ZMZ PRO 409 (409051) 2.7 MPI 150 hp - UAZ Patriot and UAZ Pro engine. Characteristics, consumption, breakdowns, reviews, pros and cons

Gazelle 405 injector: characteristics, operating features

The Gazelle 405 car with an injector engine is equipped with a new fuel supply system, which allows for more economical consumption and distribution of fuel. Let's consider the main qualitative characteristics of this engine model, operating principles, and also determine the advantages and disadvantages of using a fuel injection system.

Engine “ZMZ 405″ - Technical characteristics

The prototype of the “405” was the “406” unit, which was produced since 1997. The model came in two versions: with a carburetor and injection. The motor was used in GAZ cars and is popular because it is simple and economical.

Since the “406” unit is the basis for several modifications of the units, ZMZ engines with the abbreviations “405”, “406”, “409” have similar technical characteristics. Each of the modifications was based on the same frame and connecting rods. To improve power performance, the “409” model uses a crankshaft with an increased stroke, as well as displacers shifted by 0.4 centimeters.

Skeleton:

Technical parameters of the ZMZ-405 motor:

ZMZ 4054.10:

Operating principles of an injection engine

An injector is a special system for injecting fuel into a car engine. Unlike the operating system of a carburetor engine, here fuel is forcibly injected into the cylinder using injectors. Because of these features, cars with such systems are called injection.

When the engine is in working condition, the controller receives information about such indicators as:

• crankshaft position and speed;
• antifreeze temperature;
• vehicle speed;
• all uneven road surfaces;
• presence of malfunctions in the motor.

As a result of analyzing all received data, the controller controls the following systems and mechanisms:

• gasoline pump;
• ignition system;
• diagnostic system;
• fan of the system, which is responsible for cooling the car.

Because the system is controlled by software, injection parameters change instantly, allowing many functions and data to be taken into account.

Advantages and disadvantages

Unlike carburetor engines, engines with an injection control system can reduce fuel consumption, simplify and improve the quality of Gazelle engine control, and meet all requirements for the composition of exhaust gases

. There is no need to manually adjust the fuel supply system.

But there are also some disadvantages of using injection engines: a significantly high price, if they break down they cannot always be repaired, the fuel must only be of high quality. If you have little experience in repairing Gazelle cars, it requires constant contact with special service stations, which leads to additional costs.

Repair of main components

Repair of parts and the entire engine cooling system can be found in the ZMZ 405 repair manuals. The most common system breakdowns are the water pump and thermostat. Replacing the pump is quite simple:

1. Drain the coolant.
2. The drive belt is dismantled.
3. The water pump mounting bolts are unscrewed.
4. The old pump is removed and a new pump is installed. It is important not to forget to install the gasket.
5. Install the belt into place.
6. Fill the system with coolant.

Replacing the thermostat is carried out in the same way as a pump, only the element itself is located in a housing that consists of two elements. To change it, you just need to drain the liquid and disconnect the pipe. Then remove the cover and change the thermostat directly.

Recently, radiators have become a common malfunction; they become punctured by pebbles on the highways when the speed is high enough. Typically, motorists try to solder this element, but it does not always work.

What factors determine fuel consumption?

The main factors affecting fuel consumption on a Gazelle with a 405 engine are:

• driver behavior while driving;
• It is necessary to periodically check the condition of the wheels. Let there be more pressure in the wheels than the lack of it;
• engine warm-up time;
• additional parts that drivers often put on the car body;
• technical condition of the car;
• an empty car consumes less fuel than a loaded one;
• inclusion of a large number of additional equipment.

What can be changed

Fuel consumption will increase significantly if you constantly exceed the permissible driving speed, often move away sharply, while accelerating too much or pressing the brake pedal sharply.

Warming up the car engine also affects the amount of fuel consumed. Try not to warm up the engine for a long time, and, if possible, start driving immediately.

If you are driving short distances, then, if possible, you should not turn off the car engine, since constant turning on and off at short intervals leads to an increase in fuel consumption.

If the car is in a technically faulty condition, then the engine does not operate at full power and the fuel simply, as they say, “flies down the drain.”

Such auxiliary parts as a stove, radios or other audio systems, air conditioners, always-on headlights, wipers, even the use of winter tires affect fuel consumption. So , for example, turning on the high beam increases the amount of fuel consumed by the Gazelle by more than ten percent,

using air conditioning for a long time - by 14%, and driving with windows open at speeds exceeding 60 km/h - by more than 5%.

