, where they recorded how much fuel they had to fill in for the second time. Taking the number of mileage per shift and the amount of fuel filled a second time, we calculated that the average consumption in mixed mode was 19.9 liters.
Initially, the design of our engine did not provide for an electric clutch, the fan rotated constantly and was installed on the water pump. The electric clutch for turning on the engine cooling fan was mounted on the initiative of GAZ. The GAZ designers did not intend to install a fan electric motor, as is done on most cars, since this required a more powerful generator. After all, the GAZelle in the performance of a minibus is equipped with additional heaters and lamps. In favor of the electric clutch, its quiet operation is also partly due to it, the GAZelle passed the noise test with a margin.
The cooling system is liquid, closed, with forced circulation of liquid and an expansion tank, with liquid supply to the cylinder block.
The cooling system includes a water pump, a thermostat, water jackets in the cylinder block and cylinder head, a radiator, an expansion tank, a fan, connecting pipes, and body heating radiators.
Engine cooling systems for UAZ and GAZelle vehicles have some differences in the scheme for connecting expansion tanks and heating radiators.
Engine cooling system for GAZelle vehicles
1 - heater radiator
2 - heater valve
3 – a head of the block of cylinders
4 - gasket
6 - two-valve thermostat
8 - exhaust pipeline
9 – steam outlet
9a - pipe for supplying fluid to the expansion tank
10 - branch pipe for draining fluid from the expansion tank
11 - cork
12 – expansion tank
13 - mark "mm"
14 - thermostat housing
15 - pump of the cooling system
16 impeller
17 - connecting pipe
18 - fan
19 - radiator
20 - radiator drain plug
21 - inlet pipeline
22 - cylinder block
1 - heater radiator
2 - heater valve
3 - cylinder head
4 - gasket
5 - intercylinder channels for the passage of coolant
6 - two-valve thermostat
7 – the gauge of the index of temperature of a cooling liquid
8 - exhaust pipeline
9 - radiator cap
10 - blinds
11 - cork
12 - expansion tank
13 - mark "mm"
14 - thermostat housing
15 - cooling system pump
16 - impeller
17 - connecting pipe
18 - fan
19 - radiator
20 - radiator drain cock
21 - inlet pipeline
22 - cylinder block
23 - drain cock of the cylinder block
For normal operation of the engine, the temperature of the coolant must be maintained within plus 80°-90°C. A short engine operation at a coolant temperature of 105°C is permissible. Such a mode can occur in the hot season when driving a car with a full load on long slopes or in urban driving conditions with frequent acceleration and stops.
Maintaining the normal temperature of the coolant is carried out using a two-valve thermostat with a solid filler TC-107-01, installed in the housing.
When the engine warms up, when the temperature of the coolant is below 80°C, a small circle of coolant circulation operates. Top thermostat valve closed, bottom valve open. The coolant is pumped by a water pump into the cooling jacket of the cylinder block, from where, through the holes in the upper plate of the block and the lower plane of the cylinder head, the liquid enters the head cooling jacket, then into the thermostat housing and through the lower thermostat valve and connecting pipe - to the water pump inlet. The radiator is disconnected from the main coolant flow. For more efficient operation of the interior heating system when the fluid circulates in a small circle (this situation can be maintained for a long time at low negative ambient temperatures), there is a 9 mm throttle hole in the fluid outlet channel through the lower thermostat valve. Such throttling leads to an increase in the pressure drop at the inlet and outlet of the heating radiator and a more intensive circulation of fluid through this radiator. In addition, throttling the valve at the outlet of the liquid through the bottom valve of the thermostat reduces the likelihood of emergency engine overheating in the absence of a thermostat, because. the shunting effect of the small circle of fluid circulation is significantly weakened, so a significant part of the fluid will go through the cooling radiator. In addition, to maintain the normal operating temperature of the coolant in the cold season, UAZ vehicles have shutters in front of the radiator, with which you can adjust the amount of air passing through the radiator.
When the liquid temperature rises to 80°C or more, the upper thermostatic valve opens and the lower valve closes. Coolant circulates in a large circle.
For normal operation, the cooling system must be completely filled with liquid. When the engine warms up, the volume of liquid increases, its excess is pushed out by increasing pressure from the closed circulation volume into the expansion tank. When the temperature of the liquid drops (for example, after the engine stops working), the liquid from the expansion tank returns to the closed volume under the action of the resulting vacuum.
On UAZ vehicles, the expansion tank is directly connected to the atmosphere. The regulation of fluid exchange between the tank and the closed volume of the cooling system is regulated by two valves, inlet and outlet, located in the radiator cap.