From the above, we can conclude that before wondering why the gasoline consumption of your Gazelle has increased, analyze all your actions related to the operation of the vehicle, check the serviceability of the car engine, inspect the fuel tank, and, if possible, eliminate all problems, reduce to minimize the number of factors affecting fuel consumption.

Fuel consumption for different engines

The fuel consumption of Gazelles with different types of engines is insignificant, but still different. As already mentioned, the number of liters consumed is influenced by a number of external factors - unevenness of the road surface, traffic jams, climatic conditions, the use of a large volume of various auxiliary parts inside the car body, and much more.

Various sources of information provide different data on the fuel consumption of the Gazelle 405, injector. With an engine capacity of 2.4 liters, the average fuel consumption varies within eleven liters per hundred kilometers.

But, when using two types of fuel, this figure can be significantly reduced.

The gasoline consumption of the Gazelle ZMZ 405 per 100 km is approximately twelve liters. But this indicator is relative, since it may change under different operating conditions.

The real fuel consumption of the Gazelle per 100 km can increase significantly depending on the density of population and the condition of the roads.

When there are traffic jams or heavy traffic, the car moves at a slow speed, which leads to increased fuel consumption.

Average fuel consumption on the highway is within the stated standards, since here it is possible to adhere to the speed limit. And if your car is not too loaded, and you adhere to all the rules for using additional devices, then you should not worry about significant fuel consumption.

For example, Gazelle business, due to the introduction of more advanced technologies, has reduced fuel consumption by more than five percent. And in a Gazelle car with a Euro engine, due to the increase in engine volume, fuel is consumed even less,

in comparison with other models.

"Gazelle" V8 300 hp

Exhaust system from a BMW seventh series before installation on a Gazelle © From the owner’s archive How Saransk craftsmen installed a Japanese engine from a Lexus with an automatic transmission in a Nizhny Novgorod truck

There are smart specialists in Russia who can not only build a limousine for Putin, but also make a cargo gazelle drive faster than many passenger cars. Denis Turkin has not yet reached the former (they are resting on their laurels after the presidential inauguration), but he has appreciated the fruits of the labor of the latter - a swapped* truck and a homemade camper trailer.

* the term “swap” means replacing the engine and/or transmission of a vehicle. The word comes from the English swap (translated simply as “replacement”), which is why in Rus' they often say “swap”, but the English word is pronounced with an “o”, which means it’s correct to write “swap”.

Motors

“Well, let’s go for a ride first?” A resident of Saransk, Sergey, does not look like a representative of a tuning studio like West Coast Customs from the American cult show “Pimp My Ride,” just as his tented “Gazelle-Next” does not betray itself in any way. Just a tented gazelle. But when we slowly drive through the territory of one of the industrial zones of Saransk, I do not recognize the habits of the Nizhny Novgorod truck. Where is the rattling Chinese Cummins? Or the tedious itch of the Ulyanovsk gasoline engine? Why can't I hear the box hum?

No guys, this is not a finalized version. Before leaving on an empty street, we stop, and then Sergei steps on the gas pedal. The Gazelle takes off with such acceleration that you want to pinch yourself: are we sure we’re not in a Land Cruiser 200? And not in a BMW? The smile becomes wider, because the exhaust system accompanies the engine, as only a world-famous specialist can. Lord, this is some kind of holiday!

“I’m no longer at the age to be a hooligan in the city, but sometimes I can show what this car is capable of! — Sergei smiles. “Of course, downstream neighbors do not expect such dynamics from an ordinary-looking cargo gazelle.” A powerful engine is good outside the city, on the highway, when you need to overtake. And so my cruising speed is 90–100 km/h.”

© Denis Tyurkin

This 2013 truck was purchased used in 2016. Under the hood, instead of the factory engine, Saransk craftsmen will squeeze an eight-cylinder, three-hundred-horsepower 3UZ-FE with an automatic six-speed gearbox, which were installed on Toyota cars in the early 2000s. Not anyhow - flagship! Lexus LS, GS and SC (there was such a luxury coupe) and their right-hand drive analogues Toyota Celsior, Aristo and Soarer. Moreover, this engine, boosted, was actively used in the “silhouettes” of the Japanese Super GT racing series.

“My brother, Nikolai, is interested in SUVs - he repairs, tunes, and thanks to him, the Gazelle was equipped with a different engine,” says Sergei. “It all started five years ago with a Moray-colored Gazelle-Farmer, also with a tilt platform. The “native” engine didn’t suit me, so I first changed it to a ZMZ-409. Clueless in some situations. Therefore, the thought crept in: shouldn’t we install a motor from something more serious? I also saw enough of various entries on “Drive”... (“Drive2”, car site - “C”) I pestered my brother and said: let’s install some kind of six-cylinder. Him: leave me alone! But after a while the situation changed: he began to beg me, since he met the guys from Ulyanovsk who were actively practicing installing Toyota six-cylinder engines - in-line JZ and V-shaped 5VZ-FE. They began to think. We decided that these engines were not enough for such a car. Therefore, we decided to immediately install the eight-cylinder 1UZ. Done. Oh, and it had sound! The “cans” were from BMW, so under the open throttle the engine sounded just right. Even at idle it’s a thoroughbred sound!”

The surgical operation to implant a Japanese heart into a Nizhny Novgorod patient was carried out in Nikolai’s personal workshop. But due to the modest size of the patient’s room... it had to be halved. To do this, they removed the body and disassembled the bolted frame (it had previously been lengthened in a Nizhny Novgorod workshop). Therefore, only the front part of the gazelle was pushed into the garage. The engine itself (used, complete with automatic transmission) was bought in Penza for 50 thousand rubles. The radiator cost 5 thousand. Exhaust - completely made of stainless steel - 15 thousand. Plus the costs of welding and so on. Sergei admits that by the end of the work the costs were no longer counted. “We thought just to finish!” - he says. During the run-in of the first V8 Gazelle at a speed of 90 km/h, a problem literally emerged: the long driveshaft on the outboard actually wrapped itself in a knot, damaging part of the exhaust tract. Well, I didn’t “drag” the box along with me... So the guys empirically realized that the length of one cardan pipe should not exceed 1 m. This truck was sold after two years of operation: a random person became interested.

Then Sergei began to look for a Gazelle-Next without an engine, so as not to waste time on an unnecessary operation. He already knew that he would “implant” a V8 into this car. But a suitable option was never found. I had to buy Next with a motor. The body and propulsion unit were immediately sold, and the proceeds were used to purchase a contract 3UZ-FE with the Euro-4 environmental class. The choice for this engine was also due to its class. According to Russian legislation, when replacing a power plant, you cannot “downgrade” the class. “Cans” with vacuum dampers from the BMW seventh series were used as mufflers. That's where the thoroughbred sound comes from!

There were no particular difficulties with implementation, since brother Nikolai, after the first Gazelle, had already carried out almost a dozen similar operations on minibuses, including foreign cars (Volkswagen Crafter, Ford Transit, etc.). Only the Toyota eight-cylinder engine with automatic transmission acted as the “heart”. Clients even came to the master from other regions.

The same cardan almost tied in a knot © From the owner’s archive

“Experimentally, we realized that the fewer “native” Gazelle parts that remain during transplantation, the better,” explains Sergei. — In terms of mechanics, there are no questions for us at all, it’s all simple. But regarding electrical... There are nuances here. My brother found a specialist for this. Now they make Volkswagen Crafter from Saratov. There is a CAN bus, that is, essentially there are not many wires, but in order to “marry” a Japanese engine with a “German” one, I had to think carefully.”

Initially, Gazelle-Next had no problems with electronics, but recently an error appeared on the instrument panel. Sergei says that he knows what the reason is and will solve everything in the near future. As well as a little “kicking” of the box. This happens when, for example, you slowly approach a traffic light and stop. “Not all the contacts are energized,” he explains. “That’s why the box in some cases doesn’t “understand” what’s happening to it well. By the way, it’s good that this particular car does not have ABS. Otherwise, it would be more difficult to “marry” everything, because the electronics of the power unit are “tied” to ABS... What is the fuel consumption? How you stomp. The least that was possible was 20 liters per hundred. But it’s on gas, there’s gas equipment here.”

Since the heart transplant, Next has traveled more than 70 thousand km. As with the first “patient,” there was a problem with the cardan. But this time it was not due to a design miscalculation. More like a stupid accident. We were traveling with cargo from Nizhny Novgorod. We stopped at a gas station. We refueled. And this has to happen, when switching from “park” to “drive” the driver’s foot slipped off the brake pedal, hitting the accelerator. The wheels, naturally, could not turn, because the drive shaft collapsed due to the shock load. Again: good without damaging important parts. After replacing the crosspieces at the scene of the incident, the gazelle drove on as if nothing had happened. By the way, “native” suspended ones on a cardan are enough for 20–30 thousand km. We have not yet decided how to overcome this disease. Also, in the first winter, two UAZ radiators installed to cool the automatic transmission leaked. The reason is an incorrectly selected clamp at the place where the hose is attached to the fitting. Everything was resolved with a cheap replacement.

What else is left to do? Sergei wants to finish the slide in order to move the gearshift lever to the front console, like the new “Nexts”. In the meantime, the short lever is huddled on the floor between the seats, and it’s difficult to reach for it. Yes, and there is no decorative cover. But the owner considers the most important thing to be the legalization of all changes in the traffic police. The process is going on, but very slowly... It is new both for the car owner and for the employees of the regulatory agency.

Platform and trailer

Having replaced the engine with the gearbox, the Saransk craftsmen did not calm down and “invented” their own platform for the truck, and with it the frame for the awning. The floor of the cargo compartment has been lowered, and now the spare wheel, previously attached to the frame, lies in the back, next to the winch. A bevel was made in the rear to make it easier to drive the car inside (the Gazelle often acts as a car transporter, and once transported 12 light trailers inside). There is also a bevel at the front of the awning, which makes the car look unusual from the side. Sergei says that such a scheme has two advantages. Firstly, there is no need to install a fairing. Secondly, the slope is a continuation of the roof, which means it is possible to open the curtains a little and pull long pieces into the resulting hatch. “If you wish, you can transport eight-meter items, and everything will fit within the dimensions,” says the owner. “In the end, we came up with something between a covered tow truck and a universal platform. By the way, the front suspension was not modified, but air springs were additionally installed in the rear suspension in addition to the standard springs. After motorsport, we think carefully about the design. Because the more you strengthen something, the greater the weight becomes, which means additional reinforcement is required, and this is an increase in weight and a vicious circle. We need balance."

Sergei is also currently finishing the camper trailer. It is entirely plywood, but finished with alucobond. “I didn’t really need to come up with anything,” admits Sergei. — Everything was already invented by the Americans. At the back there is a compartment for kitchen utensils. Inside the trailer there are sleeping spaces 2 m long. Two adults and a child will fit. Above the legs there are compartments for various things. Everything will be highlighted. I consulted with the guys who produce passenger trailers in Saransk. The design was approved. They just said that the safety margin of the drawbar was too small. Like, it needs to be strengthened. I'll think about how..."

The trailer will soon appear on the streets of Saransk © Denis Tyurkin

There will be no sink in the kitchen compartment: the author believes that water will damage the structure. It is also the main enemy of the kitchen compartment door hinges. That's why Sergey installed special protected loops. “I barely found it, it’s very rare!” Soon the homemade trailer will be registered with the traffic police. There are no problems so far; the registration process, unlike motor vehicles, is simple. To do this, you only need a VIN assignment document issued by NAMI and a wheeled vehicle safety certificate. Trailer testing is not carried out.

Finally, Sergei remembers where he and his brother got their passion for such things. “From grandfather Nikolai! In the 80s, he made a UAZ-469 from a GAZ-69 SUV, and thereby became one of the first private owners of such a car. I replaced the frame, engine, body and axles... I still remember how I helped paint the fenders. Since then, we have had a craving for alterations!”

How to reduce fuel consumption

Having figured out what the fuel consumption standards for the Gazelle 405 are and comparing them with the fuel consumption indicators of your car, if you exceed them, you can significantly reduce the amount of fuel consumed per 100 km of run, adhering to just a few rules. You should:

• promptly check all systems and components of the Gazelle and carry out their repairs in a timely manner;
• use only high-quality fuels and lubricants;
• adhere to the basic rules for operating the Gazelle 405 with an injection engine;
• if you do not have sufficient experience in servicing injection engines, contact service station specialists;
• reduce to a minimum the use of air conditioning, high beams and all other additional devices;
• Carry out tuning of the Gazelle after a certain number of kilometers.

Characteristics of the cooling system

The Gazelle was equipped with engines from the Zavolzhsky Motor Plant marked ZMZ 402, ZMZ 405 and ZMZ 406. The design, circuit and operating principle of all three cooling systems are similar. Of course, there are some differences, but they are not that big.

Like any other cooling system, the ZMZ 405 engine has both positive and negative sides. So, if the thermostat breaks down, the power unit begins to overheat very much, especially in the summer season, when the temperature outside is 30 degrees Celsius or higher.

The most dangerous thing in this case is the failure of the cooling fan.